NHTSA Complaint #10223364 — 2002 FORD FOCUS

1. TWO DAYS BEFORE THE ENGINE DIED I NOTICED IT WAS HAVING PROBLEMS STARTING FIRST THING IN THE MORNING, LIKE A SPUTTERING. THEN IT WOULD GO AWAY AND THE CAR WOULD DRIVE FINE. THE CAR HAD A TRANSMISSION FLUID LEAK AND SO I CONTINUED TO MAKE SURE IT WAS AT THE RIGHT LEVELS. 2. THE DAY WHEN THE ENGINE DIED IT HAD BEEN RUNNING NORMALLY. I HAD STOPPED AT THE STORE. WHEN I GOT BACK IN MY CAR AND TURNED IT ON THE ENGINE MADE A POPPING NOISE AND THEN THE ENGINE "TURNED OVER" AND STARTED MAKING A THWAPING NOISE, LIKE CARDBOARD IN CONTACT WITH A FAN BLADE. AFTER TOWING IT TO A MECHANIC (IT WOULDN'T START, IT KEPT MAKING THUD-ISH THWAPING NOISES), WHO HAD WORKED FOR FORD PREVIOUSLY, HE SAID THAT THE 4TH PISTON HAD BROKE AND WAS GRINDING ON THE SIDE OF THE ENGINE BLOCK (HE HAD TAKEN A LOOK AT THE TIMING BELT - OK- AND WAS TESTING THE GEARS THAT THE TIMING BELT ATTACHED TO. 3 TURNED WITH THE RIGHT TORQUE BUT THE FINAL ONE AT THE BOTTOM OF THE ENGINE BLOCK DIDN'T TURN UNLESS TORQUE GREATER THAN WHAT WAS NORMALLY NEEDED WAS APPLIED. WHEN IT TURNED THERE WAS A THWAP SOUND INSIDE THE ENGINE). WHAT MADE ME WONDER IS HE SAID THAT THIS ALWAYS HAPPENED WITH THIS MODEL ON THE SINGLE OVERHEAD CAM ENGINES AT AROUND 90 TO 120 THOUSAND MILES. HE SAID THAT HE REPAIRED NUMEROUS SIMILAR INCIDENTS WITH THIS TYPE OF ENGINE, EVEN GUARANTEEING THAT OPENING UP THE ENGINE WOULD SHOW THAT THE 4TH PISTON (FARTHEST ON THE RIGHT FACING THE FRONT) BROKE. I HATE TO THINK WHAT WOULD HAVE HAPPENED IF I HAD GOTTEN ON THE FREEWAY AND THE PISTON HAD BROKE. 3. THE COST TO REPLACE WITH A NEW OEM ENGINE WAS MORE THAN THE VALUE OF THE CAR IF I WERE TO PERSONALLY SELL IT (BASED ON KELLY BLUE BOOK) AND SO WAS THE COST FOR A USED ENGINE ($1200 WAS THE LOWEST, COMPARED TO THE DUEL OVERHEAD CAM ENGINES FOR THE FOCUS WHICH I FOUND USED FOR $500. SEEMS THE DEMAND FOR THAT STYLE ENGINE IS HIGH). I HAVE NOT REPAIRED IT. I AM CONSIDERING SELLING IT TO A SCRAP YARD. *TR