The 2001 Focus with the 2.0L Zetec is mechanically simple but plagued by chronic automatic transmission failures and head gasket issues. The MTX-75 manual is reliable, but the 4-speed auto is a ticking time bomb that destroys itself through design flaws.
Automatic Transmission Failure (4F27E)
Common · high severity
Typical onset: 60,000-120,000 mi
Symptoms: harsh or delayed 2-3 upshift, shuddering on acceleration, slipping between gears, complete loss of forward gears, burned transmission fluid smell
Fix: The 4F27E auto is fundamentally flawed with weak valve body, failing torque converter, and inadequate internal oil cooling. Rebuild quality is poor—most shops recommend replacement with remanufactured unit. 6-8 labor hours for R&R, plus fluid and cooler line flush. Many owners switch to manual transmission from donor car (16-20 hours labor).
Estimated cost: $2,200-3,500
Head Gasket Failure (2.0L Zetec)
Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: white smoke from exhaust, coolant loss without visible leaks, rough idle when cold, milky oil on dipstick or filler cap, overheating in traffic
Fix: Ford's MLS gasket fails between cylinders 2-3 most often. Head must be checked for warpage (commonly .006-.010 over spec). Machine work adds $150-250. Job requires timing belt replacement simultaneously. 10-12 labor hours including resurface. Water pump and thermostat should be done at same time.
Estimated cost: $1,800-2,600
Ignition Coil Pack Failure
Common · medium severity
Typical onset: 50,000-90,000 mi
Symptoms: misfire codes P0300-P0304, rough idle and hesitation, loss of power under load, failed emissions test, check engine light flashing
Fix: The coil-on-plug design allows moisture intrusion. Usually starts with one cylinder, but all four fail within 10,000 miles of each other. Replace all four coils and spark plugs as set to avoid comebacks. 1.5 labor hours. Use Motorcraft or OE-equivalent only—aftermarket failures are common.
Estimated cost: $350-550
Front Door Latch Mechanism Failure
Common · medium severity
Symptoms: door won't close or latch properly, door flies open while driving, interior light stays on constantly, door ajar warning with doors closed, unable to open door from inside or outside
Fix: Factory latch mechanism has weak pawl springs and plastic components that wear or break. This was subject to recall 01V251 but many cars never got fixed. Requires complete latch assembly replacement. 1.5-2 labor hours per door including door panel removal and latch adjustment. Driver door fails most often.
Estimated cost: $200-350
Rear Lower Control Arm Bushing Failure
Common · low severity
Typical onset: 70,000-110,000 mi
Symptoms: clunking over bumps from rear, wandering or loose feeling at highway speeds, uneven rear tire wear on inside edges, rear end skips sideways over bumps
Fix: The rear multi-link suspension uses soft rubber bushings that deteriorate and tear. Sloppy handling results but not dangerous. Replace both lower control arms with bushings pressed in—pressing bushings into old arms rarely lasts. 2.5 labor hours for both sides including alignment.
Estimated cost: $400-600
Power Steering Pressure Hose Leak
Occasional · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: power steering fluid puddles under car, groaning noise when turning at low speed, heavy steering feel, fluid spray visible on engine belly pan
Fix: High-pressure hose from pump to rack develops pinhole leaks or splits at crimp fittings. Leaks often spray fluid onto exhaust causing smoke and smell. Hose replacement requires some disassembly of airbox and access from below. 1.5 labor hours plus system flush and bleed.
Estimated cost: $250-400
Owner tips
If buying with automatic transmission, budget for replacement immediately—it's not if, but when
Change coolant every 30,000 miles with proper Ford Gold coolant to delay head gasket failure
Check door latches during test drive—open and close all doors firmly and verify interior lights work correctly
Inspect for oil weeping around head gasket mating surface at 75,000+ miles as early warning
Manual transmission cars are significantly more reliable and worth seeking out
Buy only with manual transmission and budget $2,000 for eventual head work—automatics are endless money pits.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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RIDE CONTROL, LLC (RIDE CONTROL) IS RECALLING CERTAIN READYMOUNT ASSEMBLIES, P/N 746641MT AND 746646MT, WITH CORRESPONDING AFTERMARKET CUSTOMER PART NUMBERS: GABRIEL G56944 AND GABRIEL G56945, AND PRIVATELY BRANDED PARTSMASTER WITH PART NUMBERS G68944 AND G68945. THE READYMOUNT ASSEMBLIES WERE SOLD AS AFTERMARKET SERVICE EQUIPMENT FOR USE ON CERTAIN 2000 THROUGH 2005 FORD FOCUS VEHICLES. THESE ASSEMBLIES WERE ASSEMBLED WITH A NUT WITHOUT THE NECESSARY WASHER. THE ABSENCE OF THE WASHER CAN ALLOW THE READYMOUNT ASSEMBLY TO PULL APART THE TOP MOUNT.
Consequence: IF THE ASSEMBLY SEPARATES DURING INSTALLATION, IT COULD RESULT IN INJURY TO THE INSTALLER. IF THE ASSEMBLY SEPARATES WHILE THE VEHICLE IS IN MOTION, IT COULD RESULT IN SECONDARY DAMAGE TO THE VEHICLE AND POSSIBLY RESULT IN A VEHICLE CRASH.
Remedy: RIDE CONTROL WILL NOTIFY OWNERS AND WILL SET UP PROCEDURES TO INSPECT, REPAIR, AND/OR REPLACE THE AFFECTED PARTS WITHOUT CHARGE TO THE OWNER. THE SAFETY RECALL BEGAN ON MARCH 30, 2012. OWNERS MAY CONTACT RIDE CONTROL AT 1-800-999-3903.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 09E012000
2009-04-07
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
EXTERIOR LIGHTING:HEADLIGHTS · 08E050000
2008-08-11
K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 2008. OWNERS MAY CONTACT K2 MOTOR AT 1-909-839-2992.
EXTERIOR LIGHTING · 06E049000
2006-05-24
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
EXTERIOR LIGHTING · 06E026000
2006-03-23
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
LATCHES/LOCKS/LINKAGES:DOORS:LATCH · 05V030000
2005-02-01 · EA04023
CERTAIN PASSENGER VEHICLES WITH FOUR OR FIVE DOORS AND ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, A BUILD-UP OF CORROSION AT THE PAWL PIVOT AREA OF THE REAR DOOR LATCH CAN CAUSE A BINDING CONDITION OF THE PAWL THAT MAY AFFECT PROPER ENGAGEMENT OF THE PAWL INTO THE CATCH. THE OCCUPANT MAY EXPERIENCE DIFFICULTY OPENING OR CLOSING A REAR DOOR, AND EVENTUALLY THE REAR DOOR MAY NOT LATCH PROPERLY.
Consequence: IF NOT LATCHED PROPERLY, THE DOOR MAY OPEN WHILE THE VEHICLE IS IN MOTION. IF AN OCCUPANT FELL OUT OF THE VEHICLE, PERSONAL INJURIES COULD OCCUR.
Remedy: DEALERS WILL HAVE A LOWER ROCKER SEAL ADDED TO THE DOOR AND HAVE THE REAR DOOR LATCHES EVALUATED FREE OF CHARGE. A LATCH THAT PASSES THE EVALUATION WILL BE LUBRICATED TO PREVENT FUTURE CORROSION. A LATCH THAT DOES NOT PASS THE EVALUATION WILL BE REPLACED. IN ADDITION, A STICKER WILL BE AFFIXED TO THE REAR DOORS ADVISING THE OWNERS TO USE THE RECOMMENDED LUBRICANT. THE RECALL BEGAN ON MARCH 9, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
FUEL SYSTEM, GASOLINE · 03V482000
2003-11-19 · EA02022
ON CERTAIN PASSENGER VEHICLES, CONTAMINATION OF THE FILTER IN THE FUEL DELIVERY MODULE (FDM) CAN REDUCE, AND EVENTUALLY BLOCK, THE FLOW OF FUEL TO THE ENGINE.
Consequence: THIS MAY CAUSE ENGINE HESITATION, LOSS OF POWER, SURGING, AND OTHER SIMILAR SYMPTOMS. OVER TIME, THE FILTER MAY BECOME SUFFICIENTLY BLOCKED TO CAUSE THE ENGINE TO STALL, WHICH COULD RESULT IN A CRASH.
Remedy: THIS ACTION IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN AND IS NOT BEING CONDUCTED UNDER THE SAFETY ACT. ALL OWNERS WILL BE NOTIFIED OF THE PROBLEM, AND DEALERS WILL REPLACE THE FDM WITH A NEW DESIGN AT NO CHARGE IF THE OWNER REPORTS THAT THE VEHICLE EXHIBITS ANY OF THE IDENTIFIED SYMPTOMS. THE FREE REPLACEMENT WILL BE AVAILABLE FOR A PERIOD OF 10 YEARS FOLLOWING THE ORIGINAL PURCHASE OF THE VEHICLE, WITH NO MILEAGE LIMIT. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING NOVEMBER 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
CERTAIN PASSENGER VEHICLES EQUIPPED WITH ZETEC ENGINES, LOOSE OR BROKEN ATTACHMENTS AND MISROUTED BATTERY CABLES COULD LEAD TO CABLE INSULATION DAMAGE.
Consequence: THIS, IN TURN, COULD CAUSE THE BATTERY CABLES TO SHORT RESULTING IN HEAT DAMAGE TO THE CABLES. BESIDES HEAT DAMAGE, THE "CHECK ENGINE" LIGHT MAY ILLUMINATE, THE VEHICLE MAY FAIL TO START, OR SMOKE, MELTING, OR FIRE COULD ALSO OCCUR.
Remedy: DEALERS WILL INSPECT THE BATTERY CABLES FOR THE CONDITION OF THE CABLE INSULATION AND PROPER TIGHTENING OF THE TERMINAL ENDS. AS NECESSARY, CABLES WILL BE REROUTED, RETAINING CLIPS INSTALLED, AND DAMAGED BATTERY CABLES REPLACED. OWNER NOTIFICATION BEGAN FEBRUARY 10, 2003. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
STEERING:LINKAGES · 02V289000
2002-11-06
CERTAIN PASSENGER VEHICLES HAVE LOOSE PINCH BOLTS THAT SECURE THE LOWER CONTROL ARM TO THE STEERING KNUCKLE HAVE BEEN REPORTED.
Consequence: LOOSE PINCH BOLTS COULD EXHIBIT NOISE, VIBRATION AND, IN EXTREME CASES IF LEFT UNCORRECTED, SEPARATION OF THE JOINT OR FRACTURE OF THE BALL JOINT STUD, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE STEERING KNUCKLE PINCH BOLT FOR TIGHTNESS AND CORRECT AS NECESSARY. OWNER NOTIFICATION BEGAN FEBRUARY 10, 2003. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
WHEELS:LUGS/NUTS/BOLTS/STUDS · 01I017000
2001-11-29
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 2000-2001 FORD FOCUS PASSENGER VEHICLES, ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIOM, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, AND WISCONSIN. IN HIGH CORROSION AREAS, WHERE SALT IS USED ON ROADWAYS IN THE WINTER, THE REAR WHEEL BEARING SEAL RACE CAN EXPERIENCE SURFACE CORROSION. IF THIS CONDITION OCCURS, THE WHEEL BEARING SEALS COULD BECOME DAMAGED AND ALLOW CONTAMINATION TO ENTER THE WHEEL BEARINGS.
Consequence: THE WHEEL BEARINGS COULD PREMATURELY WEAR AND CAUSE A NOTICEABLE NOISE. IF NOT REPAIRED, THIS CONDITION COULD PROGRESS TO THE POINT WHERE THE WHEEL BEGINS TO WOBBLE.
Remedy: DEALERS WILL REPLACE THE REAR WHEEL BEARINGS AT NO COST TO THE CONSUMER. ADDITIONAL BEARING SEALS WILL ALSO BE INSTALLED TO ENSURE A SMOOTH RIDE. THIS PROGRAM WILL BE IN EFFECT UNTIL DECEMBER 31, 2002, REGARDLESS OF MILEAGE. EVEN IF THE VEHICLE HAS ALREADY BEEN SERVICED UNDER RECALL CAMPAIGN 00S31, FORD HAS TAKEN ADDITIONAL STEPS TO KEEP THE WHEEL BEARINGS IN TOP SHAPE.
OWNERS CAN CONTACT FORD AT 1-866-436-7332, CONCERNING THIS PROGRAM.
VEHICLE DESCRIPTION: PASSENGER CARS, SPORT UTILITY VEHICLES, AND LIGHT AND MEDIUM DUTY PICKUP TRUCKS. A SWITCH LOCATED IN THE PLASTIC COVER OF THE WIPER MOTOR GEAR CASE COULD MALFUNCTION AND OVERHEAT, POTENTIALLY RESULTING IN LOSS OF INTERMITTENT WIPER FUNCTION, LOSS OF WIPER PARK FUNCTION, COMPLETE LOSS OF WIPER FUNCTION, OR IGNITION OF THE PLASTIC COVER MATERIAL. SWITCH MALFUNCTION IS MOST LIKELY TO OCCUR WHEN THE INTERMITTENT SETTING OF THE WIPERS IS BEING USED, OR WHEN SNOW OR ICE OBSTRUCTS THE BLADES FROM RETURNING TO THE "PARKED" POSITION AT THE BOTTOM OF THE WINDSHIELD. THESE VEHICLES WERE BUILT AT THE FOLLOWING ASSEMBLY PLANTS: ATLANTA PLANT FROM 2/11/00 THROUGH 7/31/00; CHICAGO PLANT FROM 2/14/00 THROUGH 8/4/00; KANSAS CITY PLANT FROM 2/26/00 TO 9/4/00; KENTUCKY TRUCK PLANT FROM 2/18/00 TO 8/31/00; MICHIGAN TRUCK PLANT FROM 2/23/00 THROUGH 8/3/00; NORFOLK PLANT FROM 2/21/00 THROUGH 7/27/00; WAYNE STAMPING AND ASSEMBLY PLANT FROM 2/25/00 THROUGH 8/15/00; AND WIXOM PLANT FROM 2/15/00 THROUGH 8/8/00.
Consequence: LOSS OF VISIBILITY WHILE DRIVING INCREASES THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE DATE CODE ON THE WIPER MOTOR. MOTORS BUILT WITH THE SUSPECT TIME FRAME WILL HAVE THE WIPER MOTOR GEAR CASE COVER REPLACED. OWNER NOTIFICATION BEGAN AUGUST 20, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
SEATS:FRONT ASSEMBLY:RECLINER · 01V108000
2001-03-28
PM CERTAIN SEDANS AND WAGONS, THE SEAT BACK RECLINER HANDLE SPRING COULD HAVE BEEN DAMAGED DURING AN IN-PROCESS TEST AND THE OCCUPANT MAY NOTICE A CHUCKING, OR PERCEIVED LOOSENESS OF THE FRONT SEAT BACK, OR THE SEAT BACK COULD UNEXPECTEDLY RECLINE.
Consequence: IF THE SEAT BACK UNEXPECTEDLY RECLINES WHILE THE CAR IS BEING DRIVEN, IT COULD RESULT IN LOSS OF VEHICLE CONTROL.
Remedy: DEALERS WILL REPLACE THE SEAT BACK RECLINER HANDLE SPRING FOR THE DRIVER AND FRONT PASSENGER SEATS. OWNER NOTIFICATION BEGAN APRIL 3, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
SEATS:FRONT ASSEMBLY:RECLINER · 00V418000
2000-12-14
VEHICLE DESCRIPTION: STATION WAGONS AND 3-DOOR VEHICLES. THE SUBJECT VEHICLES HAVE A FOLDING 60/40 SECOND SEAT THAT BECOMES A LOAD FLOOR IN THE FOLDED POSITION. WHEN THE 60% PORTION OF THE SEAT IS FOLDED DOWN AND A LOAD IS APPLIED TO THE FRONT EDGE OF THE LOAD FLOOR, THE OUTBOARD HINGE PIVOT COULD DISENGAGE FROM THE HINGE.
Consequence: IF THE SEAT IS THEN RETURNED TO THE UPRIGHT POSITION WITHOUT RE-ENGAGING THE HINGE PIVOT, THE SEAT AND SEAT BELTS MAY NOT PROVIDE THE INTENDED LEVEL OF PERFORMANCE IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL INSTALL A REVISED SEAT BACK HINGE PIVOT.
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