2004 Ford Focus fuel system problems

Filed Aug 22, 2019 · Body, Electrical · 250,000 miles · SC

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.

Filed Jul 19, 2019 · Fuel system, Locks · WA

Tl* the contact owns a 2004 ford focus. The contact stated that the vehicle experienced the same failures listed in the federal safety agency campaign number: 06e056000 (fuel system, gasoline) and the federal safety agency 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.

Filed Apr 23, 2014 · Fuel system · 145,600 miles · AZ

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".

Filed Oct 3, 2013 · Fuel system · 100,000 miles · NY

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 the federal safety agency 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.

Filed May 22, 2009 · Fuel system · 5,000 miles · CA

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.

Filed Jan 18, 2008 · Fuel system · 16,000 miles · AK

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.

Filed Aug 21, 2007 · Fuel system · 48,073 miles · CT

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?

Filed May 16, 2007 · Fuel system · 53,898 miles · IL

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.

Filed Jun 5, 2006 · Fuel system · 29,000 miles · NJ

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.

Filed Aug 28, 2005 · Acceleration, Fuel system · 9,996 miles · WI

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.