Ford car mechanic in Banja Luka

Dual-mass flywheel and clutch

Vibrations at idle, rattle on start and stop, jerking at low revs, harder gear engagement.

Uzrok /The dual-mass flywheel absorbs diesel engine vibrations. On the 1.6 and 1.8 TDCi it usually lasts 150,000-180,000 km, but city driving and frequent gear changes speed up wear. Once it fails, vibrations go straight into the gearbox.

Popravka /Replacing the flywheel together with a full clutch kit in one job. On the Focus Mk2 and Mondeo we also replace the clutch slave cylinder since it sits inside the gearbox, so we do not drop the box twice.

DPF filter and oil dilution

DPF warning on the dashboard, power loss, limp mode, oil level above max, fuel smell in the oil.

Uzrok /The Ford 1.6 TDCi (PSA DV6 engine) has a well-known issue - failed regenerations dilute the engine oil with diesel because fuel is injected into the cylinders during regen but does not fully burn. Short trips and a cold engine are the main culprits.

Popravka /Forced regeneration via the diagnostic tool, DPF cleaning or replacement if needed, and an oil change when the oil is diluted. We also explain to owners how to drive so the DPF actually regenerates.

Injector seals - the black death

Ticking sound from the engine, black oily deposits around the injectors, smell of exhaust gases under the bonnet.

Uzrok /Copper injector washers leak and exhaust gases under pressure form hard black carbon deposits around the injector seats. Left alone, the injectors bake into the head and cannot be removed without special tools.

Popravka /We react at the first signs - replacing copper washers and thoroughly cleaning the seats. If injectors are already stuck, we extract them with special tools and rebuild the seats in the cylinder head.

EGR valve and EGR cooler

Power loss, uneven running, black smoke, check engine light, higher fuel consumption.

Uzrok /The EGR valve clogs with carbon and on the 2.0 TDCi Mondeo and S-Max the EGR cooler often cracks, letting coolant into the exhaust system. Short trips make the clogging much worse.

Popravka /Removing, ultrasonic cleaning or replacing the EGR valve. If the EGR cooler is cracked we replace it - mandatory since coolant leaking through the engine causes further damage.

PowerShift DCT automatic gearbox

Jerking when pulling away, clutch slip, clunking during gear changes, dashboard error, poor city behaviour.

Uzrok /The Ford PowerShift (dry dual-clutch) is known for problems - clutches wear much earlier than expected and the TCM has software bugs. Fiesta, Focus Mk3 and Mondeo Mk4 with this gearbox are the most affected.

Popravka /First a full diagnostic - we check whether the fault is in the clutch, the TCM or the adaptation. Minor problems can be solved with adaptation and a software update, bigger ones need a clutch replacement or a gearbox overhaul.

Rear trailing arm bushings on the Focus

Knocking from the rear over bumps, unstable handling in corners, uneven rear tyre wear.

Uzrok /Rear trailing arm bushings are a notorious weak point of the Focus Mk2 and Mk3. On our roads they last 60,000-80,000 km. Weak rubber and constant stress from rough surfaces kill them quickly.

Popravka /Pressing new bushings into the arm or replacing the whole rear arm with new bushings already fitted. Sometimes replacing the complete arm is faster and safer than pressing.

EcoBoost 1.0 head gasket and timing belt

Coolant loss with no visible leak, white smoke from the exhaust, overheating, antifreeze smell.

Uzrok /The Ford 1.0 EcoBoost (new Fiesta and Focus) has a known issue with the head gasket and the oil-bathed timing belt tensioner. The tensioner breaks down, debris goes into the engine, and the head gasket fails.

Popravka /For smaller leaks - head gasket replacement together with the timing kit and a new tensioner. For bigger damage, a full inspection of the head and block, since cracks do happen. We always explain the full picture to the owner before starting work.

High pressure pump and injectors 2.0 TDCi

Hard starting, power loss, higher fuel use, metal particles in the fuel, fuel system error.

Uzrok /On the 2.0 TDCi engine in the Mondeo, S-Max and Galaxy the high pressure pump (HPFP) can fail and throw metal particles through the whole fuel system. When that happens, injectors and the common rail take damage too. Poor fuel quality and water in the tank speed up the failure.

Popravka /Full fuel system cleaning, pump replacement, new filters and injectors when necessary. A costly repair, which is why preventive fuel filter changes on time save the owner a lot of money.