Now the weather has turned colder I felt the need to put a bit of heat on in the Mk2.5 but turning the control to maximum didn't produce any. My wife had earlier remarked the control seemed to want to spring back. I pulled out the radio to get access to the back of the panel and found the exposed length of Bowden wire had bunched up into an inverted 'U'. After straightening it the control is now working again but IMHO this is a rather stupid design. Stranded Bowden cables are designed to pull, not push, and it will only take a small amount of resistance at the flap for this to happen again.

Ok, this is the first time it's happened in 12 years (as far as I know) but I'm not impressed. If the cable needs to push it should be solid wire not stranded.

21 hours ago, mjt said:

Bowden cables are designed to pull, not push, and it will only take a small amount of resistance at the flap for this to happen again.

Normally in this type of application there is a return spring that would keep the flap closed by default and turning the knob would cause the cable to pull against the spring and open the flap.

I'm not saying that this is the way your system was designed, only that it is usual to have a return spring.

Now, this thread of 'poor design' could be s real runner LOL

36 minutes ago, StephenFord said:

Now, this thread of 'poor design' could be s real runner LOL

I think you've just thrown down the gauntlet there!😀

OK, I'll kick off LOL On my Mk2, when the tailgate is wet (from rain or a wash) opening it allows it to empty a pint of water inside the boot - poor design...'

Ecoboost 1.0 nothing more to be said 🤣

1 hour ago, StephenFord said:

OK, I'll kick off LOL On my Mk2, when the tailgate is wet (from rain or a wash) opening it allows it to empty a pint of water inside the boot - poor design...'

Ford havent improved it much over time as when you open the hatch on the mk4 if you are stood in the wrong place at the time ov opening you get a very wet foot but only on the right hand side.......so stand to the left when opening the boot or let the Mrs go and open it and deny any knowledge 🤭

1 hour ago, StephenFord said:

OK, I'll kick off LOL On my Mk2, when the tailgate is wet (from rain or a wash) opening it allows it to empty a pint of water inside the boot - poor design...'

Ford actually issued a fix for this, first as a TSB I think, then incorporated into production on the mk2.5 (maybe late mk2’s too) with plastic strips attached the sides of the tailgate glass. 
 

Still remember Ford having similar issues with failures of the optional in-boot CD changer on the original Puma. It got a soaking every time you opened the tailgate when the car was wet. Change in strut damping spec was the fix in that case iirc

12 minutes ago, troy45 said:

Ford actually issued a fix for this, first as a TSB I think, then incorporated into production on the mk2.5 (maybe late mk2’s too) with plastic strips attached the sides of the tailgate glass. 

That sounds intriguing. Any part numbers for such things? I suppose their availability for a 17 year old car would be unlikely though...

2 hours ago, StephenFord said:

Any part numbers for such things?

Ask and you shall receive 😀

RHS = 1539801  and  LHS = 1539802

£28.50 each

Example of supplier: https://shop.ford.co.uk/products/ford-focus-rear-boot-tailgate-o-s-window-moulding

10 mins of searching the web and putting nice red circles on screenshots and I got beaten too it 😅

Finished result below, the example I found on eBay was £28 😲 so you’ll be glad they’re available cheaper 

 

5 minutes ago, troy45 said:

the example I found on eBay was £28 😲 so you’ll be glad they’re available cheaper 

One thing I can tell you for sure. Even if they were £28 for a pair including free P&P the chance of Stephen spending that kind of money just to keep dry is ............? well let's just say not very likely 🤣

10 hours ago, troy45 said:

10 mins of searching the web and putting nice red circles on screenshots and I got beaten too it 😅

Finished result below, the example I found on eBay was £28 😲 so you’ll be glad they’re available cheaper 

 

 

You could still come up trump! Lol I searched eBay but can't find the cheaper listing. Have you a link, or a product code?

16 hours ago, unofix said:

Normally in this type of application there is a return spring that would keep the flap closed by default and turning the knob would cause the cable to pull against the spring and open the flap.

I'm not saying that this the way your system was designed, only that it is usual to have a return spring.

Agreed, however getting access to the flap looks to be quite difficult so I don't think I'll be trying to check for a broken spring. Maybe one of the techs on here might know if there is one. Personally I wouldn't be surprised to find there isn't one and this is just another piece of typical Ford poor design.

This thread has indeed become a runner. I can add boots full of water, door seals falling off and screenwash tracking through to the BCM (Mk3), water ingress through rear light screws (Mk2). Keep 'em coming .

I've always thought t*sticles were a poor design.  Oh wait, it has to be car related?  

The start button on the Mk3 & 4...have to be a contortionist to reach up behind the steering wheel for it!  

The windscreen angle on the Mk3 that basically just reflects the dash in even the slightest hint of sunlight.

The cruise control setup on the Mk2 - having to switch the system on before being able to use it, but with no signs of whether it's on or off, and resetting to off again after every start.

The cruise control setup on the (late) Mk4 - removing the clutch cancel function!

The oil filter change on the Mk2 1.6 TDCI - having to unbolt a boost pipe to remove the filter.

The ridiculous tab on the Mk2.5 sidelight bulb which eventually snaps off and makes it virtually impossible to replace the bulb.

The unnecessarily long and deep front bumper overhang on the Mk3 that gets caught on every kerb you try to carefully mount.

The electric brake booster on the Mk4.  The brakes are either on or off, there's nothing in between.

The digital dash on the Mk4.  Too cluttered, too much unnecessary guff, slightly fuzzy.  

The Eolys DPF system on Mk2 diesels.  Never did work correctly...you can't just dribble some fuel additive in and hope that's at the correct amount and distributed evenly though the tank!

The pan roof blind in the Mk4 being made of a thin, light coloured material...not stopping any sort of heat from passing straight through and cooking my balding head on one side.

The full leather seats in the Mk4 Vignale...whatever happened to padding seats?  These things are rock solid!

14 hours ago, unofix said:

Ecoboost 1.0 nothing more to be said 🤣

Add the diesel ecoblue 2.0 to that one. And the 1.5 for good measure. And and . I'd better stop. 

With all the water dripping in comments on tailgate, I will add the Mk5 Mondeo hatchback to that one. Washing my Hyundai in a min so may need to add another. 

1 minute ago, iantt said:

And and . I'd better stop. 

There is a Guy just posted a question about changing the oil in his auto gearbox, and his 'Mechanic' refused to do the job. I was thinking you could may be offer to lend a hand 🤣

The poster thinks it's an easy job and can't understand why the mechanic won't do the work for him 😂

2 minutes ago, unofix said:

There is a Guy just posted a question about changing the oil in his auto gearbox, and his 'Mechanic' refused to do the job. I was thinking you could may be offer to lend a hand 🤣

The poster thinks it's an easy job and can't understand why the mechanic won't do the work for him 😂

I just read that and the penny didn't drop until I read it again. I get the feeling he may not want my help . I don't blame him really as I've only got 42 years experience  🤣🤣

Will have to have a positive thread about good design . All this negativity on forums does my head in some times. Ah, the shape of some anti depressant tablets are a poor design making me choke. Or is that the design intent. 🤣🤣🤣🤣

Koreans can't do any better

1 hour ago, StephenFord said:

You could still come up trump! Lol I searched eBay but can't find the cheaper listing. Have you a link, or a product code?

I just searched the finis codes, example of 1 here

https://shop.ford.co.uk/products/ford-focus-rear-boot-tailgate-o-s-window-moulding

back on topic which is unusual for me haha, my previous 2005 model had the stuck flaps which broke the cable resulting in me having to replace them and finding person with thin arms to reach up to the flaps and force them apart i beleive in the US due to the temps they would weld themselves together if not manipulated regularly.

14 hours ago, troy45 said:

Ford actually issued a fix for this, first as a TSB I think, then incorporated into production on the mk2.5 (maybe late mk2’s too) with plastic strips attached the sides of the tailgate glass. 
 

Still remember Ford having similar issues with failures of the optional in-boot CD changer on the original Puma. It got a soaking every time you opened the tailgate when the car was wet. Change in strut damping spec was the fix in that case iirc

Mine has the strips along the glass, but still gets water ingress i think via the grab handle ive yet to investigate.

I think the whole timing sprocket setup on the Mk2 1.6 Petrol engine is a poor design. To change the belt, it requires removing more components than I think should be necessary. If I was designing an engine, I would also make it possible to replace the water pump without removing the timing belt.

I have changed other timing belts in the past where the sprockets were located on the shafts with keyways. This is unlike the Mk2 where they are free to rotate once the bolts are removed.

There was no need to physically lock anything on those engines. As long as the marks on the sprockets were kept aligned with the marks on the engine, the timing stayed as it was before the belts were removed.