SevereAffected: 2004-201170,000–130,000 miles

Ford Focus Mk2 1.8 TDCi — Starter Motor Solenoid / Brush Wear

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

Severity

Severe

DIY Difficulty

Moderate

Est. Cost

£150–£350

OBD Codes

None

Symptoms

A single loud 'click' when turning the key, but engine doesn't crank
Engine cranks very slowly despite a fully charged battery
Whirring or grinding noise after the engine starts

Root Cause

The carbon brushes inside the motor wear down to the copper wiring, or the contacts inside the solenoid burn out from repeated arcing.

How To Fix

Confirm battery voltage is strong under load (to rule out a dead battery).
Replace the starter motor unit.
Ensure main earth straps from engine block to chassis are clean and tight.
Cost: £150-350

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£60–£140
Independent Garage	£150–£350
Main Dealership	£240–£560

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.

Dual Mass Flywheel (DMF) Failure

Severe

2004-201170,000–120,000 miles£600–£800

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

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