What is the likelihood of a gearbox failing at just 30,000 miles?

We bought a used 2019 Ford Focus Active X in March 2024. As of Sep 2025 the car has only done just over 30,000 miles, 1 previous owner and has been regularly serviced. At the time of purchase we also purchased a 3 year extended warranty. The car developed a sudden fault in March 2025 whereby the car just jumped out of 2nd gear into neutral while driving along. This was accompanied by juddering and lack of ability to engage 2nd gear. We immediately got the car inspected by a mechanic who inspected the car in detail and concluded that the 2nd gear issue was due to a gearbox failure.

The warranty provider is refusing to agree to a repair on the basis that the issue *may* be due to wear and tear. They initially rejected the claim outright - ignoring their own engineers report. They are now demanding that we prove that it's not wear and tear by paying to strip down the gearbox (almost the same cost as replacing) and then waiting for their engineer to attend and inspect (they took 3 weeks to turn up for initial inspection).

This appears to be unreasonable cost shifting and avoidance of contractural responsibility. What is the probability of a well maintained 2019 Ford Focus gearbox failing at 30k miles due to wear and tear?

Asked on 5 September 2025 by Barney Walker

Answered by David Ross

The probability of a gearbox failure at 30,000 miles is impossible to calculate accurately as how the vehicle is used can have a bearing on its lifespan, but it is considered as a 'lifetime' component of the vehicle in that it should not need to be replaced within a reasonable mileage of 100,000 miles or more with the correct maintenance. You have the option to seek out third party estimates for the replacement of the gearbox and/or the cost of a stripdown and inspection to determine the cause of the fault and taking your complaint to a trade association if the warranty provider is a member, or potentially complaining to the Financial Ombudsman Service if the warranty provider is underwritten by an insurance company.

Tags: faults warranty issues gearbox failures

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