ModerateAffected: 2004-201140,000–100,000 miles

Ford Focus Mk2 1.8 TDCi — Sticking Brake Calipers (Slider Pins Seized)

The floating brake caliper design relies on sliding pins. In the UK climate, salt and water ingress cause these pins to rust and seize solid.

Severity

Moderate

DIY Difficulty

Moderate

Est. Cost

£80–£150

OBD Codes

None

Component Diagram

Brakes

Typical layout and location for the Brakes assembly.

Reference Illustration

Symptoms

Car pulls to one side when driving
Burning smell coming from one wheel after driving
One alloy wheel feels extremely hot to the touch
Severe, uneven brake pad wear

Root Cause

The rubber dust boots around the caliper slider pins perish or split. Water and road salt enter the cavity, rusting the steel pin into the aluminum caliper bracket.

How To Fix

Remove the caliper and attempt to extract the seized pin using heat and vice grips.
Clean the bore thoroughly with a wire brush.
Fit new slider pins with high-temperature silicone grease.
If the pin snaps, a new caliper carrier is required.
Cost: £80-150

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£32–£60
Independent Garage	£80–£150
Main Dealership	£128–£240

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.