The Ford Focus RS Engine is Seriously Bad & Ford Had to Know. This one Locked Up! 

In the end, what do you think Ford will do about this?

I'm currently working at Ford. I've literally worked the station putting head gaskets on the new Focus engines (well, before I got laid off and production of the new Focus engines got moved to China). This isn't necessarily super germane to the engineering problems, but speaks to Ford's general attitude- I was trained on that station by another temp employee for less than 10 minutes before being left unsupervised to do it for an entire shift. I was shown the task a few times, observed doing it 'correctly', and then left to my own devices. I'm fairly knowledgeable about cars, so I realized that I shouldn't smear the gasket sealant that is already applied when the engine reaches your station, however, this was never even mentioned to me. Virtually nothing that I would have considered pertinent to the job was explained. What if I put the gasket on upside down and then have to flip it? Oh, whoops, it's all covered in the sealant, and now there's less than there should be on the correct side, guess this engine's going though. I just missed one of the two indexing points and have now pushed the gasket into the sealant, but have to now pivot the whole thing a couple degrees to get it to sit correctly, guess what, that engine's going through. Accidentally smeared a big chunk of sealant off with my hand while placing the gasket. Godspeed lil' engine. I'm not saying I ever did any of this, but based on my interactions with the rest of the work force, I can virtually guarantee situations like that occurred. Now, take into account that roughly 50% of Ford's workforce is part-time temp workers. Half of the assembly of that engine is being performed to this 'standard' with a comparable level of experience at the specific tasks. It was a rare occasion for me to perform a job I had done before, mainly because the temp workers were slotted wherever needed. Everyone actually showed up today? Ok, send the highest payed legacy workers home and slot a part time worker into their team (team, not task, you sure as fuck aren't getting the job that legacy worker was doing). Team 3 is short people today? Grab a temp from team 7 and stick them in a job. And here's the best part- they're not giving you the simplest, easiest to understand jobs, because anyone with seniority is instantly going to bitch if you get slotted into an easier job than them. So, there you go. Part time workers with no incentive to do well (we don't get profit sharing, earn vacation, sick days, or seniority, have no pension, etc, etc) are performing the most difficult or time consuming assembly tasks, mostly unsupervised, that they have virtually no experience doing. "Ford- Quality First" Oh, fun bonus story of working on the final engine test stations. If the engine doesn't pass, you retest it. If it still doesn't pass, you retest it. If it still doesn't pass, you 'reject' it, meaning it does a loop on the conveyor system, and hopefully passes for one of the other stations. Who knows, since they're being made in China now, maybe the next year's Focus engines will be rock solid (oh right, Ford can't design an engine correctly either..). (edited for grammar/ punctuation)

Mine blew a head gasket at 7k miles. They replaced the head. It did it again at 18k miles. They replaced the motor.

What do you call a Ford RS with 20,000 miles on it? A miracle

"A year later Frank found the fifth drive mode, Blown Headgasket Mode" hahahaha 😂

The problem with this engine is not the open deck design, it's probably the coolant loop. The turbo headers are integrated into the cylinder head, and the engine coolant is used to cool the headers. Research of a very popular German RS and ST (Beast Factory) tuner has shown that steam bubbles build up in the hottest area of the coolant loop. And that's next to the headers between cylinder 2 and 3, where the 4 exhaust pipes come together. The steam bubbles collect at the highest point of the cooling loop, which is at exactly this point, so they stay there and don't exit the system. Steam bubbles can't conduct heat nearly as good as liquid coolant, so these parts of the head and block get even hotter and hotter, beyond 1000°C. This leads to the head and block deforming. They did a very detailed explanation on how the coolant runs, how they tested it, and why this is not an open deck problem. They even explained why the Mustang Ecoboost is not having these issues. I can't give more details out of my head, but you should get the idea. Apparently there have been broken engines with the old and the new head gaskets. Beast Factory uses waterless coolant to work around the problem, since it has a higher boiling point. They did not encounter cooling problems on testing, yet, but only time can tell.

That had me cracking up!! Tokyo drift, Poor guy and his dreams ... Ford crushed them.

So this is how ken block gets those smokey drifts! Lmfao

“A year later Frank found the fifth drive mode called blown head gasket mode” lmaoooooo

Blown head gasket mode! Love it

First video of yours, you easily sold me on your channel in this video alone the quality is amazing makes it very enjoyable to watch and all facts are straight up and the pictures of what you are talking about are an awesome addition.

Great Video, Very direct with explanation, details and Look forward to hearing more about what Ford is doing for RS Owners.

i have ford focus 2014 - 60,000 km now the problem in speed 1& 2 not working as well.

A+ on the production value! Production value + solid content = a very happy subscriber! I can't say the same for Frank Focus. Keep these kind of videos coming Alex and this channel will take off. I've been with you since 1k subs.

Excellent video, thanks for all your time and effort, Bob 😎

I have a 2017 Ford Focus not an RS just a sport model. It has had the exact same issue as this video! They are in the process of replacing the engine block, does that mean it will just happen again anyway?

Thanks for the video. For did put out the FSA and I got a new head and head gasket. Ford took responsibility for it and my car is all fixed at no cost to me, including free rental car for the 2 weeks. I do like the car very much. Hopefully, all is fixed. It runs great so far. Update: It had an undiagnosable issue with the auto engine stop/start. Ford took the car back and gave me a 2018 RS. The head gasket issue was on certain models and build time-lines. The 2018s did not have the HG issue as they addressed it. My 2018 now has 45k miles on it and It’s been 100% reliable. I absolutely love it. Also, I do get a bit of a Subaru fan boy/RS hater vibe here but who know heh. There's a portion of this vid that shows how good a WRX head is, opposed to the RS head.. b/c we all know that Subarus never blow a head gasket 🤣.

Thank you for taking the time to make theses videos. I believe you have a solid future doing this given your expertise and polished presentations.

Reason why I bought an ST: the RS has a bored out block which is the same as the one in the ST, but therefore has weaker cylinder linings/ walls. Also, both cars have cast rather than forged pistons and con rods. So don't do pulls from low revvs in high gears. The head gasket is also weak because it can't cope with the compression ratios. Usual situation with Fast Fords: great cars, but built to a cost. Great ideas for health of car: meticulously replace oil every 7500 miles; drain and replace coolant every 20-30,000 miles, and do a regular decarbonisation every few thousand miles too (because of the direct injection)

Great video and presentation. This issue is not unique to the 2.3. My 2.0 EB in 2016 Edge had the same issues. First eating coolant, they replaced the head at 25K, by 39K they had to replace the long block for same issues.

“Blown head gasket mode”. Hehe

Alex: You Rock! You provide a logical and linear analysis of a complex problem in a manner that "Non Car Guy's and Gals" can understand. You need an agent to set you up with a syndicated Cable TV Show. Keep up the great work and Happy Holidays.

"blown head gasket mode" lmaooo

I wonder if a vented support ring machined to fit around the cylinders would help with the flexing issue ?

Awesome vid Alex. Every one gets better. I can tell you're getting more comfortable in front of the camera.

That was an awesome video! I hope there are more just like this in the future, I’m sure there is enough weird stories just like this one with other car manufacturers. Great job dude!

Im getting a 2012 Focus SEL. I really like the focus. I understand that this year had recall problems which Im going to get taken care of for cheap. my searching tells me It's the purge valve line because It has idling problems. Should I get a different year? What's the best year to go for? Last, can I replace the cylinder gasket head with a semi-open deck aftermarket part? And if yes can I get some recommendations?

Thank you so much. Now I understand better why theres no 2019 or 2020 focus RS. You saved me from getting into a 30k mile 2017 RS

Great video Alex, can’t wait to see more of these

Fantastic video man, great work and perfect presentation

Good video. Given Ford's history gas tank diff shields with design defects, unless it's projected to cost more than lawsuits they'll ignore it. Anyway, you mentioned suggestions. How about Toyota's ongoing software issues. From the killer Priuses a few years back to the current Tacoma drive by wire issues that they can't seem to resolve. Of all the companies in the world you might expect not to be able to get software right, Toyota is hard to believe.

Hey first of all thanks for the video. I own a 2016 ford mustang 2.3 ecoboost premium that is also leaking coolant in the engine... my question is: isn't it the same engine than the focus rs so it migh have the same problem??? Im taking it to the dealership this week, i havent been able to drive it since it was diagnosed ☹

I *really* like the idea of a channel that looks at how many newer cars have time bomb issues.

Love this type of video. subscribed. Keep up the good work.

was this issue fixed in the 2018 model? before i end up buying i should look more into it

Comprehensive and excellent review of this issue. Wanted one of these after I gave up on Subaru for making yet another ugly WRX. The new one looks like a Carolla, And the RS looks cool. Kind looks like the WRC Fiesta that MSport races. But that block design to me is just asking for trouble.

You should do a video about the rod bearing issues in S65 and S85 engines. Manufacturer defect? Just plain false? User error?

My college instructor worked on engineering the ford focus rs engine. He loves this engine and would often speak of the politics when building it. They had to meet the hp & torque ratings near the desired rpms, make the power-band smooth. I wonder what his explanation of this would be.

I know I am late, but does was this problem fixed for the 2017 or 2018 model year?

do you have anything on the transmission temperature issues of the 2006 Dodge Dakota or any Dodge with a 42rle transmission

Great video. I would love to see you do a video and get your thoughts on the Mercedes m156 engine head bolt issue.

Keep this series up!

I saw another video concerning this where the guy said that it is very possible that the RS was mistakenly fitted with the head gasket at the factory from the 2.3 ECO Mustang engine. Both are 2.3, but the design of the blocks are different. His evidence is pretty convincing.

This is an awesome video! Thank you so much for this key info on the RS reliability. Looks like the RS is a good candidate for engine swap, any info on people doing this? If so, what engine they used? I know pretty sorry thing to have to do for car that’s only couple years old!!

Great informative content👍. Don’t own an rs but subscribed.

Newbie first video of yours subbed good job very informative

is this still a problem in the 18’ ? i’ve wanted an RS since it came out, but now i’m having my doubts.

Thanks for your video ! I was going to buy an RS but lucky I didn't. They really should have put legs at the top of those cylinders.. especially because the head gasket covers the openings anyway with only holes for the coolant to travel through so having legs to support it wouldn't slow coolant flow in any way IMO.

At least Ford is taking care of the problem. When I grenaded my transmission on my 02' WRX it was stock except for a Exedy OE replacement clutch that I had installed at a Subaru dealership. The transmission was making a ticking noise after the clutch install that it wasn't making before it. I took it back and they informed me that I had some broken teeth on 2nd gear and blamed it on hard launches. I was still breaking the clutch in and had not taken the car over 3K rpm which is barely getting into boost. I contacted a SOA rep and they basicly said it was my fault even though lots of people were having the same problem. Its good that RS owners are documenting on You Tube. Keep Ford honest.

The engine isn't bad in the least. The head gasket issue is from the ecostang's gasket being put on the RS by accident in the earlier builds. The difference is a single hole for routing coolant.

Can you do one on the fiesta st please!!! I have a 2015 an i have a weird tin sound just curious!!! Thank you, also, great RS video

When the smokes coming out the exhaust.. “I’m actually kinda hungry” 😂 weed joke ?

Great info and presentation. Subbed.

Great video! I had no idea that the block was that exposed. I wonder if you can cement fill portions of the block to reinforce it.

A student in my automotive class works at a local Ford dealership that was doing these recals. Apparently the problem is a few of the plants were supposedly unknowingly putting the head gasket from the Ecoboost mustang on these, and there is some notable differences on these motors all though they are basically the same.

I got a used Escort that missed when cold, pulled plugs and one had coolant. I flushed the cooling system, dumped in 3 bottles of stop leak and drove it for 10 years.

Well done mate loads of helpful info

Great detailed vid, just subbed.

Wow! I’ve been with subaru for over 12 years and I wouldn’t expect this from Ford. We change every head gasket on every subaru we sell because it’s such an issue. This just blows my mind seeing the gaskets.

nice well done ... can you do a video about the rs5 ? there is a lot of videos in the web but nobody talk's about it's issues and common problems ... i can only assume that is a very reliable engine . i'm going to purchase one audi rs5 in a near future and it would help to be prepare ... thanks

452 bad ratings by *new* RS owners! Seriously though how can you not rate this highly?! Excellent stuff, well done for this expose. Even with part replacement who wants their engine torn apart on a fairly new car? I'm not in the market for an RS bit if I was I'd be thinking very carefully right about now about a possible purchase!!!!

hey man thanks for doing the research and sharing with us. its so sad that the RS engine is poorly designed

Can someone please tell me what wheels are on this rs? I reverse image searched them but I still cant find them.

Neat! you filmed this right next to my gym and the dealership I bought my mustang GT

Subscribed great video! Please review Subaru sti blown Ringlands

Do a video on my crappy 2013 Ford Fiesta transmission. Currently a Class Action Lawsuit going on in regards to it.

What about fiesta st 2016 I haven't found any issues I'm still looking for any real problem can't find anything

The 1.9 liter engine that was in the Ford Escort was awesomely dependable (owned several of those cars) and it became the 2.0 liter engine that's in my 2001 Ford Escort and the Ford Focus. We got the extended warranty with our 2015 Ford Focus Titanium, and it has the 2.0 liter engine.

you live around Niles ?

I drive an old volvo 240 with a B230 engine , 114 HP and over 600,000 miles on it without any intervention on the engine short block When I see aberrations like that, I'm sure that I will keep it for a long time. It's sure that such a boosted engine is much more prone to troubles but it is inacceptable to put in the hands of the public engines that should be reserved for competition use where a qualified team is employed to make a close followup. I will not discuss of the technical solutions but simply say that when you buy a "new and improved" product, in fact, you buy a cheaper product that search cobayes to make the tests

Got my recall this week 2019

I almost picked up a RS.... but I ended up purchasing a almost brand new C7 Z06. Very happy with my purchase... sorry to hear about some issues with the RS...

Thank you. Good video Sir. The main problem is post warranty coverage? Those design flaws are Inherent. Those fixes aren't going give you a reliable vehicle for the long term! I like them but if I spend 40grand it won't be for one of these! Type R or WRX!

Great video and I am glad I chose the CTR.

What about the mustang EcoBoost? It uses the same 2.3 L engine?

This channel is awesome! Really interesting to follow how you tackle problems.

Thumbs up for Niles, Illinois where I grew up!

Easy fix, just put gasoline into the cooling system.

Is It same design for the 1.5 ecoboost engine? Is it same open deck design? Thank you so much...

Can u do this for the Lincoln mkx so we can get those fixed

Is this the same engine as the mustang turbo?

Very cool video. Is it also occurring in the ST?

anyone know if a bad cat converter and/or access port can blow up an engine. Mine did at 34,000 miles and Ford said I wiped the memory, it was over fueled and denied all my claims. Now on the 2nd engine, just over 1,000 miles under her belt and am getting the same errors and engine light coming on..."cat efficiency below normal", "random misfire"...etc?

Thanks for the info,👍

This is gold! Loved the intro.

Subbed after Frank Focus said exactly what the narrator said he said. Nuff said.

You had me at mode five: blown head gasket mode 😂😲😞why, Ford, Why ?!

I don't know if you get to select the points at which the ads interrupt, but lately they always seem to cut you off at a bad time, creating a cliff hanger. Annoying, I much prefer the ads to come at a natural break in the action! Great work though, you are one of the RU-vid stars. Excellent content!

I thought of replacing my Mustang GT with one of these at one time, but I think I'll keep the Coyote for now. Interestingly in Europe the 1.0 EcoBoost fitted to the Fiesta has had a lot of problems with dumping coolant and seizing up due to believe it or not a tiny plastic degas pipe melting/becoming porous.

Awesome video and this is good to know. I almost bought an RS but now glad I didn't. Ford has come a long way but I'm disappointed that this open deck design made its way into an otherwise fantastic car. If you're going to build any kind of performance car you HAVE to overengineer certain stress points in the drivetrain and the bean counters need to stay the hell out of it. Who know for sure why this happened in the case of the RS but hopefully Ford has learned a lesson. Utilizing a better design would not have increased costs by that much and has been done in the past. The 4G63 is one example. Here's to hoping Ford will get their heads out of their rears.

Man am I glad I didn't run out and get one of these. I really considered it! I have a Mazdaspeed 3 and this was the logical next step for me. Guess the Civic type R is still a possibility but I should probably wait till the problems are sussed out before really considering it also...

did ford change anything in the replacement engines? or, are they the same engine design and head gasket?

410K views in a week. Good job,Alex!!

Any word on if this is an issue with early production RS models only? Has Ford revised anything for the 17 and 18 model years? Fantastic video btw, very interesting.

I want one now wit manuel shift. Is it ok .im thinkn of buying one

I heard this at my local dealer in the UK apparently they are bringing cars in and replacing head gaskets on them free of charge and if the engine depending on what damage it's done it's going to get a new head as well

Have you heard about the transmission shift issues with Jeep Grand Cherokees? My 2015 needed to have a new transmission installed at 12,000 miles.

Very descriptive video. Good job!

Any update with Fords corrective action? They’re using this engine in the new Ranger now.

Is this basically the same engine that’s in the speed 3