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Lenny
[i]My focus was manufactured in July 2010 and its starting to rust in the boot panel,
A spot behind the rubber elbow pipe carrying the cables in to the boot panel from the roof panel, can be seen when the boot is open, ill post a picture later, only problem is where do I stand with my warranty as Iíve fitted the ST rear spoiler to the car myself, although the spoiler doesnít tough the part affected i may have voided a warranty as Iíve modified the car outside of a ford workshop.[/i]
Leemaxd
Don't sound good, is it rusting of the metal or just dirty water . Did you buy it new or second hand, just say that the spoiler was on it when you brought it, they won't know.
catch
[quote name='Lenny' timestamp='1297580339' post='113922']
[i]My focus was manufactured in July 2010 and its starting to rust in the boot panel,
A spot behind the rubber elbow pipe carrying the cables in to the boot panel from the roof panel, can be seen when the boot is open, [/quote]

Lenny, you are not alone I have a 55 plate Mk2 with the exact same problem! I noticed it after buying it from a Ford Main Dealer on the 16th October 2009 [the car it's self was described in the advertisement as being "Franchise Approved"] Now when I noticed it I thought that was strange how it rusted there.

Now because visiting the dealer I bought from, is a 44 mile round trip away. I did not look forward to the "leave it with us, we will have a look at it scenario. So I thought, it being where it is, I will sort it out, because an exact match to paint finish was not the issue with me. The fact I could kill the source of the rust was the issue. Anyway when I started cutting back the paint to treat the rust, it just appeared to grow! Now that could suggest that the car had this problem from the day it was built. But being 4 years old when I bought it, I could not say for sure. Anyway I patched it up, first cleaning and then treating the affected area with "Hammerite Kurust" treatment. I've used it before, in fact I used it on my badly rusted front wheel arches [another Ford design fault on the Mk2]and it works. [url="http://www.fordownersclub.com/forums/index.php?showtopic=8380"]Known rust problems on mk2 Focus front wheel arches Honest John says Ford did a fix [/url] But of course that rust damage was not coming from behind the paint finish, it was caused by road grit grinding down the paint protection.

Coincidently the Mk1 Focus had sills made out of rust immune composite material. With the Mk2 they took a backward step in that area. Then a year after production started on the Mk2, they realised they had a problem, so from 06 builds onwards they introduced a "compromise fix" Now it would appear from early photo's of the new Mk3 they have learned their lesson and reintroduced the composite sills., first seen on the Mk1.

Anyway I digress....

So back to the problem under discussion, I treated the boot area and painted it, well I just notice the other week it is striking through again. Now that proves to me it is a build problem with the car,in that the car is rusting from the inside out. I also had to do rust remedial work around where the rubberised cable pipe enters the bulkhead of the car. Now I only decided yesterday to take the issue up with Ford customer services. Then you post the exact same problem the day after, in a car built 5 years later, how weird is that !

Photo 1: Taken late October 09, prior to remedial work.

[IMG]http://i4.photobucket.com/albums/y147/suggy1/VF010.jpg[/IMG]

Photo 2: Paint work cut back prior to rust cure treatment applications.

[IMG]http://i4.photobucket.com/albums/y147/suggy1/chips.jpg[/IMG]

When I get dressed, I'm just sat here with a thong on at the moment [only joking] I'll nip out and take some more photo's, as I'll need them as part of my communications with Ford.



[quote]ill post a picture later[/quote]

Yes that would be good, a close up one and one showing the top of the rear opening bulkhead, along with the top of the door. [just so others can see exactly what the problem is.


[quote]only problem is where do I stand with my warranty as I’ve fitted the ST rear spoiler to the car myself, although the spoiler doesn’t tough the part affected i may have voided a warranty as I’ve modified the car outside of a ford workshop.[/i]
[/quote]

I don't think that is an issue, what you have done in no way contributed to the problem under discussion. And as I appear to have the same issue, it is not a "one off" And on that basis it is reasonable to assume many more owners out there have the same issue. I would say it indicates it is obviously a design and or build issue with the Mk2 family of Focus's

We must keep in touch in regard to how we get on when we individually contact Ford over the issue. And it will not harm our causes if we let them known we are aware of other people having the same problem on cars built five years apart. I myself would be prepared to test my case in the small claims court, if I don't get satisfaction from Ford UK. A car with a 12 year perforation warranty, breaking out in rust blisters after 4 years. And it happening to cars built five years later, showing a rust problem in less than a year after manufacture. That in an area of the vehicle not exposed to the weather, or degradation to the paint finish by road grit or stones thrown up ! I can hazard a guess in who's favour a judgement would be made.
artscot79
[/quote]

if you fitted the spoiler youreself its a 50/50 they may just ignore the spoiler but if they are clued up they wont wether or not the spoiler effects the area in question or not they can still claim you used non ford parts and a non ford fitter to put these parts on in whech case under the terms and conditions of the warranty it will now be nil and void the best way to find out is take it in and get it looked at when fitting the spoiler you did use mastic to seal the areas where it touches the body i assume
catch
not wanting to appear picky artscot79 mate, but as your replying to Lenny, why do you quote my post, and mine having photo's and my detailed replies :rolleyes: in them. Means peeps wanting to read the jist of the thread, have to scroll through a posting they have just read.

Be a mate and edit my content out, the flow of thread will be better for it, anybody else agree?
catch
on this picture you can also see where I've treated rust forming around the hole in the bulkhead that is filled by a grommet enclosing the pipe that takes water to the rear washer jet.

[IMG]http://i4.photobucket.com/albums/y147/suggy1/bulkhead120211.jpg[/IMG]

This picture: is it the washer water supply pipe grommet assembly where it enters the tail gate, causing the initial paint break down. In that when the tail gate closes it has at some time in it's life been the culprit? Who knows? But actually looking at the photo, I reckon the grommet will not sit in line with the rusty area when the tail gate is closed. Possibly I should attempt to expose the rear of this metal work by removing the roof lining at the back of the cabin.

[IMG]http://i4.photobucket.com/albums/y147/suggy1/bulkheadrust120211b.jpg[/IMG]

Never having had the head lining of a car, could anybody who has advise me best way to go about it. And does it go back OK, and will it expose the rear of the actual metal roof or bulkhead panels, or is some form of sound proofing stuck to the actual underside of the roof?

Edit: Having just been out and had a look at the roof lining, it looks like it has to come out as one whole unit. taking plastic trim of the front and rear pillars, including the C pillars, the four grab handles, all the door openings weather proof rubber mouldings, two retaining clips pushed into the roof lining behind and above the rear seats.......in short not a small job
Lenny
[quote name='artscot79' timestamp='1297598935' post='113940']
if you fitted the spoiler youreself its a 50/50 they may just ignore the spoiler but if they are clued up they wont wether or not the spoiler effects the area in question or not they can still claim you used non ford parts and a non ford fitter to put these parts on in whech case under the terms and conditions of the warranty it will now be nil and void the best way to find out is take it in and get it looked at when fitting the spoiler you did use mastic to seal the areas where it touches the body i assume
[/quote]
The ST Spoiler I’ve fitted is an original Genuine ford part bought brand new from ford in the uk, sprayed by a mate and fitted by me following the instructions supplied with it, all the parts on the car are genuine ford parts, the gray area (pardon the pun) may be that I’ve fitted it myself rather than paying them 390 to supply and fit it. the instructions dont specifiy to use any sealant in the fitting as it comes with sticky foam strips to bond around the spoiler, only advise was to use some locktite on the bolts.
Lenny
Thanks for all your information Catch, shocking to hear your having the same problem i also live 40minutes away from my local dealer, who is an ignorent pig starting to wonder who got what in the scrappage deal, First noticed it 3 weeks ago when I opened the boot I saw like a snail trail of rust on the top, so I wiped it clean, donít use the boot that often roughly 12 times since I bought the car so here it is 3 weeks later since i spotted it. only have the car since october bought it from the ford dealer direct, was a test drive model
[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0415.jpg[/img]

[IMG]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0413.jpg[/IMG]
artscot79
[quote name='Lenny' timestamp='1297629623' post='114003']
Thanks for all your information Catch, shocking to hear your having the same problem i also live 40minutes away from my local dealer, who is an ignorent pig starting to wonder who got what in the scrappage deal, First noticed it 3 weeks ago when I opened the boot I saw like a snail trail of rust on the top, so I wiped it clean, don't use the boot that often roughly 12 times since I bought the car so here it is 3 weeks later since i spotted it. only have the car since october bought it from the ford dealer direct, was a test drive model
[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0415.jpg[/img]

[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0413.jpg[/img]
[/quote]

looking at the pictures youve posted ide have to agree on a build fault my almost 10 yr old mk1 doesnt have rust in these locations to remove the roof panel is involved ive done it once and it was a pain in the rear i would take it back to ford those locations have nothing to do with the spoiler or fitting it seems to be where the water pools posibly untreated or not properly painted
catch
[b]artscot79[/b],

you have fricking gone and done it again [IMG]http://i4.photobucket.com/albums/y147/suggy1/brickwall.gif[/IMG] this double posting of image posts doesn't half make reading the thread a ball ache.

[b]Lenny[/b], any chance of a couple of brighter lit, higher resolution photo's of the damage? My photo's were taken with a 6 mega pixel camera.

Reason I'm asking is this, I'm going to contact Ford UK. I ain't wasting my time with a main dealer who because they cannot be bothered will just come up with all sorts of reasons why it ain't their problem. No, I'm going to approach Ford, and put the argument to them that it is a build issue. An issue that has been there from day one on the Mk2/2.5 models. And indeed it was still there right up to the last build of the Mk2.5 model. And to do that I need to send them clear crisp photo's that will stand up to being magnified under inspection.

Getting Ford UK to accept it is a build quality issue is the way to go IMHO. Because unless they do, your local main dealer ain't going to do the work because he will not be able to bill Ford UK for rectifying the problem.

I have taken on all sorts of manufactures, or suppliers that produce faulty components/ goods/ services and have not lost a complaint yet. And I'll tell you this, it's the first initial contact that is important, you have to present them with evidence that stands up to scrutiny. At the same time in this particular instance impressing on them you are aware of other owners with the same problem in the exact same area.

Because what your actually attempting to do in your first communique. Is making sure the email opener who first reads your complaint passes it up the food chain to somebody who has the authority to up hold your complaint. Other wise you will just get the stock reply, you will have to take it up with the dealer who sold you the vehicle.

I'll be honest here, you do have a better chance of getting it sorted at dealer level, better than me as my car is over five years old now, hence I'm not even contemplating the dealer option.And that being the case I want to use photo's of you fault when I present my complaint to Ford UK. And besides if you take it to a dealer, they may just blow it over, not actually remedy the problem. Then your back in a year eighteen months time with the same problem. So best go to Ford UK directly and get them to admit it's a build problem IMHO.
Lenny
[quote name='catch' timestamp='1297779591' post='114250']
[b]artscot79[/b],

you have fricking gone and done it again [IMG]http://i4.photobucket.com/albums/y147/suggy1/brickwall.gif[/IMG] this double posting of image posts doesn't half make reading the thread a ball ache.

[b]Lenny[/b], any chance of a couple of brighter lit, higher resolution photo's of the damage? My photo's were taken with a 6 mega pixel camera.

[/quote]
Sorry mate,
Ive only got my Nokia Phone 2.5Mega Pixle, also dont know if theirs a ford ireland but as far as im aware their all imported directly from the uk if you need any further information or if i can be of further assistance contact me,
im more in favour of reporting it to ford and getting my local panel beather to repair the rust as i would feel more confident that the rust was actualy repaired rather than a skim of paint on to cover it until warrenty expires as their a shower of Vagina's in my local dealership, sales man had an attitude with me straight away. which got worse when i told him i would buy my accessories from foed uk as their cheaper and post to my address cheaper than two 45minute trips to his garage.
top banana
well, mine has been in for repair and picking it up for repair tomorrow or monday, under warranty.
keep you updated on repair
Lenny
[size="4"][/size][size="4"][/size][size="5"][/size][quote name='catch' timestamp='1297779591' post='114250']
[b]artscot79[/b],

Getting Ford UK to accept it is a build quality issue is the way to go IMHO. Because unless they do, your local main dealer ain't going to do the work because he will not be able to bill Ford UK for rectifying the problem.

I have taken on all sorts of manufactures, or suppliers that produce faulty components/ goods/ services and have not lost a complaint yet. Then your back in a year eighteen months time with the same problem. So best go to Ford UK directly and get them to admit it's a build problem IMHO.
[/quote]

Went to ford about it, but not letting them repair it, going to professional sprayer myself costing 30euro but Iíll know itís done proper as its being paid for and not a quick skim of paint by ford to shut me up and cover the rust till warranty expires,

[u][b]Also found the root cause of the problem[/b][/u]
The rubber pipe is too long and the elbow created when the boot is closed, is rubbing off the body work causing the pain to wear and moisture to be trapped between the pipe and the body, so bought a cable tie and a sticky back pad in halfrauds done the trick, no more wearing and the pressure from the rear water jet isnít affected woo hoo case solved. :)
Daryll
So what was the verdict on getting this done under warrenty?? I read this post a couple of weeks ago then forgot about it until I opened my boot over the weekend and guess what... little patch of rust in the same place on my 2009 1.6 tdci...

Bought 2 months ago from a used car dealer (non-Ford) but it still is in the warrenty period.
Lenny
[size="4"][/size][size="4"][/size][quote name='Daryll' timestamp='1302542666' post='122513']
So what was the verdict on getting this done under warrenty?? I read this post a couple of weeks ago then forgot about it until I opened my boot over the weekend and guess what... little patch of rust in the same place on my 2009 1.6 tdci...

Bought 2 months ago from a used car dealer (non-Ford) but it still is in the warrenty period.
[/quote]
They were willing to have it repaired by their local spray garage,
but in my opinion they (Ford) will go for the cheapest quick fix job possible, to satisfy us and keep the show room quiet, as its dead money their spending all ford want is to sell, sell, sell, they don’t care about the aftercare unless were paying for it, I’d rather take mine to a sprayer who I know is good and is being paid by me to do the purpose job,
So since he’s being paid to solve the problem he will take the time needed to sand it down and re-spray it properly preventing any chance of rust creep beneath the surface

But I must add that the problem will happen again if not done as following picture:
[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0462.jpg[/img]

The smallest Cable tie possible and a sticky back pad with holes to loop tie wrap through, i have a set left if you want it PM me your details and i will post for free. Only 1 set available by me.
[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0464.jpg[/IMG]
catch
Come on Daryll.

get of your butt and post a picture of your problem :P ;) Both Lenny and I have made the effort [for the benefit of others] That way anybody else wanting to confront Ford with this obvious design fault, has the evidence of other Foci with the same problem. Saves time them bullshitting the complainant that its a one off and not their [Fords] problem. Besides Lenny's picture was crap :D

Lenny I agree with you what the problem is, and like you have decided to fix it myself, for the reasons you gave in regard to possibly them just doing a cosmetic job. I've expanded the area until I hit virgin metal. As rust creeps under the paint finish, dependent when remedial action is taken dictates how big an area that is. In my case on a 5.5 year old car it means the rust creep would be more than yours or Daryll's.

Now I treated and applied finish coats a couple of weeks back. And at the time I decided like [yourself] to remove the cause of the problem all be it in a different way. I cut a rectangle of what can best be described as a rubber compound. It was an off cut to a garage door leaf/draft excluder I had fitted a couple of years back. I very rarely throw anything away that at the time I think "that might just come in handy" And the wife has the nerve to call such stuff junk..........women what are they like.......if they cannot smear it on their skin or wear it...its rubbish :rolleyes:

Anyway I've been letting the repaired area harden before super gluing it to the bulkhead, just in case of a possibility of there being a chemical reaction that broke down the paint finish if it was not fully cured. So no picture fitted but here it is

[IMG]http://i4.photobucket.com/albums/y147/suggy1/rubberpad.jpg[/IMG]

Edit: As it looks massive in the photo, I'll add the rubber patch measurements. They are 35mmm x 20mm, which is way bigger then what I exposed length wise. I'm going to glue it on the short edges and the top edge, on old hardened paintwork. Leaving the bottom unglued in case water does some how creep in from the top. I'm expecting the top and side seals to be water proof, but you never know.

Oh the rubber pad is 2.30mm thick......I measured it with my digital tyre tread depth gauge :ph34r:
Lenny
[quote name='catch' timestamp='1302622177' post='122632']
Come on Daryll.

get of your butt and post a picture of your problem :P ;) Both Lenny and I have made the effort [for the benefit of others] That way anybody else wanting to confront Ford with this obvious design fault, has the evidence of other Foci with the same problem. Saves time them bullshitting the complainant that its a one off and not their [Fords] problem. Besides Lenny's picture was crap :D

Lenny I agree with you what the problem is, and like you have decided to fix it myself, for the reasons you gave in regard to possibly them just doing a cosmetic job. I've expanded the area until I hit virgin metal. As rust creeps under the paint finish, dependent when remedial action is taken dictates how big an area that is. In my case on a 5.5 year old car it means the rust creep would be more than yours or Daryll's.

[/quote]

Totally agree with catch on this subject daryll , with 3 of us now experiencing the same defect ford can’t say no to you, if they do e-mail them a link to this topic, my car has now got 22,000km on it manufactured June 2010 and the problem is well under way, report it to ford even if you decide to pay for it to be done yourself rather than letting ford do it, as you will bring it to the attention of the garage and potentially help other focus owners who may not be members of any forum and not know that this is a common fault. As ford will begin to see a trend.
special thanks to catch for assisting with spreading the awareness of this problem, there is also clear film used to prevent stone chips on bumpers may be possible to buy in small quantity’s
Broxson
I have noticed the other day just above my reg plate and behind slightly my boot is starting to rust with little dots of rust are starting to appear and it is a 2007 model on reading this I shall be contacting ford on this matter
catch
Just so Daryll does not think I'm picking on him ;).............I see "top banana" did not come back with his feed back as promised :rolleyes:

In regard to my motor, when I did the fix, applying Kurust rust curing treatment. I did two coats of this within the hour, then three hours to let it cure, before applying undercoat filler [as per instructions ] Then left 24 hours [as per instructions] before applying colour coats. And a few days later I applied a couple of coats of lacquer.

During all these applications, I left the boot lid open for at least 4 hours [with the boot lamp removed] So the applications which would not have hardened, were not subjected to stress by the offending rubber pipe configuration. And when I did eventually close the boot lid and used the car, I temporarily fixed that rubber pad I had made with some black UPVC electrical tape applied to the upper edge of the pad [flap like]

In fact I've had a re think since my last post, and I've decided to re a fix it as above. That way whilst relieving the stress of that pipe on the paint work [as I think it's that raised leading edge of the grommet where it is welded to the length of pipe, that does the damage]

OK I accept that to some peeps it will sound like a lot of faffing about. But this way I will be able to lift the flap 14 months down the road and see if rust is breaking through from behind the fix. As it did last time I did a quick rushed fix. I'm just the kind of guy who wants conclusive proof as to what is happening. For instance, peeps catching it early might have better results than people like me who buy a motor four years old, and the rust has had all that time to eat it's way into the bulkhead.

Of course Lenny's way, using a fixing to pull the offending joint back from the paint finish will achieve the same results as my pad.
top banana
[quote name='top banana' timestamp='1300483205' post='119070']
well, mine has been in for repair and picking it up for repair tomorrow or monday, under warranty.
keep you updated on repair
[/quote]

sorry for not replying sooner, bad family things going on.

well, car was at the Ford bodyshop for 2 days, and the rear panel where the rust was has been resprayed, but Ford also supplied the bodyshop with the stonechip protection sheet to stick to the area where the rust was. Hmmm so they are aware of the issue then, as the supplied a remidial part to prevent from happening again??!!

all seems good nearly 1 month on. Mine was the 2nd car they had in for this fault in March#!
catch
Hope the family issues get sorted soon mate.

And I hope you did not mind the tongue in check ribbing I give you. And thanks for the feed back, out of interest how big was the stone chip protection sheet they supplied to the spray shop? A photo of same in situ would be even better, or has it been blended into the body work and sprayed over to be nigh on invisible.
blueovalcraig
My Focus has done the exact same thing. Think I'll need to ring Ford in the morning. My thrust bearing in the gearbox also lets out a yelp when cold so will have to ask them about that too I guess.
Daryll
ok, I intended to take a pic, but never got around to it... now you've shamed me into it..!

<_<

Mine isn't as big as you guys :unsure: but its there, in the same place. also, my washer pipe seems to be stretched pretty tight, so I'm not sure I could use the cable tie method.
catch
Yours and Lenny's are about the same size, mine being a 55 plate, build date October 2005, just shows you how the rust spreads if it is not remedied.

So just on our forum we have found the same fault in 05 build [start of the Mk2 model] in 07, 08, 09 and 2010 build vehicles....right up until the last Mk2.5 rolls off the production line

We now have conclusive proof that it is a design flaw or production line flaw that was designed into the original Mk2 Focus in 2005 and Ford have ignored it for five years, and the flaw will been in the very last Mk2.5 model that rolls of the production line.

FORD MANAGEMENT, YOUR A SHOWER OF SH@T THE LOT OF YOU
Lenny
[quote name='catch' timestamp='1302900607' post='123082']
We now have conclusive proof that it is a design flaw or production line flaw that was designed into the original Mk2 Focus in 2005 and Ford have ignored it for five years, and the flaw will been in the very last Mk2.5 model that rolls of the production line.

[/quote]

Couldn’t agree more Catch,
And also my camera really is SH*t mate because on a close inspection my model has the anti scratch pad fitted by ford, to be honest I nearly removed it with a wipe of a cloth lol to make things worse its too small to cover the whole area and didn’t even prevent mine from happening, what can i say they made an error in manufacture and their corrective action isn’t even big enough to cover the area at risk,more of a reason why im paying to get mine repared privatly as ford messed up creating the problem and ther corrective action to prevent this problem isint working neither, :angry:
But what can we expect from a company owned by BP

[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0414j.jpg[/img]
Lenny
[quote name='Daryll' timestamp='1302888971' post='123059']
Mine isn't as big as you guys :unsure: but its there, in the same place. also, my washer pipe seems to be stretched pretty tight, so I'm not sure I could use the cable tie method.
[/quote]
sorry to inform but your rust patch is bigger than mine mate, my advise would be as soon as you can, get some wd-40 or similar and rub it in circular motions over the area this will cause a film of oil to form on the surface preventing moisture from entering and rusting further, water will pearl in droplets on top of oil,
I thought the same about my pipe but was fine I will measure the length of the pipe in the morning and let you compare if yours is the same length, still have the pad and cable tie if you want them send me a mail with your address and ill post them to you free of charge mate. It seems I can confidently say it’s better than fords solution to the problem :lol:
paramaniac
I read this post and checked my car (2009), sure enough there were marks where the cable was rubbing and had almost gone through the paint. I have stuck a patch of 3M adhesive tape over the area to stop the rubbing against the bodywork and will keep an eye on it.
shawty1984
Just checked mine (Focus Zetec 2009, 59 reg) and dads (Focus Zetec 2010, 10 reg). Mine has no pad on and you can see black marks were the pipe is rubbing. There is no rust yet. Dads has the pad with very slight black marks from the rubbing. I'm taking mine in on Wednesday for rear parking sensors, so will ask them if there is a known issue and what they suggest.
shawty1984
[quote name='Broxson' timestamp='1302646331' post='122678']
I have noticed the other day just above my reg plate and behind slightly my boot is starting to rust with little dots of rust are starting to appear and it is a 2007 model on reading this I shall be contacting ford on this matter
[/quote]


When you say little dots of rust, do you mean very tiny dots. Are they all over the car? Look quite close to the paint work. Is it a light coloured car, white? If so this could be inudstrial fallout/raildust. Nothing the dealer can do as it is not a fault on there end. If it is inudustrial fallout, clay baring the car gets it out.
shaunyg
hi guys, my old Focus ST (2006) had the exact same problem, i noticed it about a month ago but as i recently part exchanged the ST for a 2010 tdci i didn't bother doing anything about it. I've checked my new focus and there is a pad in place, was this pad fitted at production or later? i'm just curious as to remove it and check underneath to see if it covering anything that shouldn't be there, hmmmm
catch
[quote name='shaunyg' timestamp='1305095509' post='126691']
I've checked my new focus and there is a pad in place, was this pad fitted at production or later? i'm just curious as to remove it and check underneath to see if it covering anything that shouldn't be there, hmmmm
[/quote]

You want forum posters to just guess if anything lurks behind this pad?
If that's the case hang on
















.....tosses coin.....heads....
fitted at production. :D

I'd assume it's doing it's job until proved otherwise.
shaunyg
i did not specifically mean the pad on my car, but more of general question, did ford realise this was an issue and start adding the pads onto the cars which had already gone thru production but before they were initially sold?
catch
Ah I see what you mean.

Well assuming you have read the thread in full, I think you will see it points to the fact that the pad [call it what you may] is fitted prior to the car leaving the production facility, in that it is a fix for a known problem. In manufacturing the need to rectify a design fault usually takes the course of least cost.....hence the pad.
shaunyg
i thought that may have been the case, nothing like doing summat on the cheap, hey we'll cover it with summat sticky lol i'll leave mine in place and let it do its job :)
shawty1984
Just an update on the 'problem' of the rubbing I had. After reading this thread I had checked mine and my dads cars. Mine a Focus Zetec S 1.8 59 reg and my dads a Focus Zetec S 1.6 10 reg. My dads had already had a 'patch' installed which must have come from the production line I'm guessing as it is the same as the ones in these photos. Mine never had any and thus the pipe had been rubbing which had left slight black marks (no rusting). So when I took it in for reversing sensors I mentioned it to them and they were going to have a look. When I went to pick the car up they said there wasn't much they could do as there was no rust (all though I don't think he was trying to fob me off, I think he was going to suggest the film if I had not said anything anyway) and I pointed out a prevention of the rust is better than just letting it start to rust and then bringing it in so they could deal with it under warranty. They also had known about the problem as they had stuck some plastic type clear film over the area to stop the rubbing on the paintwork on other cars before. So they offered to give me some film that I could cut down to size and fit myself.
shaunyg
i thought Ford may have improved their paintwork over the years, all their cars rust after a short amount of time, my dads started shortly after getting it, so did my mums, my old 06 ST started, hope my new focus doesn't (i'm from a Ford family lol) my gf's T reg VW Polo, not a speck of rust to be seen on the body work, think Ford should take note!!! if they got their paintwork sorted it would finish their cars off nicely!
jordan_macgregor
"They were willing to have it repaired by their local spray garage,
but in my opinion they (Ford) will go for the cheapest quick fix job possible, to satisfy us and keep the show room quiet, as its dead money their spending all ford want is to sell, sell, sell, they don’t care about the aftercare unless were paying for it, I’d rather take mine to a sprayer who I know is good and is being paid by me to do the purpose job,
So since he’s being paid to solve the problem he will take the time needed to sand it down and re-spray it properly preventing any chance of rust creep beneath the surface

The smallest Cable tie possible and a sticky back pad with holes to loop tie wrap through, i have a set left if you want it PM me your details and i will post for free...."




Can i ask where you got the sticky back pads from?
Lenny
[quote name='jordan_macgregor' timestamp='1332029165' post='173134']

The smallest Cable tie possible and a sticky back pad with holes to loop tie wrap through, i have a set left if you want it PM me your details and i will post for free...."

Can i ask where you got the sticky back pads from?
[/quote]

i bought them from here mate:
[url="http://www.ebay.co.uk/itm/STRONG-DOUBLE-SIDED-STICKY-PADS-SUIT-ALL-AREAS-/110830912979?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item19ce0985d3"]http://www.ebay.co.uk/itm/STRONG-DOUBLE-SIDED-STICKY-PADS-SUIT-ALL-AREAS-/110830912979?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item19ce0985d3[/url]

but they have come apart in the last couple of weeks, with all the opening and closing of the boot door,
so im going to purchase some anti-chip film instead
[url="http://www.ebay.co.uk/itm/Vehicle-paint-protection-film-1M-X-15cm-protect-chips-scuffs-bonnet-bra-/220925776790?pt=UK_Car_Accessories_Car_Care_Cleaning&hash=item337033d396"]http://www.ebay.co.uk/itm/Vehicle-paint-protection-film-1M-X-15cm-protect-chips-scuffs-bonnet-bra-/220925776790?pt=UK_Car_Accessories_Car_Care_Cleaning&hash=item337033d396[/url]
mitch84
Will check mine later today as I think my car is the same model and year as Lennys , Am I right in thinking that the area to look for any rust marks is just under the spoiler area on the inside of the car when opening the boot?

Thanks
Lenny
[quote name='mitch84' timestamp='1332061499' post='173151']
Will check mine later today as I think my car is the same model and year as Lennys , Am I right in thinking that the area to look for any rust marks is just under the spoiler area on the inside of the car when opening the boot?

Thanks
[/quote]

yes mate,
its the flat panel that faces you when you open the boot,
not part of the boot door,
its the roof of the car where the pipe elbows and rubs off the roof section.

[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image1451-1.jpg[/img]
ChrisH
[quote name='mitch84' timestamp='1332061499' post='173151']
Will check mine later today as I think my car is the same model and year as Lennys , Am I right in thinking that the area to look for any rust marks is just under the spoiler area on the inside of the car when opening the boot?

Thanks
[/quote]
You know thinking about it, mine is rusting there also. Are ford taking this seriously, or is it basically up to us to fix? Mines a 2006 model.
Lenny
[quote name='ChrisH' timestamp='1332062598' post='173154']
You know thinking about it, mine is rusting there also. Are ford taking this seriously, or is it basically up to us to fix? Mines a 2006 model.
[/quote]

for piece of mind i fixed my own mate,
it is a fault with all mk2 and mk2.5 models mate so they do know about it and they put a clear patch on the 2008-2010 models where they thought the pipe would rub the body but in my case the put it in the wrong place, and mine started to rub beside the patch rather than on it,

[img]http://i575.photobucket.com/albums/ss192/lennymanwoods/Image0414j.jpg[/img]
mitch84
thanks for that pic Lenny , will have a look later and report back!
Lenny
[quote name='mitch84' timestamp='1332065481' post='173161']
thanks for that pic Lenny , will have a look later and report back!
[/quote]

no probs mate,
best advise i can give anyone regarding this is even if their is no sign of rust or scuffing, id still cover it with anti chip film because it is a known fault in design and likely to happen in the future,

another known fault is the seal around the bolts, that hold the rear spoiler on to the car, can deteriorate with age and allow water to leak in to the boot, so i have done some preventive action when fitting my ST rear spoiler and i put some silicone around the bolt holes prior to bolting the spoiler in to place.

overall though the mk2 and mk2.5 focus are fantastic cars, and even better now that we know about the little flaws in design so we can do our best to keep it a great motor. and perhaps an edge over others when it comes to resale because others may not have treated the effected area on theirs resulting in rust creep and blistering under the paint.
ChrisH
Thanks lenny. Will have a look in a bit for that antichip film, see if its fitted already. Looks like ive got some preventitive work to do....
catch
Well here is the "no cost" fix I decided on, the logic being, why spend money on a fix on a 6/7 year old car . In an area of the car that will only be seen when the boot is open....for on averages 4/5 seconds at that.

Fix was, clean and "cure" the rust, over paint, leave a month or so then I super glued a piece of rubber I had cut off a garage door draft/leaf seal, when I was fitting it four years ago.........I knew it would come in handy for something :D
Oh, and I smeared that wonder product silicone "GREASE" around the edges of the pad prior to offering it up to the bulkhead. Now if for some reason it continues to rust behind that pad..........well the plan is, I'll be moving it on circa mid 2014. And I very much doubt it will have ate it's way around that fix by then. :rolleyes:




[img]http://i4.photobucket.com/albums/y147/suggy1/bootpad2.jpg[/img]

Interestingly you will see by the photo that it rained during the night, and water appears to get trapped between the pipe and the bulkhead whilst the boot is closed And this folks is why I reckon it rusts in the first place......pipe over time [and not a long period of time at that going by the registrations mentioned in this thread] wears the protective paint off and the rust sets in.
mitch84
just checked mine ,cant say I notice any rust , I can see a little scratch plate like you mentioned.

One thing I notice is that on that picture you posted Lenny and the one above, that one of the pipes has a plastic type tube and the pipe on the right has no cover?

On mine I have the ribbed casing on both?
ChrisH
Had a proper look this aft, and although this area was covered in crap, (never even thought of cleaning this area :unsure: :unsure: ) There did appear to be a mark where the washer hose would rub. Gave it a good clean, and of course there is a small rust spot there. I will follow catch's advice and clean this up. Will probably brush some of that rust convertor stuff on, and then overpaint, maybe with some hammerite, and then put a rubber patch over.
Pidu
Wow, I read a lot about rusting Fords but never about rust in this particular place. Checked my 2006 estate - this area is clean (car was washed few days ago) and free of any marks, not even black marks of rubbing washer hose. I will not place any rubber there, rather some protective film, just in case ;)
catch
Pidu, maybe it's a case of you having an estate, and therefore there are differences in the structure of the tailgate opening, meaning estates don't suffer from this problem?

More feed back by other Focus estate owners posting on the thread could maybe point to that being the case or not.

Chris, just a heads up on my experiences regards this issue. I first attempted a paint only fix on this around September 2010. You can see in post number six of this thread, a photo showing the rust breaking through the over painted area again. :angry:

So with Lenny bringing up the issue again, I decided to give it another look at. And I considered that the possible failure of the original attempted fix may have been that I did not expose enough of the affected area.

You know how it is, your tempted to keep the area of repair as small as possible. When in fact all the cosmetic work you do to cover up the fix will be a waste of time and effort if you do not expose and kill all the rust at the early stages of the repair process. So think on, cut back the paint until you have a "fire break" of clean metal between the rusted area and the original paint finish.

A good thing I have found that works, is to photograph the expose effected area. Then download it to your PC, and then use the computers magnifying tool on the photo. I now do this before and after applying the rust curing product I use. And always best to do two applications of the latter as per the manufactures instructions........secret is do not rush this part of the rust fixing procedure.

Oh another tip, after the second repaint job, I thought it better to protect the affected area whilst giving the new paint finish time to harden prior to securing the protective rubber patch. So to this end a day after over painting, I just temporarily fixed the top edge the rubber patch to the bulkhead with black insulation tape. Doing this means you can just lift the patch up anytime you want to check if any rust is attempting to break through again. And you know what it blends in and you will tend to forget about it, I did and as such did not get around to permanently superglue the patch for another six months or so circa October 2011


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