Iconic front-wheel drive hot hatch beloved by enthusiasts. Powered by a robust Volvo-derived 2.5L turbocharged five-cylinder engine paired with Quaife limited-slip differential and RevoKnuckle suspension to manage torque steer. The engine is highly reliable even at high mileage when properly maintained, with many examples exceeding 100,000 miles. Main concerns are rear arch rust (widespread), RevoKnuckle bushing wear at higher mileage, timing belt replacement at 10 years or 125,000 km, clutch wear around 60,000-70,000 miles, and potential alternator failure. Verify rear arch condition before purchase - Ford warranty denials are common. Enthusiast ownership with full service history preferred.
Paint bubbling and rust on rear wheel arch lips is extremely common on both RS and ST variants · more· less
This is a widespread issue affecting the vast majority of Mk2 RS models. Stones thrown up inside the arches chip the thin paint on the arch lip edge, leading to rust. Where the bumper meets the arch is also problematic as the bumper rubs off the paint. Ford applied inadequate paint coverage inside the arches. Repair costs vary by color - Frozen White repairs around €120, but rare colors like Ultimate Green can cost 10x more. If the whole panel needs repainting, costs increase significantly. Ford warranty claims are typically denied after 6 years, claiming "bumper rub" unless full Ford service history with annual paint inspections (€15 extra per service) are documented. Prevention: apply wax oil inside rear arches and protective tape where bumper meets quarter panel.
RevoKnuckle lower arm bushing failure€150 - €1,200
Lower wishbone bushes weak and prone to perishing, causing knocking sounds and excessive wheel movement · more· less
High-mileage RS models (80,000+ km) commonly show wear in the RevoKnuckle ball joints and lower control arm bushings. Symptoms include clonking noises over bumps and visible excessive movement at the front wheels when reversing and applying brakes. Ford often insists the entire RevoKnuckle assembly (€800-1,200) must be replaced, though some specialists successfully replace just the ball joint (€150-300). Bushing replacement requires drilling out the old bushing and pressing in new ones - a difficult DIY job. Aftermarket Hardrace bushings (€200-400 for set) improve handling but require careful installation. Worn bushings also cause excessive front tire wear.
Timing belt replacement (scheduled maintenance)€580 - €850
Critical service at 10 years or 125,000 km - engine destruction if belt fails · more· less
The RS Mk2 uses a timing belt (not chain). Ford's official interval is 200,000 km or 10 years, but enthusiasts strongly recommend replacement at 7 years or 112,000 km due to age degradation. This is an interference engine - if the belt breaks, valves will contact pistons causing catastrophic damage requiring engine rebuild (€4,000-7,000+). Always replace the tensioner, water pump, auxiliary belts, and idler pulley simultaneously. Ford dealer quote €580-700, specialist garages €600-850 including water pump and MOT. The auxiliary belts can also break and damage the timing belt, so these must be inspected carefully.
Clutch and dual-mass flywheel wear€800 - €1,500
Expect clutch replacement around 60,000-70,000 miles, especially if driven hard · more· less
Standard clutch lifespan is 60,000-70,000 miles with spirited driving, though some owners report 140,000+ miles with careful use. Common symptoms include clutch pedal pulsing/vibration that matches engine speed (dual-mass flywheel issue), shuddering when pulling away in 1st/reverse, and clutch slip (test in 5th gear at 2000 rpm - revs rise without acceleration). Always replace the dual-mass flywheel when replacing clutch (adds €300-500). Some owners convert to single-mass flywheel (€600-900) but this causes gear rattle at idle and increases stalling tendency in traffic. Stock clutch handles 400-450 bhp unless launching aggressively.
Alternator failure€350 - €700
Battery/ABS/power steering warning lights, smart-charge system voltage drops · more· less
Common failure mode: battery light illuminates, followed by ABS/traction control lights, radio cuts out, power steering fails (steering becomes extremely heavy). The RS uses a smart-charge alternator that monitors voltage - at idle with minimal load should show 14.7V, dropping to 12.2-12.3V when AC/heated screen/lights all on indicates failure. 2006 models particularly affected (most now fixed). The smart-charge system requires calcium batteries - using lead-acid can cause explosions due to higher charging voltage. OEM or Denso alternators recommended (€350-500), plus auxiliary belts (€30 pair). Replace batteries over 5 years old preventatively. Failure common around 78,000-100,000 km.
Turbo downpipe bolt failure€100 - €800
Well-known issue - turbo-to-downpipe bolts work loose or snap completely · more· less
The bolts securing the downpipe to the BorgWarner K16 turbo have a notorious habit of loosening, snapping, or disappearing entirely. Symptoms include exhaust blowing/rattling sounds. If bolts snap flush, the turbo may need removal for drilling out (€600-800 labor). Use Stage 8 locking fasteners or JWR/Mountune teardrop locking tab bolts for replacement (€50-100). Torque spec is 28 Nm per workshop manual. Check these bolts at every service - a common failure point especially on modified cars. Aftermarket exhaust installations often cause bolt problems. The catalyst sensor (€150 if damaged) can be difficult to remove without heating until glowing red.
Plastic thermostat housing develops pinholes, coolant hoses perish with age · more· less
The plastic thermostat housing is a common leak point, developing microscopic pinholes or cracked O-rings. Water runs along hoses before dripping, making the source difficult to locate. Coolant hoses become brittle with age and oil contamination, causing swelling or cracking. The yellow pressure cap commonly fails, preventing proper pressure release and causing housing leaks. Heater hose connections through the firewall also leak, absorbed by padding until catastrophic. Replace thermostat housing (€150-250), all coolant hoses preventatively if over 10 years old (€200-400), and pressure cap (€20-30). Air locks require specific bleeding procedure: 2500 RPM for 8 minutes, maintain after reaching temperature for 3 minutes, spike to 4000 RPM for 5 seconds, return to 2500 RPM for 3 minutes.
Premium tire wear (Michelin Pilot Sport required)€600 - €900
235/35/19 tires required, cheap tires unsafe - budget €150-180 per corner · more· less
The RS Mk2 requires 235/35 R19 tires. Budget tires are unsafe on a 305 hp FWD car. Michelin Pilot Sport 4S (current recommendation, superior to older Super Sport) costs €150-180 per tire fitted at Costco (with €100 cashback on 4 tires). Expect rear tires to wear faster. Lifespan: 20,000-30,000 km for rear, 30,000-40,000 km for front with spirited driving. Some owners report lasting 3 years at 8,000 km/year. Worn RevoKnuckle bushings accelerate front tire wear significantly - inspect suspension if tires wear unevenly. Pilot Sport Cup 2 (track-focused) costs significantly more and wears faster on the street.
Cylinder liner cracking (very rare on RS)€2,500 - €7,000
Much more common on ST225 than RS - RS has plasma-coated liners and stronger block · more· less
The RS engine features revised head gasket and plasma-coated cylinder liners for increased durability compared to the Focus ST. The Volvo-derived engine was bored out 2mm (thinner liner walls), but Ford addressed this with coating. Cracking is extremely rare on standard RS engines - forum members report "not having heard of any standard engines going bang." Risk increases significantly on modified engines above 400 bhp. Symptoms include coolant loss, white smoke, rough running. Repair options: used engine from €400, forged rebuild €2,500, full RS conversion €3,000-7,000. The block is conservatively rated and will reliably handle 400 bhp when properly serviced.
Carbon buildup from short trips causes actuator to stick, triggering EPC light and limp mode · more· less
The BorgWarner K16 turbo actuator tends to stick when the car is driven gently or only for short trips, as carbon builds up. Symptoms: EPC warning light, sudden power loss (limp mode). VW/Ford won't sell the actuator separately from the turbo. Actuator-only repair at specialist costs €500-600. If turbo internals are damaged from prolonged sticking, full turbo replacement runs €1,200-2,500. Prevention: use premium fuel (98 RON) and give the car a spirited drive once per week to prevent carbon buildup. The stock K16 is reliable for 400 hp when maintained properly. Regular hard acceleration (Italian tune-up) keeps the system clean.
Reliable powertrain, but suspension and bodywork need attention
The Volvo-derived 2.5L engine is bulletproof - many examples exceed 100,000 miles with proper maintenance. Main concerns are wear items (clutch, bushings, rust) rather than catastrophic failures. Rear arch rust affects the vast majority of cars but is largely cosmetic. Budget for timing belt service and eventual RevoKnuckle bushing replacement. Enthusiast-owned examples with full service history are significantly more reliable than neglected examples.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Ford dealer or specialist records essential. Verify oil changes at proper intervals (every 6,000 miles for modified cars, 10,000 for stock).
Tires
Check tread depth, age (date codes), uneven wear patterns. Budget tires are a red flag - should have premium tires (Michelin Pilot Sport).
Cold start
Must start engine completely cold. Listen for unusual sounds, check for white smoke (head gasket/liner issue).
Identity check
RS is a magnet for theft - verify VIN matches on all panels, check for fake/ringer built from stolen parts. Check for outstanding finance.
Test drive
Minimum 30 minutes including varied speeds. Test clutch by accelerating hard in 5th gear at 2000 rpm - revs should not rise without acceleration.
Specific for this vehicle
Rear arch rust inspection (critical)
Inspect BOTH rear arches carefully for paint bubbling, rust on lip edges, and where bumper meets arch. This affects 70%+ of cars. Look inside wheel arches for rust. Walk away if extensive.
RevoKnuckle bushing test
Have someone reverse the car and tap brakes while you watch front wheels - excessive movement indicates worn bushings. Listen for clonking over bumps.
Timing belt service verification
Check service records - belt should be replaced every 10 years or 125,000 km. If car is 7+ years old without replacement, budget €700 immediately. This is critical.
Clutch pedal feel test
Check for pulsing/vibration through clutch pedal matching engine speed (dual-mass flywheel wear). Test for shuddering when pulling away in 1st/reverse.
Alternator and battery check
Ask about battery age (replace if 5+ years). Check battery/ABS/power steering warning lights don't illuminate. Heated windscreen should work properly.
Coolant system inspection
Check coolant level and condition. Look for dried coolant stains around thermostat housing and hose connections. Sweet smell from exhaust indicates head gasket issue.
Modification history
Ask if car was previously modified then returned to stock - may indicate hard life. Check for uprated parts. Stock car preferred unless professionally tuned with supporting mods.
Turbo downpipe bolt check
Listen for exhaust blowing/rattling sounds when cold. If possible, inspect turbo-to-downpipe connection for missing/loose bolts.
Front tire wear pattern
Uneven or excessive wear on front tires indicates suspension problems (bushings, alignment). Should wear evenly across tread.
Owner knowledge test
Ask about maintenance history, known issues. Enthusiast owners who know the car well are strongly preferred - they maintain these cars properly.
ABS sensor signal issues (if reported)Check with dealer
The Mk2 RS was not sold in North America, so most TSB databases cover the Mk3 RS. Contact a Ford dealer in Europe with the VIN to verify all recalls have been completed. The main North American recalls (head gasket, oil pump) do not apply to the Mk2's different engine.
Warranty Status
Factory warranty (3 years)Expired on all Mk2 models
Extended warranty availabilityLimited for 2009-2011 models
All Focus RS Mk2 models (2009-2011) are now outside their original factory warranty. The 10-year anti-corrosion warranty is often denied for rear arch rust unless full Ford service history with documented annual paint inspections exists. Extended warranties for 12-16 year old vehicles are difficult to obtain and expensive.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.