2004 Ford Focus Fuel system Problems

TL* THE CONTACT OWNS A 2004 FORD FOCUS. WHILE DRIVING VARIOUS SPEEDS, A LOUD NOISE WAS DETECTED FROM THE FRONT OF THE VEHICLE AND THE CHECK ENGINE INDICATOR ILLUMINATED. THE CONTACT ALSO MENTIONED THAT THE KEY OVERHEATED IN THE IGNITION SWITCH AND THE VEHICLE HESITATED TO DRIVE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED. THE CONTACT FURTHER MENTIONED THAT THE VEHICLE'S FUEL CONSUMPTION WAS HIGHER THAN NORMAL. THE CONTACT ALSO MENTIONED THAT BOTH PASSENGER DOORS WERE INOPERABLE. THE CONTACT MENTIONED THAT THE DRIVER'S SIDE DOOR NEEDED EXTRA STRENGTH TO OPEN AND THE REAR PASSENGER DOOR WAS STUCK AND WOULD NOT OPEN. THE VEHICLE WAS TAKEN TO MULTIPLE UNKNOWN DEALERS WHERE THE CONTACT WAS INFORMED THAT THE IGNITION SWITCH NEEDED TO BE REPLACED AND THE ENGINE VALVE WAS STUCK. THE CAUSE OF THE OTHER FAILURES WAS NOT DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS APPROXIMATELY 250,000.

NHTSA ID

11245773

Incident

Jan 1, 2017

Mileage

250,000 mi

TL* THE CONTACT OWNS A 2004 FORD FOCUS. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED THE SAME FAILURES LISTED IN NHTSA CAMPAIGN NUMBER: 06E056000 (FUEL SYSTEM, GASOLINE) AND NHTSA CAMPAIGN NUMBER: 05V030000 (LATCHES/LOCKS/LINKAGES). SHE STATED THAT DUE TO POOR DESIGN, THE QUICK CONNECTORS WOULD NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR WAS FULLY ATTACHED. THE CONTACT ALSO STATED THAT SHE WAS UNABLE TO OPEN THE FRONT DRIVER'S SIDE AND BOTH REAR DOORS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11233491

Incident

Jul 13, 2019

VERY DANGEROUS FAULT OR DEFECT FOUND ON MY CAR. A FUEL LINE THAT RUNS ALONG THE TOP OF THE ENGINE IS CONTACTING AN OPPOSING METAL BRACKET. THIS CHAFFING CONDITION HAS RESULTED IN DAMAGE TO THE FUEL LINE. THE FUEL LINE IS PROTECTED WITH PADDED SILVER TAPE; THE TAPE AND PADDING HAS BEEN ENTIRELY CUT BY THE BRACKET AND HAS CREATED A CUT MARK ON THE FUEL LINE. NO FUEL LEAKED BECAUSE OF THIS CONDITION. HAD THIS GONE WITHOUT DISCOVERY, THE FUEL LINE WOULD HAVE LIKELY BURST AND ALLOWED FUEL TO SPILL ON TOP OF THE ENGINE. THE METAL BRACKET CREATING THIS HAZARD IS A MOUNTING POINT FOR AN AIR BYPASS VALVE (3S41-9F491-AC). THIS VALVE AND MOUNTING BRACKET IS A COMPONENT UNIQUE TO THE PZEV VARIANT OF THE FORD FOCUS. PICTURES OF THIS DEFECT HAVE BEEN POSTED IN AN ONLINE PUBLIC FORUM LOCATED HERE-> HTTP://WWW.FOCUSFANATICS.COM/FORUM/SHOWTHREAD.PHP?T=407090 THE TITLE OF THE FORUM THREAD IS "DANGER - FUEL LINE BEING CUT ON A 2004 PZEV". *TR

NHTSA ID

10584510

Incident

Apr 22, 2014

Mileage

145,600 mi

TL* THE CONTACT OWNS A 2004 FORD FOCUS. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WHILE ATTEMPTING TO RESUME ACCELERATION. THE FUEL WARNING LIGHT ILLUMINATED AS THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE A DIAGNOSTIC WAS PERFORMED. THE AIR IDLE CONTROL WAS REPLACED, BUT THE FAILURE WAS NOT CORRECTED. THE MANUFACTURER ADVISED THE CONTACT THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER 06E056000 (FUEL SYSTEM, GASOLINE) BUT THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 100,000 AND THE CURRENT MILEAGE WAS 126,000.

NHTSA ID

10546659

Incident

Jun 1, 2012

Mileage

100,000 mi

ACCELERATOR PEDAL STICKS HAPPENED RIGHT AFTER PURCHASE IN 04, THROTTLE BODY HAS BEEN REPLACED BY DEALER TWICE ALREADY, NOW OUT OF WARRANTY AND THROTTLE BODY STICKING AGAIN. *TR

NHTSA ID

10269753

Incident

Jan 4, 2005

Mileage

5,000 mi

TL*THE CONTACT OWNS A 2004 FORD FOCUS. THE CONTACT IS UNABLE TO DRIVE THE VEHICLE DUE TO THE STRONG GAS FUMES IN THE PASSENGER COMPARTMENT. THE DEALER STATED THAT NOTHING WAS WRONG WITH THE VEHICLE AND SUGGESTED THAT THE CONTACT MAY BE SMELLING NORMAL GAS FUMES. THE VEHICLE HAS NOT BEEN DRIVEN IN THE PAST THREE OR FOUR MONTHS. A DIAGNOSTIC WAS PERFORMED AND THE RESULTS INDICATED THAT EVERYTHING PASSED. THE CAUSE OF THE FUMES HAS NOT YET BEEN DETERMINED. THE SMELL HAS CAUSED THE CONTACT'S KIDNEYS TO HURT. FORD STATED THAT THEY WOULD HELP PAY FOR THE COST, IF THEY CAN ASSIST IN DETERMINING THE DEADLY DEFECT. THE FAILURE MILEAGE WAS 16,000 AND CURRENT MILEAGE WAS 16,200.

NHTSA ID

10215383

Incident

Oct 1, 2007

Mileage

16,000 mi

MY FORD FOCUS ZX5 STALLED ON ME ON THE HIGH WAY JULY 27, LUCKY FOR ME THE TRAFFIC WAS SLOW. TOWED TO THE DEALER, THEY SAID IT WAS THE FUEL PUMP. COST ME $600 TO REPLACE IT. I GOT THE CAR BACK ON AUGUST 1, AND TWO DAYS LATER ON AUGUST 3, IT STALLED AGAIN. TOW IT BACK TO DEALER ON AUGUST 7, THE DEALER SAID IT WAS THE FUEL PUMP AGAIN, THEY SAID THE NEW FUEL PUMP THEY REPLACED TWO DAYS AGO WAS DEFECTIVE, AND THEY HAD IT FIXED ON AUGUST 8, AND ONE DAY LATER ON AUGUST 9, IT STALLED AGAIN. TOWED BACK TO DEALER THE THIRD TIME. ON AUGUST 13, THEY CALLED ME AND SAID IT WAS NOT THE FUEL PUMP. (WHAT? SO THEY DIDN'T SERIOUSLY CHECK THE CAR, AND PUT ME INTO VERY DANGEROUS SITUATIONS AGAIN AND AGAIN???) ON AUGUST 17, THEY CALLED TO INFORM ME IT WAS THE INERTIA SWITCH. I WAS VERY DISSATISFIED WITH ALL THE PROBLEMS WITH THIS VEHICLE. RENTAL COST (I ASKED FOR THE REIMBURSEMENT OF THE RENTAL AND THEY REFUSED). I QUESTIONED THE SERVICE MANAGER ABOUT THE CAR'S SAFETY CONCERN AND THEIR MECHANIC'S INCOMPETENT. THE SERVICE MANAGER KEPT SAYING THE SECOND TIME THE NEW PART WAS DEFECTIVE AND THE SWITCH PROBLEM DIDN'T SHOW UP UNTIL THE THIRD TIME. I REALLY DOUBT IT, BECAUSE EVERY TIME IT SHOWED ME THE SAME PROBLEM. AND I BELIEVE IT IS BECAUSE THEY DIDN'T FIND THE INERTIA SWITCH PROBLEM THE FIRST TIME. I ALSO CALLED THE FORD CUSTOMER ASSISTANCE AND ASKED FOR TO BE REIMBURSEMENT FOR THE RENTAL CAR. I TOLD HER ABOUT MY SAFETY CONCERN, AND SHE INFORMED ME AS LONG AS I AM STILL NOT INVOLVED IN AN ACCIDENT THERE IS NOTHING THEY CAN DO . WHAT? DO I NEED TO BE INJURED OR DEAD TO GET THEIR ATTENTION? *TR

NHTSA ID

10200269

Incident

Jul 27, 2007

Mileage

48,073 mi

RAW FUEL LEAKS FROM GASOLINE EVAPORATIVE CANISTER WHEN VEHICLE HAS BEEN RECENTLY FUELED. DRIVEABILITY PROBLEMS ACCOMPANYING LEAKAGE. INCLUDES DIFFICULTY STARTING/ HESITATING/SURGING AT HIGHWAY SPEEDS, AND STALLING AT LOW SPEED MANEUVERS.*AK

NHTSA ID

10190943

Incident

May 7, 2007

Mileage

53,898 mi

MY CAR IS AGAIN IN SERVICE DUE TO A FAULTY GAS CAP. THE WIRE WHICH ATTACHES THE GAS CAP TO CAR KEEPS GETTING CAUGHT WHEN THE CAP IS BE SCREWED ON. CHECK GAS CAP LIGHT COMES ON AND THEN THE CHECK ENGINE LIGHT COMES ON. THIS IS THE 4TH TIME IT IS IN THE SHOP FOR THIS REASON. I AM TOLD I HAVE TO CHECK EACH TIME I GET GAS TO MAKE SURE CAP IS ON PROPERLY AND THAT CONNECTING WIRE IS NOT CAUGHT. I DON'T BELIEVE MOST PEOPLE HAVE TO DO THIS. I BELIEVE THE GAS TANK LINE WAS INSTALLED IMPROPERLY AND THEREFORE IT KEEPS CAUSING THIS PROBLEM. THANK YOU. *JB

NHTSA ID

10159013

Incident

Mar 4, 2006

Mileage

29,000 mi

IN MINNEAPOLIS 4/23/04 THE CAR STALLED IN STOP AND GO FREEWAY TRAFFIC AND TOOK A FEW MINUTES ON THE FREEWAY TO RE-START-MILEAGE THEN-APPROX 2317 R/O OPEN DATE R/O CLOSE DATE 9/21/04 10/05/04 THE FIRST 4 DATES ARE TRANSMISSION RELATED. INITIALLY THE CAR WOULD POP OUT OF 2ND GEAR WHILE SLOWING OR TURNING A CORNER 2/03/05 2/10/05 BEARINGS REPLACED 2/12/05 2/15/05 CRUISE INOPERABLE 3/15/05 3/23/05 TRANSMISSION REPLACED. 3/25/05 3/30/05 THIS IS A THROTTLE BODY REPLACEMENT ALL OF THESE REPAIRS WERE DONE UNDER WARRANTY. IN A FURTHER PAGE I DO NOT KNOW WHAT "OEM" MEANS SO HAVEN'T ANSWERED THAT QUESTION. *JB

NHTSA ID

10134434

Incident

Sep 21, 2004

Mileage

9,996 mi

STEERING AND SUSPENSION/ CENTER SUPPORT BEARING/PART# Y542-3B436-A FAILED... BELIEVE CAR SOLD OUT OF ALLIGNMENT. REAR-END, BELIEVED CAUSE ALL WEAR ON FRONT SUSPENSION COMPONENTS, UNEVEN WEAR ON ALL TIRES ALSO, AND WOBBLY UNSTABLE REAR END. CAR WAS REPAIRED 6-3-2005 ALSO, THE THROTTLE BODY LINKAGE HAD TO BE REPLACED, WORN OUT, WAS CAUSING SUDDEN ACCELERATION AND HESITATED ACCELERATION, SOMETIMES ACTING LIKE STUCK....

NHTSA ID

10124155

Incident

May 27, 2005

Mileage

33,000 mi

WHILE DRIVING VEHICLE STALLED . DRIVER WAS ABLE TO RESTART THE VEHICLE FIFTEEN MINUTES LATER, AND DROVE IT TO THE DEALER. HOWEVER, MECHANIC COULD NOT DUPLICATE THE PROBLEM. DRIVER INFORMED THE MECHANIC THAT THIS PROBLEM HAS HAPPENED MORE THAN ONCE, AND HAS NOT BEEN RESOLVED. *AK FORD MRFG STATED THAT THIS TYPE OF STALLING (FAILURE) DOES NOT INDICATE A SAFETY PROBLEM. THERE HAS BEEN A CONSTANT PROBLEM WITH 1/2 TANK OF GAS OR LESS SINCE THE CAR REACH 50,000 MILES. *BF

NHTSA ID

10113693

Incident

Mar 8, 2005

Mileage

70,145 mi

CONTINUOUS PROBLEM WITH SMELL OF GAS IN VEHICLE. EXPERIENCE BAD ACCELERATION AND CAR BURNING EXCESSIVE AMOUNTS OF GAS. *BF THE VEHICLE WOULD ALSO COAST AND STOP IN THE MIDDLE OF THE STREET. THE EMISSION SYSTEM LIGHT HAD COME ON. THERE WAS AN INCIDENT WHEN THE CONSUMER VIEWED WHITE SMOKE COMING FROM OUT OF THE MUFFLER. THE CONSUMER WAS INFORMED THAT THE FUEL PUMP WAS THE PROBLEM. *SC

NHTSA ID

10107068

Incident

Jul 18, 2004