Focus Fuel Pump Issue

[giddie]

I own two 2000 Ford Focus ZX3's (don't laugh they were perfect for my wife and I while we were going through college) and they both were plagued by the same stumbling problem! Our cars would act as if they were running out of gas when the fuel gauge was reading just under a quarter tank. Instead of replacing the fuel pump I decided to clean the tank, pump, and pump sock. After removing the tank I cleaned the very filthy fuel pump sock with B-12 and rinsed the tank out using a towel and B-12. The cleaning along with a new fuel filter solved the problem for both cars! Total cost roughly $14, the cost of 2 fuel filters from AutoZone. I would recommend trying to clean the tank & a fuel-filter change before getting a replacement pump. If it doesn't work you're only out of a little time a little money; if it does work you just saved yourself several hundred dollars!

The problem seems to be that the fuel pump sits inside a "coffee-can" contraption inside the fuel-tank (this might act as some type of baffle in cornering?). My theory is that once sediment from fuel gets inside this "coffee-can" it simply deposits in the "coffee-can" and doesn't have the oportunity to flush around the rest of the tank. Since the sediment collects in a small space problems arise much quicker since the fuel pump is always drawing fuel from inside the "coffee-can" where the sediment is deposting. This is only my theory but judging by the deposits I witnessed, on both cars, on the sock and inside the can and how relatively clean the rest of the tanks were, it makes sense to me.

Remember: Try not to run your car with less than a quarter tank of gas.

If you have any questions let me know.

jason o'brien
2000 ZX3 Kona
2000ZX3

[giddie]

Here's a synopsis of how I removed the fuel tank. Its what I could remember of the top of my head. Hope this helps.

It took me probably 10-12 hours to do the whole procedure (including the 3 or 4 trips to the auto store, lazy breaks, and eating). If you have a Haynes manual it suggests removing the exhaust & heat shield but I was able to leave the heat shield & exhaust in place (simply bend the heat shield out of the way). If you don't have a Haynes manual see if you can find one, the illustrations help a lot.

First relieve the fuel pressure by removing the fuel pump fuse and running the car until it dies (do this without the car jacked up). Second, syphon as much gas as you can out of the tank (I had to remove the filler hose to get the syphon tube into the tank). Then remove the fuel supply & return line at the front of the tank and remove the filler and fent hoses at the back of the tank, the process is much easier if you remove the right-rear (US passenger) wheel. Go ahead and take the fuel filter & mounting bracket out. After that you simply remove the single bolt holding the tank straps to the car (front of tank) and lower the tank. I used a jack to help support the jack and lower the tank slowly. Once the tank is low enough disconnect the 2 vent hoses (1 in front 1 in rear) and the two electrical connections (both near the front of the tank). The tank should come out if the heat shield is bent far enough out of the way.

Once out, I emptied the rest of the fuel from the tank and removed the cap on the tank above the fuel pump. The fuel supply line that is connected to the cap was tough to get off but it does need to come off. Pulled everything out of the tank, cleaned the sock really well with berryman's B-12 and rinsed the tank out with B-12 and let dry.

Push everything back together and you've saved yourself plenty of money. I did this cleaning about 1 month ago and haven't had a single problem since. The process is time consuming (for me at least; I'm a slow worker) but its all very easy.

[freakray]

Let me think, drive a car that requires continuous maintainance and cleaning of the fuel tank, or drive a perfectly reliable car which doensn't constantly plague me and my bank account with problems?

I think I will go with the second option.

How can you justify having to remove everything to clean it?
It is a bad design and you shouldn't have to go through that at all!

Time consuming? Yes.
Time is money, yes?
Ford screwed up the design, yes.
Maybe Ford should pay you for the time it takes you to clean the gas tank which is subject to a problem through a design flaw.

Best thing I did for peace-of-mind is sell my Focus, one less thing I have to worry about.

[Rich8888]

Well, looks like i'm going to have to change a fuel pump. However, i really don't want to do the job if it's going to have to be done again within a year or less. Has anybody heard of, or tried an alternate route? Aftermarket pump? Maybe a delco that might work? Anything at all that has been tried with success will be greatly appreciated.

[Mullet]

i have a 2001 Ford Focus with 63000Km on it and the fuel pump has all ready been changed. just 3000km after warranty and all ready 750$ down the drain. i am really upset with the reliability of my focus and to top it all off the new pump is still causing some slight hesitations suring acceleration. I'm scared to go on road trips last time I went I stalled tree time because of the fuel pump......HELP

Other issues include blown EGR sensor (3 times)
Cigar lighter not working
passenger's drivers side window not working
not to mention the recalls...

[bigpappag]

i just had my car in the shop for the 5th time in three months. Every time, the car wont start, when it does, it sputters, the dies. Each time its something new, bad pcm, bad connector, i picked it up Saturday at 1pm, it was back in the shop by 4pm. Finally they figured out it was the fuel pump. The car only has 13000 miles on it, what a total piece of S$^@ In 2 years it has been in the shop at least 15 times, I will never buy another Focus

[giddie]

After working on the fuel tanks on both Foci (from my post above) and then all the other problems that began occurring after the Warranty expired (hmm?), we ditched one Focus in favor of a new HEMI. Unfortunately I think I sold the wrong Focus because since the purchase of the truck the remaining Focus has been producing check engine lights and after all my work to clean the tank the fuel pump eventually died. I guess I only succeeded in pro-longing the inevitable. Anyway, paid a mechanic $430 to replace the fuel pump because I was simply too aggrevated to do the same procedure again. Also I've got a transmission or power-steering fluid leak from an undetermined source that will eventually have to be fixed. I'm extremely disappointed in the Focus and now wish I would have purchased another proven economy car, namely a Civic. "If only I knew then what I know now...", there's probably a lot of us saying that right now.

I hope the Dodge treats me better and I hope Ford has learned from the 2000 Focus and applied the changes to the newer models. I still can't believe there hasn't been a recall issued for the fuel pumps, how can we rally up and make Ford responsible?

jason o'brien.

[danaeh]

can anyone give advice on how you got ford to cover this part under warranty? i have a 2000 w/a little over 50,000 miles and just found out i need a new fuel pump which ford told me will cost close to $700 -- i called ford corporate after reading all of your posts and they told me there is nothing they can do for me! any advice would be great!

[kcarlen]

In the thread some people have indicated that the pump was replaced. One individual said that he bought one for 70 bucks..shipped! I live in Toronto, Ontario Canada and I CANNOT FIND AN AFTERMARKET PUMP!! Could someone direct me to a site and or name of company that builds a BETTER pump than the original replacement that FOR will sell me??

[st96q3vt]

Just found this forum yesterday while researching the root of my problem.. losing power while cornering at high speed, engine stalled even when I still have a quarter tank of gas left and engine keeps getting 'hiccups' at 70-80 mph. So, right after reading all of your posts, I called my Ford dealership, explained the exact thing and suggested it may have to do with the fuel pump. The guy at Ford immediately agreed with me. I asked him about the repair costs and if it is under warranty (I just have 38K miles on the car). He said he'll have to check with Ford. 5 mins later, he called back and said Ford just started the recall program for fuel pump this morning (meaning yesterday 11/15/03!!) . So, I immediately sent the car over to them, waited 3 hours, and I'm out! I hope everything goes well this time... If you see me post another message soon with Ford problem, please be advised that at that time, I'll be driving another car and nope... not any of those Fords!!

[kcarlen]

Thanks for the info. Is there a recall specific number that you can post??? Our dealer does not know anything about this recall.
In the last week, I have done a lot of troubleshooting on my own. I don't actually think that I have a fuel pump problem. The car pulls hard after the hard starting has subsided. I have some kind of weird electrical thing happening. I moved to a different forum because this one is really low in activity. I moved to focusfanatics.com, which has a lot more action and posts.
I Hate Ford Focus at this point. I just want to make it start properly every day, regardless of temperature. I don't want a gauge sweep every morning,...and I want to use my power lock with confidence.....and the list goes on. I just bought CAA because of this damn car.
When all of the glitches are sorted out the car will be OK, I hope. I just have too much money invested to sell it for a loss. Ford really doesn't care about us 15-20K guys I guess.

[jxxxy]

Just got '01 Focus out of the shop. Replaced Fuel Pump. Car would die for no reason. Wait 5 minutes and it would start right up.
This was happening for the past 5 months intermittently. Last time was barely able to pull off the hyway. Had it towed to the dealer, the next day it started right up. Told them all along it will start if you wait 5 minutes but they had to recreate the problem. They wouldn't check anything unless they could recreate it. Left it for 2 days finally they said they think it was the fule pump.

I told them to give me a loaner and have one of their family members drive my car for a month.

To make a long story short
Duked it out with the Ford service manager and the district manager.
Contacted Ford customer service. Finally they agreed to replace it

This is a very dangerous car. It should be recalled for the pump.

[ncbro]

This just in from the net: I did a google search on ford focus fuel pump;

News: Ford to replace Focus vehicle fuel part - Seattle Post Intelligencer - Nov 19, 2003
Try Google News: Search news for ford focus fuel pump or browse the latest headlines.


Wednesday, November 19, 2003 · Last updated 4:05 p.m. PT

Ford to replace Focus vehicle fuel part

THE ASSOCIATED PRESS

WASHINGTON -- Ford Motor Co. said Wednesday it will replace a part in the fuel system of 671,000 Ford Focus vehicles because it can cause the engine to stall.

Ford received reports of seven accidents and one injury due to the problem, spokesman Glenn Ray said. It is notifying Focus owners this week about the defect.

Focuses from 2000 and 2001 are affected. The part will be replaced for free if dealers determine it is causing engine problems. Engine problems caused by something else won't be covered, Ford said.

Ray said certain types of fuel can progressively clog the fuel pump filters, causing the vehicle to hesitate, surge and eventually stall. The part was redesigned in 2002 once Ford began learning of the problem, Ray said. A new part had to be designed for 2000 and 2001 vehicles.

Ford is not conducting an official recall of the vehicle because the company determined it isn't a significant safety risk. Even if the vehicle reaches the point where it stalls, Ray said, drivers can still maneuver their vehicles and restart them.

Ray said hesitation or stalling is most likely to occur in vehicles that have been driven 20,000 to 30,000 miles. Vehicles with less than a quarter tank of gas also are prone, he said.

---

On the Net:

Ford Motor Co., http://www.ford.com

[Marynik007]

The Program or recall number is 03N01

But there is a little thing that says if you have no problems right now do nothing

If you have Mild to moderate symptoms wait till January when the new design Pump is avalible

If you have major problems go to the dealer imediatly.

Tom

[roguesavant]

This is great to know.... I was in the high speed lane where two highways merge into five lanes, and my car suddenly lost power and I had to coast across all the lanes filled with cars and semis to get to the berm, where I sat for a few minutes with my hazards on until my car started again.

This same thing happened two weeks ago, right before I took my 2003 ZX3 in to the dealership for its 15,000 mile check-up. I described it to the mechanic as feeling like a vapor lock, or running out of gas, and asked them to check it out, but they told me that they were unable to "reproduce the problem." From the sounds of all your comments, I would think they would have known immediately what the problem was. Anyway, when it happened again yesterday the "check engine light" came on, so they came and towed it away and diagnosed it as the fuel pump, which they are going to replace under warranty. They are saying that it's my responsibility to lay out $60 for a fuel filter, though -- do you think that's reasonable?

And as far the fuel pump failure not being a significant problem because you can still steer, that means absolutely nothing when you've got semis crawling up your butt on a congested 5 lane highway!