MinorAffected: 2004-201150,000–120,000 miles

Ford Focus Mk2 1.6 TDCi 110bhp — Electric Window Regulator Cable Failure

The cables inside the electric window regulator mechanism fray and snap, causing the window glass to drop into the door frame.

Severity

Minor

DIY Difficulty

Moderate

Est. Cost

£100–£200

OBD Codes

None

Symptoms

Grinding or crunching noise when operating the window switch
Window glass drops down into the door and won't come up
Window sits crooked in the frame

Root Cause

The steel cables run over plastic pulleys. The plastic pulleys degrade and crack, or the cable frays and tangles inside the motor drum.

How To Fix

Remove the interior door card to access the regulator.
Tape the window glass 'up' temporarily to secure the vehicle.
Replace the entire window regulator mechanism (usually supplied without the motor).
Cost: £100-200

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£40–£80
Independent Garage	£100–£200
Main Dealership	£160–£320

Other Faults on This Variant

EGR Valve Failure

Moderate

2005-201160,000–120,000 miles£80–£300

The EGR valve is a common failure on the 1.6 TDCi engine, causing power loss, rough idle, and excessive smoke.

Dual Mass Flywheel (DMF) Failure

Severe

2004-201180,000–150,000 miles£600–£1200

DMF failure is one of the most expensive known faults on the 1.6 TDCi. Typically requires replacement of flywheel and clutch together.

Turbocharger Failure

Severe

2004-2011100,000–180,000 miles£400–£900

Turbo failure on the 1.6 TDCi is common at higher mileages, often caused by oil starvation or sludge blockage.

Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.