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.

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fairly significant
Typical Repair Cost:
No data
Average Mileage:
42,800 miles
Total Complaints:
1 complaints

Most Common Solutions:

  1. not sure (1 reports)
2004 Ford Focus cooling system problems

cooling system problem

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2004 Ford Focus Owner Comments

problem #1

May 152007

Focus SE 2.L Dohc Zetec

  • Automatic transmission
  • 42,800 miles


Repeated coolant leaks, first at thermostat at the completely idiotic PLASTIC thermostat housing... One of Fords better ideas? Plastic housing attached to a flush aluminum head with a "rubber-band" type O-ring? There's only about 1/16th of an inch of sealing surface and about the same compression distance? What were they thinking?

Housing leaks even when not cracked or broken, and breaks or cracks happen easily and will allow it to leak even more.

Thermostat housing cover, again made of PLASTIC is attached with 3 torx head screws. Not machine screws mind you, more like wood screws that bite into plastic only, not metal inserts. What a messed up design. No clear shot at the torx head screws which are by design a straight in design. They left 1/4 of the thermostat housing cover unsecured with no screw to keep pressure on the cover and then depend on a compressed O-ring to seal against the cover?

I've had repeated leaks block to housing, resorted to RTV to end those. Have had a leak at the cover that ends up needing a new O-ring at least once a year.

Have replaced the Torx screws with hex heads so that service isn't as frustrating. But screwing into plastic repeatedly isn't a good idea as at some point it yields and strips.

I'd like to have a metal thermostat housing and a gasket thank you Ford designers...

- , Effort, PA, USA

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