Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

My Focus 1l Ecoboost was making a tapping noise so i booked it into the garage. They took it to a Ford dealer who stripped the enginge to discover that the crankshift has broken up and have advised that the engine needs replaced.

Any advice on what could have caused this would be much appreciated. Car is a 62 plate and covered around 38K. Serviced in Dec. Oil and water levels were fine and no warning lights were on.

Ford Focus 1l Ecoboost - Damaged crankshaft - craig-pd130

What's the service history of the car? Has it been serviced on schedule? When did it start making the tapping noise, and how long has it been making it?

Unfortunately, random mechanical failures can happen even on engines that are fully serviced and driven carefully .... there may not be a definitive reason for the problem,

Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

Was only serviced in Dec and had all the previous stamps in the book for the age of the car.

Noticed the noise on the Sun and it was booked in on the Wed. Was advised by the garage the car was still ok to drive

Ford Focus 1l Ecoboost - Damaged crankshaft - SLO76
Seems to be developing a rather nasty reputation as a soft engine the 1L Ecoboost. Loads of cases of engine failure on the net and a very disinterested manufacturer that's simply ignoring customers plight.

It's usually down to coolant loss and resulting overheating though. There was a hasty redesign I believe in 2013 to solve this and a related recall and failures so far do seem less common on later cars but there's definitely an issue with these. Head gasket failure is alarmingly common too. So much so that I no longer recommend any Focus with this engine or the notorious PSA 1.6 diesel. Shame really as it's otherwise a brilliant little car so is the Fiesta.

Wish they'd asked Yamaha or Mazda to design them same as the previous NA 1.6 and 1.8 petrols which were very robust.

Edited by SLO76 on 28/04/2017 at 23:03

Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

Never had ny coolant issues personaly. Oil and water levels have been fine since i owned the car. I know there was issues with the DGAS pipe around my cars year. Will need to investigate if the car was recalled before i bought it.

Ford Focus 1l Ecoboost - Damaged crankshaft - SLO76
From what you say I'm assuming you had decided to maintain it out with the main dealer network? On complex turbocharged engines like this it's vital they are correctly maintained and sadly Dodgy Joe's backstreet workshop doesn't always have the know how to do so. They often bung any old oil in which is a killer on modern high tech stuff like this. These are very oil specific engines which are easily damaged by the incorrect grade.

Also had it been maintained by the main dealer they would have made sure you were aware of any technical bulletins advising on any preventive maintenance. They're advised to watch out for typical faults discovered through the dealer network and rectify or advise accordingly.

Ford are being a***holes regarding goodwill on Ecoboost failures even with a dealer history but you've no chance if it's been serviced by someone else sadly.
Ford Focus 1l Ecoboost - Damaged crankshaft - Wackyracer

James, join the facebook group for the Ford Focus Ecoboost 1.0L. there is lots of advice there for dealing with Ford with regard to this engines failing.

Ford Focus 1l Ecoboost - Damaged crankshaft - corax

What is Ford service regime with this engine? Not oil changes every 20k is it? I would have thought that overheating would usually show up at the head gaskets first. A broken crankshaft sounds like the component being weak or lack of oil lubrication.

I would have thought that these smaller, more stressed engines would need more regular oil changes of the right type of oil.

Just read that it runs very hot (all the more reason to service them regularly then) and one failure was down to a coolant hose catastrophically failing. Doesn't it show up in the testing of new vehicles? It must show signs of stress beforehand.

Edited by corax on 29/04/2017 at 12:49

Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

Wasnt serviced by Ford but at a vauxhall dealer (with a great reputation) from where I bought the car.

Ford Focus 1l Ecoboost - Damaged crankshaft - John F

My Focus 1l Ecoboost was making a tapping noise........stripped the enginge to discover that the crankshift has broken up ........

??! More details, please. Any chance of a photo of the damage? The duff hose coolant loss is well known - is this another type of problem? Dodgy supplier to the (?Romanian) engine factory?

Ford Focus 1l Ecoboost - Damaged crankshaft - corax

Dodgy supplier to the (?Romanian) engine factory?

You're probably right John F. Cost cutting. If I was forced to choose, I would rather have something like an ancilliary fail though, like the Valeo aircon compressors VAG were using, rather than a crucial cooling part of an engine that runs hot!

Ford Focus 1l Ecoboost - Damaged crankshaft - Wackyracer

From some of the photos I've seen the cylinder heads have melted inside the exhaust ports close to the valve guides.

Ford Focus 1l Ecoboost - Damaged crankshaft - madf

As I understand it, Ford specify 0w-20 oil. Use of ANY other oil = big problems. Car Mechanics have an article in this month detailing all teh issues.

I would not buy one serviced outside teh dealer network based on that article.

Conclusion: fragile highly tuned engine with zero scope for any failure in coolant or oil system.. Like ZERO ..

Ford Focus 1l Ecoboost - Damaged crankshaft - bazza

Conclusion: fragile highly tuned engine with zero scope for any failure in coolant or oil system.. Like ZERO ....

I agree totally, but to some extent, greater or less we do not know, this is true of all the current crop of very downsized petrol turbos. Although I've driven a few and am very impressed, including this Ecoboost, I can't help thinking just how hard they are working, constantly on boost, constantly running very hot, relying on perfect lubrication and cooling. For that reason, I shall try and avoid, although that is difficult. I'm curious to find out how robust the new Honda 1.0 and Toyota 1.2 turn out after a few years use and 100,000 miles, compared to the old Vtecs and VVTi non turbo designs. Perhaps we have to accept that they may no longer go to 200K or so , but perhaps also this doesn't matter if the current trend of changing cars every 3 years once the newness has worn off continues. Manufacturers after all are hardly concerned with the 2nd, 3rd, 4th owners!

Ford Focus 1l Ecoboost - Damaged crankshaft - JEREMYH

I completly agree with you this maybe something we have to accept

This however should be pointed out at the point of ordering so that you can change your mind and like some of us just run good 90s cars

Ford Focus 1l Ecoboost - Damaged crankshaft - John F

As I understand it, Ford specify 0w-20 oil.....

Conclusion: fragile highly tuned engine with zero scope for any failure in coolant or oil system..

Not looking good for longevity, although there must be umpteen thousands of them doing OK. Saw this (below) on another site discussing oil choice.....so I suppose you pays your money and takes your choice. I wonder how the Peugeot Pure-tech 1.2 is faring by comparison - I rather fancy a 2008 with EAT-6 when our (t)rusty Focus dies...

Depends how you drive. If you drive hard the TBN number will drop to zero rapidly (and then you have acid in your oil eating-away at the metal parts). But if you drive a constant 60mph for thousands of miles, the TBN will barely drop at all.

The low TBN 0w-20 is recommended for only 6000 or 7500 miles. The high TBN 5w-20 is recommended for 15,000 miles.

Edited by John F on 29/04/2017 at 18:33

Ford Focus 1l Ecoboost - Damaged crankshaft - Wackyracer

I would not buy one serviced outside teh dealer network based on that article.

I wouldn't buy one at all, many of the cars that have failed on the facebook group were only serviced by the Ford dealers they were bought from and many of them have less than 30,000miles on the clock when they needed a complete engine. There is one as low as 15,000miles. Many have previously had the Degas hose updates done too.

Ford Focus 1l Ecoboost - Damaged crankshaft - veloceman
All very worrying this.
My partner has a 2013 Festa 1.0 ecoboost from new.
Now covered almost 50k, serviced every 12k/12months.

What to me is a brilliant car in every respect is turning out to be a ticking time bomb.
I keep telling her to change it but she is saving for a house.
- Fingers crossed!
Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

Sorry no photos as of yet the car is still with Ford awaiting an inspector from the Warranty company.

Ford Focus 1l Ecoboost - Damaged crankshaft - Stanb Sevento

I find it hard to imagine any servicing items that could cause a crankshaft to break. Oil can’t , it may damage bearings, pistons or valves but break a crankshaft, don’t think so. If its broken its either fatigue, being overloaded or defective from the start which is by far the most likely. A look at the broken bit would give a big clue.

I assume there were on other clues that something was wrong, car running Ok with no noises. If one part breaks the increased stress will cause multipal breaks so all parts need looked at to identify where it started.

As a rule petrol engines use cast crankshafts where as diesel use forged ( much tougher ) Castings are prone to manufacturing defects like gas inclusions or impurities and are sensitive to the way they are cooled once cast. I would be fighting this with Ford insisting that Ford examine the part and pay for the replacement. It would take some other catastrophic failure in the engine to break a sound crankshaft. You need to have a go at Ford about this, they have the facilities to test this.

Edited by Stanb Sevento on 30/04/2017 at 15:52

Ford Focus 1l Ecoboost - Damaged crankshaft - galileo

As far as I know Ford used spheroidal graphite cast iron crankshafts for many years, these had a good reputation, other manufacturers also used S G iron cranks.

I once had the forged steel crankshaft on an MG (with the XPAG 1 1/4 litre engine) break across the front journal, 45 degree fatigue failure originating at the oil-drilling. No warning, no other damage, just sudden knocking at 30 mph cruise

.(At the time I was following a Metallurgy degree course)

As said above, inspection of the fracture surface should confirm or eliminate fatigue, suggesting a defective crankshaft, or overstress due to other component failure.

Edited by galileo on 30/04/2017 at 16:59

Ford Focus 1l Ecoboost - Damaged crankshaft - jc2

Fords first use of SG crankshafts was in 1959(105E).

Ford Focus 1l Ecoboost - Damaged crankshaft - daveyK_UK
Am I correct to presume the above is true of the 1.0 engine in whichever Ford vehicle they are installed?
C-max, grand C-max, tourneo connect, etc?

Edited by daveyK_UK on 30/04/2017 at 22:14

Ford Focus 1l Ecoboost - Damaged crankshaft - galileo

Fords first use of SG crankshafts was in 1959(105E).

I thought that was when they introduced them, by 1964 when I had an interview at Ford's Dagenham the foundry was turning them out by the thousand for Anglias/Cortinas etc. Shell-moulded as I recall so minimal machining allowance needed.

Ford Focus 1l Ecoboost - Damaged crankshaft - Stanb Sevento

.(At the time I was following a Metallurgy degree course)

Small world. I abandoned a carer in Metallurgy after only three years at the age of 25. I was forced into it by low pay and a wife , mortgage and young child. The UK does not value scientists or engineers, unlike Japan or China. Took a junior management job with a major tyre manufacturer and increased my pay by 275% Felt like a millionaire for a while but its a bit sad really.

Ford Focus 1l Ecoboost - Damaged crankshaft - bazza

Looking around the net, there's clearly some weaknesses around the cooling system/degas hose/gasket leaks on the 1.0 unit. I am not sure whether a temperature gauge is fitted to the Fords or not, if not, overheating will not be noticed in time, hence the head gasket/engine damage being encountered. The engine is very novel and interesting ,with exhaust manifold built into head, tiny turbo, cambelt running in oil, variable oil pump output ( if I recall). But most owners, I am sure are completely unaware just how complex and potentially fragile ( read expensive) the unit is. On the other hand, there must be hundreds of thousands of these motors in service, and the failure rate is probably very low as a percentage. Of course that's no help to those unlucky owners faced with a £5000 bill on a 3 to 4 year old car just out of warranty. A bit similar to the VW DSG gearbox fiasco

Ford Focus 1l Ecoboost - Damaged crankshaft - daveyK_UK
Does anyone have the retail price for one of these engines?
Ford Focus 1l Ecoboost - Damaged crankshaft - James McClelland

I've been told £3750 plus VAT at 20%. Not sure if this includes labour costs though.

Ford Focus 1l Ecoboost - Damaged crankshaft - daveyK_UK

£3750 will be the cost of the labour as well.

No way its that price, surely not?

Ford Focus 1l Ecoboost - Damaged crankshaft - Wackyracer

£3750 will be the cost of the labour as well.

No way its that price, surely not?

Most people who have been told they need a new engine have been quoted £5000 inculding the labour.

Ford Focus 1l Ecoboost - Damaged crankshaft - Fishermans Bend

You could get a low mileage engine secondhand , with a warranty, for less. Then get shot of the thing PDQ.

Ford Focus 1l Ecoboost - Damaged crankshaft - Stanb Sevento

Does no one rebuild engines anymore ? Firstly it may only need a short engine If the cylinder head and camshaft are OK And a crankshaft is not a particularly expensive thing. There are loads of engineering shops around that specialise in this sort of thing. You cant be sure exactly whats needed till the thing is fully dismantled but just going straight for a new engine seems a bit over the top to me.

If the car was still running then the chances are the pistons and conrods are OK along with the cylinder head and camshaft, all the expensive bits.

Ford Focus 1l Ecoboost - Damaged crankshaft - Manatee

No, they don't mend things any more except on properly old cars. Labour cost I suppose, and the infrequency of having to do it that means the skills are not readily available in main dealers. Although a friend did have a fairly full rebuild of a 3.5 litre XK120 engine (which turned out to be out of a MkVII anyway) that cost IIRC about £4,000. That included stitching the block which had a crack in it, and seemed fairly reasonable to me.

Ford Focus 1l Ecoboost - Damaged crankshaft - bathtub tom

Does no one rebuild engines anymore ?

I recall one modern engine could not be re-built. Unbolting the block from the sump (IIRC) caused such stresses as to distort the thing.

I'm currently looking at a late nineteenth century engine that will need new pistons and would gladly pay a few grand for a new engine compared to the cost of getting new pistons made!

Ford Focus 1l Ecoboost - Damaged crankshaft - daveyK_UK
Is it fair to assume the engine will cost Ford considerably less than £1k?
Ford Focus 1l Ecoboost - Damaged crankshaft - Oli rag
I suspect it isn't an easy engine to strip and rebuild. The cam belt which has an oil bath is quoted as being a 7 hour job to replace at a cost of £800.

It is supposed to last for 10 years or 150000 miles, however HJ has a failure at 108000 listed in the fiesta good/ bad section.
Ford Focus 1l Ecoboost - Damaged crankshaft - corax
I suspect it isn't an easy engine to strip and rebuild. The cam belt which has an oil bath is quoted as being a 7 hour job to replace at a cost of £800. It is supposed to last for 10 years or 150000 miles, however HJ has a failure at 108000 listed in the fiesta good/ bad section.

I never took much notice of that traditional 'sell at 100k' mindset that people had, with cars of the nineties having the potential to last much longer, but it looks like this type of engine is going to bring that back with a vengeance. These cars will be worthless at that stage once people have got used to the intended lifespan.

I think this is the last gasp of the internal combustion engine (for private transport) before electric vehicles are developed further. I still don't see how they can all be charged (which will presumably be at night when everyone is home from work) unless the national power grid is uprated. A couple of years ago we were being told that there was no spare capacity, and that's just for todays demand.

Ford Focus 1l Ecoboost - Damaged crankshaft - Stanb Sevento

Things obviously have moved on since I did anything of this nature, 20 years,. it was a thriving industry at one time. I used to tune engines as a hobby ( long story ) and there was a shop in Glasgow called “Piston and Components” who’s counter only had a pile of reference books they could look up everything you could possibly need to rebuild an engine. Pistons , bearings, rings sets, valves, valve springs you name it, not just standard sizes but plus sizes for rebores and regrinds, and 90% in stock. You could drop off a crankshaft on a Monday and pick it up on a Wednesday reground and with the correct oversize bearings. Sounds like the dark ages now.

Mechanical reliability is better now inspite of a lot of the horror stories, better fuel, better oil, better oil circulation and crank case breathing. Better quality control is likely another but you wonder at times.

I’d say £1K is a reasonable guess for ex works cost, largely automated probably. Its amazing how these nightmare jobs like cam belts become a piece of cake when the engine is out of the car and sitting on a stand.in front of you.

 

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