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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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
69,891 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.

2004 Ford Focus fuel system problems

fuel system problem

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2004 Ford Focus Owner Comments

problem #3

Apr 222014

Focus 4-cyl

  • 145,600 miles


Very dangerous fault or defect found on my car. A fuel line that runs along the top of the engine is contacting an opposing metal bracket. This chaffing condition has resulted in damage to the fuel line. The fuel line is protected with padded silver tape; the tape and padding has been entirely cut by the bracket and has created a cut mark on the fuel line. No fuel leaked because of this condition. Had this gone without discovery, the fuel line would have likely burst and allowed fuel to spill on top of the engine. The metal bracket creating this hazard is a mounting point for an air bypass valve (3S41-9F491-ac). This valve and mounting bracket is a component unique to the pzev variant of the Ford Focus. Pictures of this defect have been posted in an online public forum located here-> the title of the forum thread is "danger - fuel line being cut on a 2004 pzev".

- Mesa, AZ, USA

problem #2

Oct 012007

Focus 4-cyl

  • Manual transmission
  • 16,000 miles
The contact owns a 2004 Ford Focus. The contact is unable to drive the vehicle due to the strong gas fumes in the passenger compartment. The dealer stated that nothing was wrong with the vehicle and suggested that the contact may be smelling normal gas fumes. The vehicle has not been driven in the past three or four months. A diagnostic was performed and the results indicated that everything passed. The cause of the fumes has not yet been determined. The smell has caused the contact's kidneys to hurt. Ford stated that they would help pay for the cost, if they can assist in determining the deadly defect. The failure mileage was 16,000 and current mileage was 16,200.

- Anchorage, AK, USA

problem #1

Jul 272007


  • Automatic transmission
  • 48,073 miles
My Ford Focus ZX5 stalled on me on the high way July 27, lucky for me the traffic was slow. Towed to the dealer, they said it was the fuel pump. Cost me $600 to replace it. I got the car back on August 1, and two days later on August 3, it stalled again. Tow it back to dealer on August 7, the dealer said it was the fuel pump again, they said the new fuel pump they replaced two days ago was defective, and they had it fixed on August 8, and one day later on August 9, it stalled again. Towed back to dealer the third time. On August 13, they called me and said it was not the fuel pump. (what" so they didn't seriously check the car, and put me into very dangerous situations again and again??") on August 17, they called to inform me it was the inertia switch. I was very dissatisfied with all the problems with this vehicle. Rental cost (I asked for the reimbursement of the rental and they refused). I questioned the service manager about the car's safety concern and their mechanic's incompetent. The service manager kept saying the second time the new part was defective and the switch problem didn't show up until the third time. I really doubt it, because every time it showed me the same problem. And I believe it is because they didn't find the inertia switch problem the first time. I also called the Ford customer assistance and asked for to be reimbursement for the rental car. I told her about my safety concern, and she informed me as long as I am still not involved in an accident there is nothing they can do. What" do I need to be injured or dead to get their attention"

- Stamford, CT, USA

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