Electrical problem with MK2 focus

[ntelas]

I have a focus MK2 2005 that I got recently. There has been an intermittent issue with the electric system.

The airbag light flashes(sometimes handbrake and others too, radio and climate restart (to default settings)and the display backlight flickers. Also my trip and radio clock reset many of the times. While this usually happens once per trip, sometimes it doesn't stop doing it for minutes(constant flickering-radio climate restarts-airbag and handbrake light). 

I also lose access to cruise control but I'm not sure if it connects with this issue because I lose it even when I don't have the mentioned symptoms.

Moreover, the OBD2 port doesn't connect with the ECU 99% of the time. I know I have a check engine light for a catalyst, but the light is off because the gauge cluster doesn't read the ECU. When I see the check engine light I can also connect via OBD. An electrician told me he also saw can bus errors when connected with his laptop.

I've scheduled with them to fix it, but till then I would like to hear from you if there are any ideas.

I've tried so far to swap all small fuses from both fuse boxes, remove and replug the plugs from the fuse boxes, hit the gauge cluster from the top to check if it's the issue. None of this worked.

 

Here is a video I uploaded showing the issue. 

I feel like I'm forgetting something, so feel free to ask anything so I can provide more information. 

[mjt]

From the age of your car the most likely cause is the failure of solder joints in the instrument cluster due to the use of lead-free solder (unless you're already aware of the problem and have had yours resoldered). There have been numerous threads on this forum about it.

The lead-free solder is more brittle and over time the vibration of the vehicle work-hardens it and the joints crack. The problem is normally with the joints for the main harness connector and the solution is to have the old solder removed and then resoldered with the older conventional tin/lead variety.

[ntelas]

Just now, mjt said:

From the age of your car the most likely cause is the failure of solder joints in the instrument cluster due to the use of lead-free solder (unless you're already aware of the problem and have had yours resoldered). There have been numerous threads on this forum about it.

I've read them, even watched videos on how it can be done! My scheduled service appointment is with a ford specialist that does the resoldering as well. If it's that, then I'm good to go!

Could the cluster cause the power failure to all the modules though(airbag, radio, climate etc)?

[mjt]

It doesn't supply power to the modules but the fault generates multiple canbus errors which in turn cause spurious error codes to be generated. It might also generate spurious data that the other modules interpret as commands (though I'm not 100% confident about that statement). I think the first port of call would be to get the cluster solder joints looked at and if necessary resoldered - in fact once the cluster is disassembled it would be wise to do it anyway - and then see what error conditions you're left with.

You could also have issues with other parts of the canbus system. @StephenFordhad to carry out major surgery on a car of your age because of problems with the various connectors throughout the system.

[StephenFord]

32 minutes ago, mjt said:

... @StephenFordhad to carry out major surgery on a car of your age because of problems with the various connectors throughout the system.

I should really correct that in I removed the instrument cluster and sent it off to a specialist to fix. You almost credit me with doing something quite technical that I have no skill whatsoever in doing LOL However, the removal of the cluster was in itself a major achievement for me, of which I'm still very proud 🤣

[ntelas]

I just searched a bit and found that there are 3 connectors by the left door and behind a trim. Is that information right? This kind of makes sense as (even in the video) when I open and close the door the problem either gets solved or worsens. 

Is it easy to check these connectors?

[ntelas]

This is where I found the information:

https://www.fordownersclub.com/forums/topic/33911-2006-focus-engine-system-fault/?do=findComment&comment=771281&_rid=158708

"The bus also goes through a couple of connectors just in front of the passenger door, behind the plastic trim. (There are three down there, two of which carry the HS-CAN bus), and un-plugging these will separate the cluster and diagnostic connector from all stuff under the bonnet..."

[mjt]

58 minutes ago, StephenFord said:

You almost credit me with doing something quite technical that I have no skill whatsoever in doing LOL

Doh! Sorry Stephen, I got the wrong bloke! and senility is preventing me from remembering the right one I was thinking of the member who completely rewired the canbus on his brother-in-law's car.

[mjt]

It was @isetta.

[ntelas]

Can someone please tell me how to remove the panel so I can check the connectors of CAN bus I mentioned earlier? I don't want to break it.

[unofix]

21 hours ago, mjt said:

. I think the first port of call would be to get the cluster solder joints looked at and if necessary resoldered - in fact once the cluster is disassembled it would be wise to do it anyway - and then see what error conditions you're left with.

Yes the instrument cluster would be the first place I'd check.

[mjt]

1 hour ago, ntelas said:

Can someone please tell me how to remove the panel so I can check the connectors of CAN bus I mentioned earlier? I don't want to break it

Fully extend and lower the steering column, unclip the rubber gaiter from the column top shroud then pull the bezel attached to the lower edge of the instrument panel rearwards and remove it. This will reveal two screws at the bottom of the panel. Remove these. The panel simply clips in at the top so gently pry it downwards to release.

[StephenFord]

7 minutes ago, mjt said:

Fully extend and lower the steering column, unclip the rubber gaiter from the column top shroud then pull the bezel attached to the lower edge of the instrument panel rearwards and remove it. This will reveal two screws at the bottom of the panel. Remove these. The panel simply clips in at the top so gently pry it downwards to release.

Nothing to add apart from the 2 x screws are T20..., also, there is one single cable connector at rear and you need to unlclip the cage, and once released, it simply pulls away.

 

[ntelas]

28 minutes ago, mjt said:

Fully extend and lower the steering column, unclip the rubber gaiter from the column top shroud then pull the bezel attached to the lower edge of the instrument panel rearwards and remove it. This will reveal two screws at the bottom of the panel. Remove these. The panel simply clips in at the top so gently pry it downwards to release.

I don't mean to remove the cluster. This is too much for me and I don't see the point of removing it myself since I won't be able to do anything on it. This will get done by the electrician. 

I am asking about the 3 plugs by the a pillar. I quoted someone's comment and that's what they're saying. 

Sorry if I wasn't clear.

[mjt]

Ah, ok. I haven't been in that area so I'll have to leave it to one of the more expert members.

[ntelas]

Just went to check and resolder the contacts of the cluster. Electrician was sceptical about it being the issue. I told him to do it anyways. 

Drove the car and after 10 minutes is did it again. So it's not the cluster.

He also suggested that maybe it's the contacts behind the key mill. I guess I'll take it there tomorrow again to swap that part. 

[ntelas]

An update:

The electrician swapped the ignition contact as well, this didn't work either. (2 weeks ago)

This car's left and rear Speakers didn't work from when I got it. Suddenly today, the rest of the Speakers started playing while cruising. I thought they were blown! The sound level was constantly changing, and when I turned the car off and then on, they were off again.

I checked the Speakers with the combo 3–6 keys held down for a couple of seconds. 

I am now assuming that maybe the same cable that sends sound to the speakers is also the cable that makes the car act weirdly and resets modules.

Not only that, but I also moved-pushed each door connector to see if it makes a difference. None. I then swapped the whole Radio unit for another similar one, the same behavior. No change in the speaker output.

I will certainly take the car to the electrician again, but until then, any suggestions are appreciated.

[ntelas]

[RL123]

I would still suspect can bus at cluster or BCM/gem Fusebox.  Should have U codes registered

[ntelas]

Swapped GEM and nothing improved.

[RL123]

My son’s cluster was bench tested, solder joints repaired with lead solder and retested I believe before handing back to me with lifetime warranty. 
lead free solder was originally used throughout the cluster so not only the connector pins.

[ntelas]

1 hour ago, RL123 said:

My son’s cluster was bench tested, solder joints repaired with lead solder and retested I believe before handing back to me with lifetime warranty. 
lead free solder was originally used throughout the cluster so not only the connector pins.

I should tell this to the car electrician because he seems baffled by the issue.

I also got this new code with an OBD scan app. Seem to reenforce the cluster issue. 

[RL123]

1 hour ago, ntelas said:

I should tell this to the car electrician because he seems baffled by the issue.

I also got this new code with an OBD scan app. Seem to reenforce the cluster issue. 

I’ve read that Forscan through apps are not that reliable on reading all modules and laptop and good elm327 is the way to go.

[ntelas]

The problem was the radio. I've disconnected it since Monday and it hasn't done it since. 

[TomsFocus]

1 hour ago, ntelas said:

The problem was the radio. I've disconnected it since Monday and it hasn't done it since. 

Thanks for posting the solution!

First time I've seen a radio cause issues like this on the Mk2.  Will have to add that to the list of dodgy electronic parts along with the GEM & the cluster.