Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

CarComplaints.com Notes: The 2002 Ford Focus 2.0L SOHC engine has a defect where the intake valve seat fails. The valve then falls into the cylinder, destroying the engine & most owner relationships with Ford in the process.

3.2

definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
41,575 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2002 Ford Focus clutch problems

clutch problem

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2002 Ford Focus Owner Comments

problem #11

Nov 172006

Focus 4-cyl

  • Manual transmission
  • 62,000 miles

A D V E R T I S E M E N T S

Clutch assembly has a leak of fluid into the interior of the car (down the clutch armature to the clutch pad and to floor mat, if significant leakage) which has a) caused the clutch pedal pad to become slippery and fall off due to the fluid seeping behind the pad [after market replacements not available due to relative youth of car, therefore necessitating service at dealer], B) causes the brake light to come on sporadically due to a drop in brake fluid (clutch hydraulics share a reservoir with brake system), although no finding of corresponding brake trouble can be made [problem temporarily disappears when fluid level topped off] and C) causes sporadic clutch "softening" and decreased effectiveness. Issue has been brought to the attention of both dealer and independent service providers several times, but none can find a fault with the braking system as indicated by the error light and therefore none indicate that a trouble exists. The leak is not obvious upon visual inspection of the braking system and the problem does not appear to have a negative impact on braking power (unless left too long and brake fluid levels drop significantly). Unable to locate precise location of leak (suspect either reservoir or some associated line to clutch hydraulics) or to determine why only clutch system appears to be impacted. 1) no noticeable/known events leading to failure; uncertain how long condition existed prior to initial documented problem 2) see failure and consequences noted above 3) no correction in place yet as dealer service does not yet acknowledge problem and did not "find" problem at recent 60K service work-up (included total systems check and full brake inspection with fluid top offs) problem with brake light firing manifest approximately every two weeks (since first noted in November 2006) due to fluid loss, particularly when temperature drops below 30 degrees Fahrenheit. Issue is "resolved" by adding brake fluid to reservoir.

- Waukegan, IL, USA

problem #10

Sep 012005

Focus 4-cyl

  • Manual transmission
  • 62,000 miles
Failing clutch master cylinder. This is not a part that has a recommended replacement term. This part has failed prior to the tune up mileage. It failed less than 2K miles out of warranty.

- West Carrollton, OH, USA

problem #9

Jan 092006

Focus 4-cyl

  • Manual transmission
  • 90,000 miles
Ignition will not turn. Clutch master cylinder leaks.

- Auburn, WA, USA

problem #8

Aug 012005

Focus 4-cyl

  • Manual transmission
  • 45,000 miles

A D V E R T I S E M E N T S

45,000 mile car has leaking clutch master cylinder. Clutch pedal is wet and slippery with brake fluid. I've had to add brake due to the leak. I'm afraid that my brakes will go out or that my foot will slip off of the clutch pedal. I still havn't had it fixed yet because the replacement part will likely fail also. It's a common problem according to the dealer I took it to for an estimate.

- Cincinnati, OH, USA

problem #7

Nov 162005

Focus 4-cyl

  • Manual transmission
  • 42,000 miles
The clutch master cylinder leaks at a premature mileage. I only noticed it at around the 42K mark but it has happened for an unknown amount longer. The leak goes through the clutch pedal and into the interior of the drivers side cabin. It gets all over the carpet and can cause future damage to my carpet and possibly floor. The fluid is very corrosive and since its on the same system as the brakes it also affects my brakes. This is a very serious problem and I was not covered under warranty since it was out of warranty even though this is a very serious problem that seems to be happening to a lot of Ford Focus owners out there.

- Staten Island, NY, USA

problem #6

Sep 012005

Focus 4-cyl

  • Manual transmission
  • 36,000 miles
The events leading up to the failure were daily use. The clutch master cylinder is located inside the vehicle. It is a very common failure for it to begin leaking, dripping on the carpet and eventually causing the rubber pad on the clutch pedal to fall off. This in itself is dangerous, but the hydraulic clutch utilizes the same fluid reservoir as the brake system, so the brakes could be affected by a leaking clutch. On my vehicle, I replaced the clutch master cylinder myself. When I was under the car, I noticed a drip from the drain hole in the bell housing- the slave cylinder is leaking, too. These are not "consumable" parts of a car. The simultaneous failure of both indicates that either they are woefully under-engineered, or the seals they used are not compatible with brake fluid. Because of the corrosive nature of brake fluid, having it drip into the carpet and padding of the interior of my car is a bit of a concern. All in all, this is a major shortcoming that compromises the safety of the vehicle.

- Portland, OR, USA

problem #5

Mar 212005

Focus 4-cyl

  • Manual transmission
  • 16,200 miles

A D V E R T I S E M E N T S

(1) I first noticed unusual stains on the carpet underneath the clutch pedal during December, 2004, but assumed initially that it was from something on my shoes. (2) on 03/21/05, the clutch pedal pad fell off while the car was in motion, distracting me, but fortunately did not result in an accident. (3) on 03/28/05 I searched the nhts ODI complaint data base and found an identical complaint, ODI id number:10107639, date of failure: 01/20/05. I will be taking the vehicle this week and this information to the authorized Ford dealer for warranty repair although the original purchase was on 01/31/02, but I will claim the problem started in December 2004 when the vehicle was still in warranty.

- Durham, NC, USA

problem #4

Jan 202005

Focus 4-cyl

  • Manual transmission
  • 39,700 miles
Clutch master cylinder leaks clutch fluid. Fluid runs down stem of clutch pedal, loosening the rubber pedal pad, which proceeds to fall off in certain situations while vehicle is in motion. Also clutch master cylinder fluid is supplied by brake master cylinder reservoir!!! this leak can potentially cause brake failure as fluid leaks out of brake master cylinder.

- Metamora, IL, USA

problem #3

May 062004

Focus 4-cyl

  • Manual transmission
  • 36,140 miles
On Thursday 5/6/04 the 2002 Ford Focus was being driven when the clutch assembly broke off under the dash board, disabling the vehicle. The vehicle had to be coasted off the roadway, and towed to the dealership. The broken pin was found on the floor under the clutch pedal. It could easily be determined that the pin broke off some type of bracket. You could see the welding and what appeared to be part of the bracket. The piece was given to the dealer. The dealer was also informed not to discard any parts. The next day we were notified that this would not be covered under the warranty (unfortunately the vehicle was just over the allowed warranty mileage) however, I inquired as to how this could happen to a vehicle that is only two years old unless it was due to some manufacturers defect. They said they could not help me since there were no other reports or complaints about this. I informed them them that I would be following up with Ford Motor Co. I was later informed that this repair would cost me more than $600. I contacted Ford and I was told that there was nothing they could do. Forunately there was no injury, however, I dread to think what could have happened if the car was being friven on an interstate at 65 mph or more when this occurred. The ironic thing about this whole ordeal is that the only part I was told they needed was the pin that broke, but the only way to get the pin was to get the whole clutch pedal assembly, and guess who paid for that? I am hoping to get some satifactory feedback re: This problem. Thank you.

- Lebanon, PA, USA

problem #2

May 172003

Focus

  • 28,290 miles
The vehicles clutch made loud noises when the gears were shifted.

- Goleta, CA, USA

problem #1

Apr 152002

Focus

  • Manual transmission
  • miles
Consumer applied both brakes and clutch at 70 mph, and vehicle did not slow down. This has happened 3 times. Pedals were too close together.

- Great Barrington, MA, USA

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