SevereAffected: 2004-201170,000–120,000 miles

Ford Focus Mk2 1.8 TDCi — Dual Mass Flywheel (DMF) Failure

The 1.8 TDCi produces strong low-end torque which destroys the internal springs of the Dual Mass Flywheel.

Severity

Severe

DIY Difficulty

Professional Only

Est. Cost

£600–£800

OBD Codes

None

Component Diagram

Flywheel

Typical layout and location for the Flywheel assembly.

Reference Illustration

Symptoms

Clattering noise at idle
Vibration through the clutch pedal
Difficult gear selection

Root Cause

Internal springs in the DMF weaken and shatter. Often exacerbated by driving in too high a gear at low RPM.

How To Fix

Replace DMF and clutch kit. Do not fit a solid flywheel conversion as it damages the gearbox input shaft. Cost: £600-800

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£240–£320
Independent Garage	£600–£800
Main Dealership	£960–£1280

Other Faults on This Variant

Electric Window Regulator Cable Failure

Minor

2004-201150,000–120,000 miles£100–£200

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

Engine Thermostat Sticking Open

Minor

2004-201160,000–120,000 miles£100–£250

The engine coolant thermostat fails in the 'open' position. The engine never reaches its optimal operating temperature, killing fuel economy.

Starter Motor Solenoid / Brush Wear

Severe

2004-201170,000–130,000 miles£150–£350

The starter motor wears out internally. This is particularly common on vehicles equipped with Stop/Start systems.

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