My newly acquired Focus has 124,000 miles on the clock and has a couple of issues. I bought it as a cheap run-around and a project to learn how to work on cars myself. 

When the engine is under load at around 3000 rpm and at motorway speeds, it intermittently rattles like marbles in a tin can. However, it does seem to rattle consistently on the motorway. At lower speeds, it doesn't rattle unless shifting around 3000 rpm point. It makes the same noise when engaging the clutch to change gear. The clutch is also quite heavy for what I expected in a Focus. Setting off in first gear isn't smooth and tends to judder a lot, especially as the car gets hotter.

From what I've read about the timing chain on the QQDB Duratech engines, they seem to be bulletproof. So I'm ruling that out for now until I inspect it.

I think the rattle is either related to the swirl flaps or the clutch. I'm going to take the intake manifold off to inspect and remove the swirl flaps. If this fixes the rattle, I will buy a new aftermarket intake manifold from Autodoc. They seem cheap enough.

It also seems that the clutch is on its last legs (in my inexperienced opinion), so I'm going to change it. However, I can't find anywhere that stocks a new dual mass flywheel for this car, and it seems impossible to get one.

Does anyone recondition dual mass flywheels? I don't fancy buying one from the scrapyard unless it can be reconditioned. If it is the source of the rattle, what are my options for sourcing a DMF?

I really appreciate any help you can provide.

What is a Ford model: Doe 🤔

13 hours ago, unofix said:

What is a Ford model: Doe 🤔

Very few sold.  They were too dear...