Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt
Took car in for motorcraft service and mentioned when booking it in i had seen small amount of oil on my drive.
Was called and advised that it was a faulty sump plug ,so obviously agreed for them to change this.
Picked it up and next day noticed oil was still leaking out.
Took it back and was informed it was a turbo pipe of some sort that was leaking, this part wasn,t in stock and was ordered and car booked in for a week later .
After a couple of days noticed that it was difficult to get into reverse gear.
Called them about this and asked if I could take it in for them to investigate as was concerned that the oil maybe leaking from gearbox.
Took it back to them and they changed the Turbo pipe and said clutch was fine but gave it an Amber Warning and to maybe take it back in 4-6 months .
The next day driving to work there was a Red Warning Light saying LOW BRAKE FLUID so called them and spoke to technician who advised me to check fluid level and I found it was low so bought brake fluid and topped it up myself and this got rid of the Warning . I asked them why wasnt this checked in the service I had done and there response was it isn,t included in the service ( I would have thought to check and advise was though).
The next day I once again couldnt get my car into any gear whilst the engine was running but ok when engine was off and had to loan a car to go to work so at this point losing faith in this garage and gave them a poor mark on there ( How did we do Email ) .
Got home that same afternoon and was contacted by there reception to say that my car was booked in the next day to change the Turbo Pipe , I told them this had been done 2 days earlier ( not the best organisation process to say the least ) and that I was totally disappointed with there service and the receptionist then got there Service Leader to call me back.
The service leader made arrangements to come and pick my car up next day.
I spoke to him at the end of the day and he said it was worse than they thought and that it looked like the Master slave clutch cylinder had burst in the gearbox and told me the Worst Case Scenario cost would be £580 I was taken aback by this but he said they would double check it and that the work could not be done due to New Year Bank hols etc until 3rd Jan 2017 and on this day there reception called me with a price of £1890 and at this point I just couldnt speak to her and asked that she checked the costs .
The next day she called and says they where now £2961 .85 has the Technician said I need a new gearbox as well.
Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - SLO76
This shower of sharletons are at it and yet another example of why I believe that you should maintain a full dealer or genuine specialist service history with a complex motor like this. Quite simply this lot and many like them haven't a clue what they're doing with your car. Take it to your nearest Ford dealer to be correctly diagnosed, it'll cost to fix but they won't tell you nonsense like you need a new gearbox when clearly you do not and it's likely something simple. These are generally reliable cars excluding the 1.6 PSA diesel. Keep us informed how you get on because this is a car I particularly like and may buy at some point.

Edited by SLO76 on 08/01/2017 at 11:26

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - gordonbennet

Don't check brake fluid on a service, worth a double face palm that one.

As said, avoid that bunch at all costs put it down to experience and take it somewhere else, i'd also let the mechanic who takes over know what the last lot butchered so he can double check their work, might cos a few quid to do so but if they've bodged something which later breaks and all your engine oil vanishes whilst you are on the motorway it will be a lot more expensive.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Hi There this is a Ford Main Dealer

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Sorry missed this out but this is with a Ford Main Dealership and they say the Clutch as disintegrated and blown a hole in the Gearbox .???

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - elekie&a/c doctor
Not too sure why it needs a new gearbox.loss of brake fluid is most likely due to the clutch slave cylinder leaking.it shares the same fluid reservoir as the brakes.Guess it is going to need a new clutch kit,which includes the slave cylinder.
Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Thanks for your reply they are saying that the Clutch has disintegrated and blown a hole in the gearbox they have sent me photos , and here is costs list

Please see below as requested the brake down for the repair needed on your vehicle

Clutch repair

Clutch 196.67

Cylindar 69.31

Bolts 4.98

Clutch Fluid 8.07

Gearbox oil 60.24

Labour 382.50

Plus vat

Clutch repair £866.12

When removing gearbox tech reported issue and requires replacement gearbox additional parts

Gearbox 1411.00

Flywheel 271.94

Bolts 21.00

Labour 42.50

Plus vat

Gearbox repair £2095.72

Total cost of repair to Clutch and gearbox - £2961.85inc

We will need to order gearbox

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - gordonbennet

Maybe this is only me, but do the photos show internal damage inside the bell housing, or is there other damage present (such as the box fell on the floor from 5ft and split open?).

I haven't removed one of these boxes but in theory at least the box should be repairable, it should only be casing damage, after all.

I'd be wanting to see the box in the flesh if it were mine, then assessing (with advice from a gearbox rebuilder via lots of your own pictures) whether a repair to the casing is feasable or if the front casting might be replaceable individually.

Seems bonkers to me to replace an entire box, but at a main dealer that's likely to be pretty standard practice.

I'm surprised at how it took several visits and a replacement sump bolt and turbo pipe for a main dealer to finally notice the oil was coming from a punctured gearbox after all, doesn't fill one with confidence about the quality of work there, and no we don't check brake fluid levels on service is still a howler that would see me never darken their doorstep again.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - skidpan

I'm surprised at how it took several visits and a replacement sump bolt and turbo pipe for a main dealer to finally notice the oil was coming from a punctured gearbox after all, doesn't fill one with confidence about the quality of work there,

Does not surprise me.

Had a 2005 Mini Cooper S. Started to drip oil at about 1 year old. It was at the gearbox end of the engine and appeared to be quite thick but did not smell like traditional gear oil.

Garage initially said it was sump plug so dropped the oil and fitted a new plug and washer.

Dry for a bit then started again. They said it was the sump gasket so off with the sump etc.

Dry for a bit then started again. This time they said it was the crank oil seal and they would need the car for a week.

Dry for a bit and stated again. Went to a different BMW/Mini dealer who said it was the diff and they would need the car for another week. Car was due for changing mid summer so decided to bring it forward 3 or 4 months. PX'd it as was and presumably they did the warranty repair before selling it.

Probably the only Mini that had 4 oil changes in the first 2 1/2 years and 13,000 miles.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - bolt

Maybe this is only me, but do the photos show internal damage inside the bell housing, or is there other damage present (such as the box fell on the floor from 5ft and split open?).

I haven't removed one of these boxes but in theory at least the box should be repairable, it should only be casing damage, after all.

I'd be wanting to see the box in the flesh if it were mine, then assessing (with advice from a gearbox rebuilder via lots of your own pictures) whether a repair to the casing is feasable or if the front casting might be replaceable individually.

Seems bonkers to me to replace an entire box, but at a main dealer that's likely to be pretty standard practice.

I'm surprised at how it took several visits and a replacement sump bolt and turbo pipe for a main dealer to finally notice the oil was coming from a punctured gearbox after all, doesn't fill one with confidence about the quality of work there, and no we don't check brake fluid levels on service is still a howler that would see me never darken their doorstep again.

I agree with GB, though I used to work for a ford main dealer but never took a gearbox off the car for a clutch change, we hung it from driveshafts,it was quicker

also never seen a clutch break a bell housing, unless it was dropped from a height and then it only cracked not smashed, maybe they are not as thick as they used to be but even then they take some breaking

Main dealers do strip boxes down, and we could replace parts on the 80s boxes in an hour, refit box in 20mins.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

www.flickr.com/photos/14726217@N08/

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - RichardW

Sorry to hear the tale of woe.

Somewhat worrying that they missed the oil leak as in fact being clutch fluid or gearbox oil.

They may well have checked the brake fluid level and it could have been OK - a serious leak from the clutch slave could well have drained it quickly.

Most of the cost of the repair is in the new box - there must be a cheaper option; either a repair of the one you have (which was working OK when you drove it in there), or a second hand one. However, you are a bit stuck between a rock and a hard place as the car is presumably in bits on the ramp, and they will want it out pronto. If you put the photos up somewhere like photobucket and link them we can have a look and see if it looks like it could be repaired. I would think sourcing, and convincing them to fit, a 2nd hand box is likely to be the most time / cost effective way out (unless it is obvious that the damage to the box was caused during its removal).

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Thanks hope this link shows photos , I am considering sourcing parts myself even if I can save a couple of hundred poiunds but you are right I am stuck between a rock and a hardplace.

tinyurl.com/jj8u7b9

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - SLO76

Sorry missed this out but this is with a Ford Main Dealership and they say the Clutch as disintegrated and blown a hole in the Gearbox .???

That's poor service from a main dealer. A brake fluid check is part of the service shedule as far as I'm concerned, certainly any motor I've put into a main dealer lists it on the check sheet. As far as the clutch failure ruining the gearbox I assume they actually mean the dual mass flywheel has broken up and somehow damaged the gearbox. This isn't unheard of on Fords, particularly diesels. But it's rare that it would damage the box unless you've driven it for a while after its been broken. Were there any rattling noises particularly on start up or when the car was in neutral?

Edited by SLO76 on 08/01/2017 at 15:50

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Thanks for taking time to reply but I never had any indication/ noise etc but I tend to always have music on so possibly had missed it , can you put pictures up on this site ?? has I have some .

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - gordonbennet

, can you put pictures up on this site ?? has I have some

not directly, but you can upload them to a site like phtot sharing site like flickr or photobucket, then give us the link (probabaly best use tinyurl) and we can then view them

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Hope this works thanks

tinyurl.com/jj8u7b9

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - Big John

Wow re pictures

There have also been problems with original Sachs clutch cover plates self desctucting causing damage and machining through the gearbox casing with the Skoda Superb II 2.0 CR diesel fitted with six speed box and concentric clutch slave cylinder - posted on a Skoda forum

Edited by Big John on 08/01/2017 at 21:12

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - gordonbennet

That's pretty drastic stuff i've never seen a clutch disintegrate and cause further damage as bad as that, don't know if the front casting is a separate part, doubt it, but even if that hole is repairable its going to have to come off for repair and to clean out the innards of the box from whatever shrapnel has ended up inside, a few days turn around at best.

Can see why the Ford workshops are suggesting going for a new complete box, at their labour rates it's probably the cost effective option, plus with that damage chances are you are going to have to pay the surcharge on a recon.

Other options include a good used unit, but if it turns out not to be a good unit you'll be paying the labour for removals and refittings, doubt the Ford garage would consider sourcing.

Might be worth speaking with an indy gearbox workshops tomorrow, sending them the pics, see if they can come up with a plan, but that isn't going to suit the Ford garage who no doubt want it fixed and out of workshop space.

Rock and hard place indeed and you have our sympathies.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Thankyou for your advice just gutted really but will have to move on and bite the bullet so to speak

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - bolt

Thankyou for your advice just gutted really but will have to move on and bite the bullet so to speak

Try and get a different make of clutch as that pressure plate IMO is a bad design ie cheap and nasty, good luck anyway.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - RichardW

Ouch! That's nasty... Surprised that was not making a horrific noise! Could be repaired with a new casing, but would need a full box strip and rebuild, and I'd be worried about any bits of the casing that might have gone round inside... I would fit a 2nd hand box - there are loads on e-bay around £200 - most will have come from write offs, so are likely good - manual boxes rarely give trouble these days. Dealer might not play ball though. Your best bet in that case might be get them to put it back together sufficiently that it can be moved, then get it to a local non-franchised garage to replace the clutch and fit a used box. Will cost you a bit in labour at the dealer, but you will save on the parts - a lot in the case of the box!!

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

many thanks for the advice , currently looking into this and have asked the dealer how much is there bill for the investigation work, has I cant afford there prices and will get car towed to a mate of a mate so to speak.

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - SLO76
Every sympathy. I always regarded petrol Focus's as pretty bulletproof aside from the issues on some 1.0Ecoboost engines. I like the ballance of performance and comfort on this model, quick but not as hard riding as the ST. This has put me right off.

Find a good local gearbox specialist and speak to them, they might be able to arrange transport of the car to them and will know exactly what happened. Big weakness of main dealers is they don't fix things they just replace and charge. But usually they're more likely to service the thing properly.

Hope you find a cheap fix that lasts, at least long enough to get shot of it at auction or trade in.
Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Thanks for taking time to reply , still waiting for dealers to respond to my email for costs so far .

Just in process of sourcing a gearbox replacement .

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - peter moss

There are so many horror stories about dealers /garages doing or not doing work on vehicles and with todays cars being designed not to be worked on by diy,ers with the special tools equipment and knoweledge its a case of do you feel lucky punk when you go to a dealer /garage ,

I drive a french automatic with the dreaded AL4 unit i downloaded 3 manuals for the trans unit and found that one application had a condition counter in the software that counted up to 32000 miles and put it into limp mode [time to change the fluid ] the counter has to be reset and needs the clip bidirectional scanner so i asked them how much to just reset the software he said iv just asked my top tech and he has never heard of any condition counter , i said thats strange it has a condition ssensor on the bottom of the unit , he just waved it on .

so my take on problems with your car is to get a tablet with screencord and before you decide to do anything with your vehicle record all and any videos from youtube relating to your vehicle you are then looking at people who know how how to fix problems and what to look for if a problem is coming up

I have a loads of how to vids on pen drives and have learned a lot not only about my vehicle but also about modern systems /oils fluids and vehicle computers / relays testing procedures ,

As for your problem i would probably go to savage yard like Trents and get another gearbox with a 3 months garantee along with a flywheel ,put a new slave in it and clutch thats if the cars worth it or get a recon box , ok hope you get it sorted ,good luck with it !

Ford Focus 2011 1.6 Petrol 150 psi Mk 3 Miles 52K - Clutch and Gearbox issue plus total Dispair - steve mckevitt

Hi There thanks for taking time to comment , I have finally got the car from the Main Dealers and in process of sourcing a 2nd hand gearbox and new clutch / flywheel etc through the help of a local mechanic.

I asked what I owed them and had this back

As requested the labour charge for the removal of the gearbox is £229.50 but as you are a good customer we will do it for £145.00inc Vat.

Rubbing salt in the wound I think .

Main Dealers wouldnt even help the Towing Truck guy I sent to pick it up ie my car was parked in a very tight space , they just came out give him the key and walked back inside , he was helped /guided by a couple guys who happened to be looking at a car to buy.

 

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