Popular C-segment family car with plentiful parts supply and reasonable running costs. The 2.0 TDCi engine uses a timing chain rather than a belt, but DPF issues are common on short-journey cars. Main concerns: dual-mass flywheel and clutch slave cylinder failures (both expensive), EPAS steering rack failures requiring subframe removal, manual gearbox synchromesh weakness, and diesel particulate filter problems. Injectors typically last 100,000 km. The door latch recall (2012-2015) must be verified completed.
Expected Annual Maintenance Costs
€1,050 - €2,100/year
15,000 km/year
Fixed costs
€550-900
Risk buffer
€500-1,200
What Can Break
bars = likelihood
Dual-mass flywheel and clutch failure€1,000 - €1,800
DMF fails causing rattle, vibration, and bellhousing noise · more· less
Dual-mass flywheels are a common failure point on TDCi Focus models. Symptoms include chattering or rattling at idle, a clonk when going on/off throttle, and vibrations through the clutch pedal. The DMF costs €400-500 parts alone, and clutch kit adds another €75-100. Total job at independent garages runs €1,000-1,200, while Ford dealers charge up to €1,600-1,800. Since transmission removal is required, always replace both DMF and clutch together. Failures typically occur between 80,000-120,000 km.
EPAS (electric power steering) rack failure€900 - €3,500
Sudden loss of power steering assistance while driving · more· less
The EPAS system is subject to electrical failures causing sudden loss of power steering. Common causes include a faulty torque sensor, motor within the EPAS unit, or cold solder joints on circuit boards taking humidity. Fault codes include U3000-96 (Control Module), U3000-49 (Power Steering Control Unit Fault), and C102D-00-C8 (High Friction). Remanufactured steering rack costs around €300, but total replacement including labor runs €2,500-3,500 because the front subframe must be removed. The EPAS control unit and mechanical rack were matched at factory and cannot be replaced separately. This is a well-documented issue across the Mk3 generation.
Blocked filter from short trips prevents regeneration, causes limp mode · more· less
DPF blockage is very common on Focus TDCi models used primarily for short trips. The filter cannot regenerate properly without sustained highway driving (20+ minutes at motorway speeds). Symptoms include continuous regeneration cycles every 10 minutes, limp mode activation, and eventually complete blockage. Manual regeneration at a Ford or independent garage costs €200-250. Professional DPF cleaning runs €300-500. New DPF replacement costs €800-1,500 including fitting. Contributing factors include blocked fuel vaporizers (common on these engines), faulty injectors, stuck EGR throttle, failed DPF/EGT sensors, and failed glow plugs. Never interrupt a regeneration cycle mid-process as it dumps unburnt fuel into the oil sump.
Clutch slave cylinder leak€400 - €1,200
Internal slave cylinder leaks brake fluid into bellhousing · more· less
The clutch slave cylinder is located inside the bellhousing (concentric type). When it fails, brake fluid leaks into the bellhousing and drains out through a small drain hole at the flange. Symptoms include clutch pedal going to floor without resistance, car jumping forward when started in gear, and extremely narrow clutch engagement (about 1 inch of pedal travel). Some aftermarket LUK slave cylinders have been reported as defective, with gaskets melting and fluid leaking. Since the slave is inside the gearbox, transmission removal is required for replacement. Always replace the clutch at the same time since the gearbox is already out. Cost is €400-600 if just slave is replaced during other work, or €1,000-1,200 when clutch and DMF are included.
Injector failure€420 - €1,600
Injectors typically fail around 100,000 km causing poor running · more· less
Diesel injectors on the 2.0 TDCi typically last around 100,000 km before failure. Single injector replacement at an independent garage costs €420-560 (parts €200-250, labor 1 hour, plus ECU coding with injector number). Ford dealers charge €480-560. Replacement takes less than 1 hour to fit, but the ECU must be updated with the number stamped on the injector. While not necessary to replace all four injectors at once, it's often more economical to do so since the labor cost is similar. New injectors from European suppliers cost around €750 for a full set of four. At high mileages, the fuel pump and injection pump can also fail if the vehicle hasn't been properly maintained.
Manual gearbox synchromesh wear€150 - €1,800
Transmission slips from 1st or 2nd gear into neutral, crunching on shifts · more· less
The Mk3 Focus 2.0 TDCi manual transmission has weak synchromesh, particularly on 2nd and 3rd gears. Symptoms include crunching when shifting (especially at high RPMs), gear popping out into neutral occasionally, and grinding if the gear isn't forced when changing. When synchros fail, gears grind as they engage then shoot the shifter back to neutral. Changing manual transmission fluid may help temporarily but does not fix worn synchros. Second-hand gearbox costs €100-300 plus fitting. Brand new gearbox costs thousands. These transmissions need upgraded synchros with an upgraded clutch sooner than later. This is a known weakness across the Mk3 generation.
EGR valve carbon buildup€0 - €600
Town driving clogs EGR causing limp mode and loss of power · more· less
Town driving on short trips clogs the EGR valve with carbon deposits, which can restrict exhaust gas flow and cause the valve to stick open. Symptoms include limp mode, loss of power, and rough running. The EGR valve on the 2.0 TDCi can be removed and cleaned in 15 minutes (with vehicle on lift). Cleaning involves spraying EGR cleaner, scrubbing with a toothbrush, and removing carbon from the valve passage. Some owners clean it every 6 months preventatively, covering it in WD-40 overnight. Replacement EGR valve costs €250-350 parts plus €100-150 labor. These engines need a good burnout on the motorway (20 minutes in 4th gear) regularly to prevent buildup.
Engine mount failure (passenger side)€150 - €450
Vibration in cabin, clunking when engaging drive or reverse · more· less
Engine mount failures are common on the Focus, particularly the passenger-side hydraulic mount. Symptoms include vibration in the cabin while the engine is running, a clunk felt and heard when putting the vehicle into drive or reverse, and clunking at bumps/acceleration/deceleration. When hydraulic mounts fail, liquid drips from the mount. Replacement costs €150-250 for a single mount at an independent garage (OEM part €110, labor €40-100), or €250-350 at Ford dealers. Replacing all three mounts at the same time (€300-450) can prevent repeat failure of the front mount. Important: Use OEM Ford/Motorcraft mounts - aftermarket mounts will cause vibration. The passenger side engine mount is the most problematic.
Reliable for daily use but has several expensive weak points
The Ford Focus Mk3 2.0 TDCi is considered one of the more reliable models in the C-segment class with plentiful spare parts at reasonable prices. However, it has several known expensive failure points including the dual-mass flywheel, clutch slave cylinder, and EPAS steering rack. The DPF system requires regular motorway driving to stay healthy. Overall, it's a dependable family car when properly maintained, but not as bulletproof as equivalent Japanese diesel models. Diesel models are said to be slightly more dependable than petrol alternatives.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Ford dealer or specialist records essential. Verify DPF regeneration history if available.
Tires
Check tread depth, age (date codes), and uneven wear patterns. Check for excessive rear tire wear (factory misalignment issue on some cars).
Cold start
Must start engine completely cold. Listen for DMF rattle, timing chain noise, or unusual sounds.
Body condition
Check for rust, accident damage, paint mismatch. Inspect door latches carefully (recall issue).
Test drive
Minimum 30 minutes including highway speeds. Test power steering at various speeds and during parking maneuvers.
Specific for this vehicle
Listen for DMF rattle on cold start
Start engine completely cold and listen for chattering, rattling, or banging sounds from bellhousing. Rattle on cold start is a telltale DMF failure sign.
Test EPAS system thoroughly
Drive the car and make tight turns at low speed. Listen for unusual noises. Check for any warning lights. Test steering feel at highway speeds.
Check for DPF warning lights
Ask owner about DPF regeneration frequency. Check for stored fault codes. Avoid cars used only for short trips (under 10 km).
Test all gears for synchromesh issues
Shift through all gears during test drive. Listen for crunching, especially 2nd and 3rd. Feel if gears try to pop out of engagement.
Inspect clutch slave cylinder for leaks
Look for brake fluid staining around the small drain hole at the bottom of the bellhousing where it mates to the engine block.
Check clutch engagement point
Normal clutch should engage in the middle of pedal travel. Engagement at very top or bottom indicates wear or slave cylinder issues.
Verify door latch recall completed
Contact Ford with VIN to verify the door latch recall (2012-2015 models) has been completed. Doors may not latch securely.
Check for engine vibration
With engine running at idle, feel for excessive vibration in cabin. Failed engine mounts are common.
Inspect brake discs for warping
Check for brake judder or vibration when braking at highway speeds. Disc warping is relatively common.
Contact a Ford dealer with the VIN to verify all recalls have been completed. The door latch recall is particularly important as it affects roughly 1.5 million Focus models from 2012-2015 and can cause doors to appear closed when they are not. The 2.0 TDCi engine overheating recall (2014-2015 production) affected the engine control module calibration and could cause the engine to breach its oil sump in severe cases.
Warranty Status
Factory warranty (3 years / 100,000 km)Expired on all Mk3
Corrosion warranty (12 years)Check on older models
All Mk3 models outside factory warranty
All Ford Focus Mk3 models (2011-2018) are now outside their original factory warranty period. Extended warranties may be available through Ford dealers or third-party providers, but carefully review coverage exclusions. The 12-year corrosion warranty may still apply to earlier Mk3 models (2011-2013). Check with Ford using the VIN for warranty status.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.