Recalls: Ford Focus XR5 Turbo
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Ford Focus XR5 Turbo
No recall information is available for the Ford Focus XR5 Turbo. To search for recalls of Ford models, please visit Product Safety Recalls Australia: Ford.
Problems and faults: Ford Focus XR5 Turbo
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
Ford Focus XR5 Turbo: PCV diaphragm rupture (B5254T3)
For the 2.5-litre B5254T3 turbocharged petrol engine, the positive crankcase ventilation (PCV) diaphragm – located in the oil filter housing – may rupture. Symptoms of a ruptured PCV diaphragm include:
- A high-pitched, whining/whistling noise that increases with engine speed. This noise is caused by excessive crankcase pressure escaping via the oil seals. For reference, this noise stops when the dipstick is removed (since removing the dipstick releases back pressure, see video below);
- A lack of boost pressure in low gears;
- Excessive oil consumption;
- High oil pressure at idle;
- Blue smoke from the exhaust; and,
- Illumination of the engine warning light.
To fix, the air filter housing assembly needs to be removed so that the oil filter housing can be replaced. Sometimes, the breather hose from the assembly to the block may be damaged and also require replacement.
If the PCV diaphragm has ruptured, the vehicle should not be run until the oil filter housing is replaced since doing so could damage the camshaft or crankshaft oil seals and cause oil leaks. If an oil leak occurs at the timing belt end, the timing belt and seals must be replaced. If, however, an oil leak occurs at the crankshaft’s main oil seal, then the gearbox must be removed, the seal replaced and, in extreme cases, the clutch replaced.
It is understood that Ford/Volvo subsequently introduced an uprated diaphragm which had an additional vent on the diaphragm cover, though failures of the updated diaphragm do still occur. Failures are more common in low mileage vehicles that:
- Have been used to drive short distances since the engine does not reach its operating temperatures; and,
- Reside in high humidity environments.
Ford Focus XR5 Turbo: cracked cylinder liners (B5254T3)
The 2.5-litre B5254T3 engine had an open deck block and steel cylinder liners that were press-fitted into the block. For standard B5254T3 engines, however, there have been rare cases of cracked cylinder liners (also known as sleeves). Symptoms of cracked cylinder liners include:
- Misfire when cold;
- Loss of coolant;
- Excessive white smoke; and,
- Rough running on start-up.
Engines that have been modified for greater power are considered more vulnerable to cracked cylinder liners (particularly beyond 240 kW) due to the following factors –
- Excessive boost pressure;
- Aggressive ignition timing from poorly developed aftermarket tunes; and,
- Coolant leaks that have not been rectified (see also ‘coolant leaks’, below).
It has also been suggested that cracked cylinder liners were most common for pre-April 2008 engines, though cracked liners have been observed in all years of Focus XR5 Turbo engines.
For B5254T3 engines to produce more than 300 bhp (224 kW), OEM Denied recommends a ‘block mod’ in which the cylinder head is removed and stainless steel shims are fitted in the expansion gaps between the cylinder liners. Although this does not guarantee that cracked cylinder liners will not happen, OEM Denied has not seen this occur in the vehicles they have worked upon.
B5254T3 engine: solenoid boost valve
For the 2.5-litre B5254T3 turbocharged petrol engine, the solenoid boost valve is susceptible to failure. If there is a lack of performance and the boost gauge boost doesn’t go beyond a quarter of the dial, this is indicative of a failed solenoid boost valve. If the valve is operating properly, the dial on the boost pressure gauge should go beyond halfway before settling down in the middle.
Ford Focus XR5 Turbo: coolant leaks
Ford Focus XR5 Turbo vehicles are susceptible to coolant leaks from –
- The thermostat housing at the cylinder head side gasket. Specifically, the leak occurs at the bottom corner and a mirror is required to see it;
- The turbo coolant feed and return; and,
- The radiator top hose joint at the back of the engine on the gearbox side.
The coolant hoses may also experience internal delamination as the vehicle ages. Where internal delamination has occurred, the hoses will appear swollen in size.
For 2008-10 Ford Focus XR5 Turbo vehicles, the driver’s side bottom corner of the radiator may also leak. The leak usually occurs from the sealant join between the alloy radiator core and the plastic end tank. Since a sponge at the bottom of the radiator absorbs most coolant drips, it is rare that coolant will leak and form visible drops on the floor. As such, a pressure test of the coolant system is recommended at each service to detect this leak. Fitment of a fully alloy radiator is recommended to prevent future failures.
Ford Focus XR5 Turbo: suspension
For the Ford Focus XR5 Turbo, the following suspension components may wear prematurely:
- The front anti-roll bar drop links;
- The rear bushes on the front wishbones bushes (oil-filled).
It is recommended that the oil-filled bushes be replaced with more durable polyurethane bushes.
Ford Focus XR5 Turbo: clutch does not return
For the Ford Focus XR5 Turbo, the clutch pedal may not fully return to the ‘up’ position. This may be due to:
- The seal from the original slave cylinder tearing and becoming stuck in the clutch line – this usually occurs after the clutch has been replaced. To fix, the clutch line has to be removed, blown out with compressed air and then have clean brake fluid poured through it. The brake fluid should flow easily and consistently in both directions; or,
- In the case of hard driving (during or after), hydraulic fluid may boil and cause air bubbles to form. To fix, the clutch should be bled and high boiling-point DOT 5.1 fluid used.
Ford Focus XR5 Turbo: air conditioning
- During full throttle acceleration, the air conditioning compressor clutch is designed to shut down to reduce accessory losses;
- The air conditioning may stop working due to failure of the air conditioning compressor clutch – this is caused by the spacing shims expanding and preventing the clutch from fully engaging. A common symptom of this fault is the air conditioning blowing cold for 10-15 minutes and then blowing hot; and,
- The air conditioning may stop working due to a refrigerant leaking from the compressor shaft seal.
Ford Focus XR5 Turbo: drive shafts
For the Ford Focus XR5 Turbo, the OEM drive shafts have a ball-type CV joint for the outer and a tripod style joint for the inner – this design enables the shafts to have some ‘in and out’ movement with suspension articulation. However, hard acceleration from rest will quickly destroy the original drive shafts.
In contrast, aftermarket drive shafts tend to have inner and outer ball type CV joints which restrict the ‘in and out’ movement. As a result, however, most aftermarket shafts cause vibrations during driving as they lock up on themselves.
As Ford Focus XR5 Turbo vehicles age, the CV boots can split – these need to be replaced promptly or grease will be flung out of the driveshaft as it rotates and the shaft will require replacement.
Ford Focus XR5 Turbo: front wheel bearings
For the Ford Focus XR5 Turbo, the front wheel bearings are:
- A complete hub and bearing setup;
- An interference press fit into the knuckle with no retaining clips; and,
- Not serviceable.
Over time, the hub assembly can start to ‘walk out’ of the hub. When this occurs, the gap between the ABS trigger wheel and the sensor is too great for the sensor to get a reading so it causes the ABS and TC warning light to illuminate; vehicle performance is also greatly reduced.
Ford Focus XR5 Turbo: corrosion/rust
For the Ford Focus XR5 Turbo, corrosion can occur in the following areas:
- Rear wheel arches (where a slightly misaligned bumper can rub away the paint); and,
- The tailgate and hatch area (particularly where the tailgate’s rubber buffer meets the body).
Ford Focus XR5 Turbo: other problems and faults
- Difficulty starting the vehicle and poor engine performance – including entering ‘limp home’ mode – may be due to the Power Control Module (PCM) cluster gateway not closing properly and draining the battery; reprogramming the PCM should fix the problem.
- Engine vibration, ‘engine malfunction’ warnings and entering ‘limp home’ mode may be due to a fault in the throttle body switch which requires replacement. In the interim, stopping the vehicle, turning the engine off and waiting five minutes should re-set the switch and enable the journey to be completed.
- The Recaro seat bases have a reputation for cracking – this is generally preceded by creaking noises from the seat.
- The windscreen washers could leak and rainwater could drain into the spark plug housing and cause corrosion.
AustralianCar.Reviews thanks OEM Denied for their contributions to this page.
