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Old 10-04-2011, 06:27   #1 (permalink)
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Advice please on focus clutch noise

hi guys

Bought a 2002/2003 1.8 TDCI focus 160k but had lots of engine work done so seemed like a good buy, seemed fine on test drive apart from it seemed like battery was low when I started it because starter seemed weak, but thought id charge battery when i got home, got all the way home.

Test battery when I got home and its fine

Now heres the problems

Starter seems weak to start, turns twice before weakly starting.

At idle with the clutch not pressed can hear a grinding noise about every second, and vibration, when I press clutch in it all stops and everything is fine. If i rest my foot on the clutch can feel a strong tapping on the peddle.

Car pulls off fine, no noise or vibration when driving, just at idle

Was driving yesterday and did notice when I pulled off the clutch got stuck about half way, then popped while i was moving and clutch engaged more

I dont know if this is normal but clutch seems really low, bout an inch i reckon til clutch is fully engaged

I fear it may be flywheel, but i have noticed different symptoms from people so i dont know

any advice please would be great
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Old 10-04-2011, 07:25   #2 (permalink)
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Re: Advice please on focus clutch noise

Looks like you have a clutch / DMF (Dual Mass Flywheel ) fault . Common fault on that car . This could also be related to " lazy " starter / starter dragging . Might be advisable to get battery and starter load tested if problem persists but get clutch checked out first in case it collapses / get worse .
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Old 10-04-2011, 09:05   #3 (permalink)
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Re: Advice please on focus clutch noise

Ah beat me to it R.S, I was going to say he must have a DMF too.

In the case of the DMF, you will need to take the trans out, and chances are it is toast, mine is toast and it's only at 118k-120K. Just don't get mad when you see the price for a new DMF, just find a conversion kit, to convert it to a single piece flywheel. A DMF can be up around $800 bucks, or you can find a conversion kit for around $400-$500. Just what ever you do, use a organic clutch plate, unless your making big power.

This> Brake & Front End < will explain in great detail what a Dual Mass flywheel is all about. Yes this article is talking about older cars, but it's still a problem with the newish ones too.


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Old 10-04-2011, 09:27   #4 (permalink)
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Re: Advice please on focus clutch noise

You can get a conversion kit for that car , here is an example ,

Prospect Auto Spares Product Range

Products › Dual Mass To Solid Flywheel Conversion Kits › Ford Dual Mass To Solid Flywheel Conversion Kit › Ford Focus Dual Mass To Solid Flywheel Conversion Kit
Ford Focus Dual Mass To Solid Flywheel Conversion Kit
Vehicle : Ford > Focus

Ford Focus Dual Mass To Solid Flywheel Conversion Kit

Ford Focus 1.8 TDCi Dual Mass To Solid Flywheel Conversion Kit (CK9836) (2001 - 2004) - £ 279.99


Might help you .
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Old 10-04-2011, 13:08   #5 (permalink)
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Re: Advice please on focus clutch noise

Finding a conversion kit should not be hard at all, be sure to check E-bay, I found my kit at a company for $527, I go on E-bay, and the same company was selling it for $456.

So look around a bit before spending. And that doesn't mean buy the cheapest POS you can find. lol, JK.
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How-to directory.

Ford focus DTC codes.

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Old 10-04-2011, 13:33   #6 (permalink)
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Re: Advice please on focus clutch noise

The link I supplied is cheaper still and in UK where poster stays .When you buy parts like that or parts in general through E-bay or others , you can have serious problems if they fail and you try to claim under warranty . Plus you dont know if the parts are genuine or fakes in many cases , not just car parts .
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Old 10-04-2011, 17:14   #7 (permalink)
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Re: Advice please on focus clutch noise

Well in my case the seller of the kit on e-bay, is the company that makes the kit.

But yes some things you have to watch out for, using pay-pal is a good way to protect yourself as far as money goes. Damages is another big story.

EDIT: you are right R.S, I looked over both products on the companies site and E-bay, and the clutch disc size are different. But the E-bay one is actually saying the size I need, which is 9 3/8. IDK, looks like I will do some more searching too.
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How-to directory.

Ford focus DTC codes.

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Old 10-05-2011, 04:26   #8 (permalink)
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Re: Advice please on focus clutch noise

I always like to get parts locally , even if it cost a little extra . That way if you have any problems , you can go back and speak to the supplier direct and get it sorted out there and then . Also if you get messed about you can always drag the guy over the counter !!
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Old 10-05-2011, 16:47   #9 (permalink)
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Re: Advice please on focus clutch noise

Well I've decided to go with a well known company called FSWERKS, they have a focus clutch kit with flywheel for about $550.

I've heard tons of people say this kit is the best for the 2.3l. It just cost a little extra.
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How-to directory.

Ford focus DTC codes.

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Old 10-06-2011, 12:47   #10 (permalink)
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Re: Advice please on focus clutch noise

Looks good company / supplier .

Exedy, LuK and Sachs Clutches for Ford Focus
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