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2010 Focus 1.6Tdci Rusting!!


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#1 Lenny

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Posted 13 February 2011 - 07:08 AM

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.


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#2 Leemaxd

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Posted 13 February 2011 - 09:28 AM

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.

#3 catch

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Posted 13 February 2011 - 11:36 AM

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,


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. Known rust problems on mk2 Focus front wheel arches Honest John says Ford did a fix 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.

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

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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.



ill post a picture later



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.


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 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.

#4 artscot79

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Posted 13 February 2011 - 12:18 PM

[/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

#5 catch

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Posted 13 February 2011 - 12:50 PM

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?

#6 catch

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Posted 13 February 2011 - 02:17 PM

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.

Posted Image

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.

Posted Image

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

#7 Lenny

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Posted 13 February 2011 - 08:16 PM

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

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.

#8 Lenny

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Posted 13 February 2011 - 08:50 PM

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
Posted Image

Posted Image

#9 artscot79

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Posted 13 February 2011 - 10:12 PM

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
Posted Image

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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

#10 catch

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Posted 15 February 2011 - 02:29 PM

artscot79,

you have fricking gone and done it again Posted Image this double posting of image posts doesn't half make reading the thread a ball ache.

Lenny, 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.

#11 Lenny

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Posted 16 February 2011 - 08:13 PM

artscot79,

you have fricking gone and done it again Posted Image this double posting of image posts doesn't half make reading the thread a ball ache.

Lenny, 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.

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 !Removed!'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.

#12 top banana

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Posted 18 March 2011 - 09:30 PM

well, mine has been in for repair and picking it up for repair tomorrow or monday, under warranty.
keep you updated on repair

#13 Lenny

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Posted 09 April 2011 - 04:32 PM

[size="4"][/size]

artscot79,

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.


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,

Also found the root cause of the problem
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. :)

#14 Daryll

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Posted 11 April 2011 - 05:34 PM

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.

#15 Lenny

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Posted 11 April 2011 - 08:50 PM

[size="4"][/size]

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.

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:
Posted Image

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.
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