Death rattle

We have a Ford Fiesta ST150 that was an ex-demonstration model and was bought 2 years ago. It had a service just before we bought it and as it's my husband's pride and joy doesn't go very far. Hence it has only done about 3,000 miles since we've had it, so it wasn't serviced last year. It has just had a service and MOT on the 1st April, the warranty was up 30th March. My husband took it for a run and it developed a rattle. He took it straight to Ford Thorne who booked it in for the following Friday. They looked at the car, said they thought the noise was coming from the timing chain but that it would cost £300 to take the top off and look before they did anything. When asked if they would help towards the cost the said no as we had missed a service. It doesn't say a lot for the car if after 13,000 miles from new it develops a major fault. Do you have recommendations as to what we can do? It is sitting on the drive at the moment as we are scared to use it, but think it will cost over £1,000 to repair. We are happy to pay towards the repair but think Fords could offer to pay half the cost.

Asked on 3 July 2010 by AW, via email

Answered by Honest John
Get a second opinion. This reads like the swirl flaps in the inlet manifold may have become detached, a problem that occurs on Mondeos that this engine came from. The engine can ingest the broken bits of swirl flap, so it’s vital to get this fixed before the car is driven. But, of course, if it hasn't been serviced properly then neither the supplying dealer nor Ford are liable.
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