The ultimate hot hatch from Ford's performance division. This AWD turbo missile delivers 350 hp through a sophisticated torque-vectoring rear differential with drift mode. Early cars (built before July 2017) were plagued by a head gasket recall - verify FSA17B32 completion before purchase. The complex AWD system (PTU and RDU) is the weak link for reliability, especially on track or with tuning. Clutch, brakes, and tires wear quickly under spirited driving. Carbon buildup on intake valves requires walnut blasting around 80,000 km. Not for gentle drivers or tight budgets, but one of the most engaging hot hatches ever made when maintained properly.
Wrong gasket used on early production - Ford recall FSA17B32 covers repair · more· less
Cars built before July 6, 2017 received the wrong head gasket (Mustang spec instead of RS spec) due to production line mix-up. Symptoms include white exhaust smoke, coolant consumption, sweet smell in exhaust, misfires (codes P0300-P0304), loss of cabin heat, and engine overheating. Ford issued recall FSA17B32 covering replacement of head gasket and cylinder head if needed, with no mileage limit. Check door jamb build date - if before 10/17, verify recall completion. If repair was done before July 2018, post-recall oil leaks are possible. Cost is €0 if covered by recall, otherwise €3,000-4,500 for independent repair.
RDU/PTU overheating and failure€1,500 - €4,000
AWD system weak link - overheats on track, can't handle big power upgrades · more· less
The Power Transfer Unit (PTU) and Rear Drive Unit (RDU) are the AWD system's vulnerable points. PTU overheats during track use, RDU overheats during drifting/gymkhana. When overheating occurs, system goes into limp mode and disables AWD to prevent damage. RDU clutch packs can only handle 15-20% more torque than stock - tuned cars become increasingly front-wheel-drive as power increases. Complete RDU replacement costs €3,000-4,000. PTU oil leaks are common on early cars. Warning light appears after 800 km of track use requiring fluid service. Enthusiasts recommend PTU/RDU oil changes annually (€150-200) despite no official service interval. RDU is sealed for life but can be serviced at specialists.
Clutch and dual-mass flywheel wear€1,500 - €3,000
Heavy clutch wears quickly with spirited driving or tuning, 10-hour labor job · more· less
The stock clutch struggles with aggressive launches and track use. Tuned cars (especially over 400 hp) will slip the clutch prematurely. Dual-mass flywheel should be replaced with clutch as it cannot be resurfaced. Parts cost approximately €800 for flywheel + €500 for clutch kit. Labor is 10 hours at €80-100/hour due to complexity. Total dealer cost €2,500-3,000, independent specialist €1,500-2,200. Aftermarket performance clutches with single-mass flywheel available from €1,000 fitted. Symptoms include slipping under load, difficulty engaging gears, and juddering. Typical lifespan 60,000-100,000 km with normal driving, much less with track use or tuning.
Carbon buildup on intake valves€400 - €800
Direct injection means fuel never washes valves - walnut blasting required · more· less
All direct-injection engines suffer this issue. Fuel injectors spray directly into cylinders, so fuel never passes intake valves. Oil vapors from PCV system recirculate and bake onto valve backs. Symptoms include rough idle, reduced performance, and misfires. Noticeable buildup appears by 25,000 km, becomes problematic around 80,000-100,000 km. Fuel additives and spray cleaners are ineffective. Only proper fix is walnut shell media blasting (€400-600) requiring intake manifold removal. Some specialists offer chemical cleaning for €200-300 but less effective. Installing catch can (€200-400) reduces future buildup but may void warranty. Preventive measures: use premium fuel, occasional high-RPM runs (Italian tune-up), change oil every 8,000 km max with low-NOACK synthetic.
Turbocharger failure or boost leaks€800 - €2,500
Charge pipe clamps loosen, turbo can fail from oil starvation or heat · more· less
Boost leaks are common and obvious - loud whistling/screaming under boost. Most often caused by loose charge pipe clamps (especially under intercooler near oil filter) or blown charge pipes. Better quality clamps eliminate issue. Check all clamps at every oil change. Actual turbo failures are less common but occur from oil starvation, excessive heat, or tuning beyond safe limits. Symptoms include excessive smoke (blue/black), loss of power, unusual whining/grinding noises. Turbo replacement costs €1,800-2,500 at dealer, €800-1,500 at independent shop. Upgraded intercooler (€600-1,200) essential for track use or tuning to prevent heat soak. Stock intercooler adequate for street use but heat soaks quickly during spirited driving.
Brake pad and disc wear€600 - €1,200
High-performance car eats brakes - front pads every 20,000-30,000 km · more· less
The RS weighs 1,570 kg and makes 350 hp - brakes work hard. Front discs are 350mm x 25mm vented. OEM Ford front discs + pads fitted cost approximately €1,000. Doing yourself: front pads €150-220, rear pads €100-150, front discs €180-220 each, rear discs €80-100 each. Track use dramatically accelerates wear - track pads like EBC Bluestuff (€100-150) recommended. For street: EBC Yellowstuff pads with slotted discs are popular (€300-400 for fronts). Ferodo DS2500 not recommended for road use. Expect front pad replacement every 20,000-30,000 km with spirited driving, 40,000-50,000 km with gentle driving. Rear pads last 60,000-80,000 km. Discs typically last 2-3 pad changes.
Tire replacement€800 - €1,400
235/35R19 performance tires wear fast - rear tires gone in 15,000-25,000 km · more· less
Stock tire size is 235/35R19 on 8J wheels (5x108 PCD, ET52). OEM Michelin Pilot Sport Cup 2 or Pilot Sport 4S. Budget performance tires €140-180 each, premium (Michelin PS4S, Continental SportContact) €200-240 each. Full set €800-1,400 fitted. Rear tires wear much faster than fronts due to AWD torque vectoring and drift mode abuse. Typical life: rear 15,000-25,000 km, front 25,000-40,000 km with spirited driving. Gentle drivers can see 35,000+ km from rears. 245/35R19 fits without issue and gives slightly better grip. Track use destroys tires quickly. Check for uneven wear indicating alignment issues (€80-120). Wheel bearings can cause AWD to disable if they develop play.
High-pressure fuel pump failure€600 - €1,500
Direct injection HPFP can fail, causing low fuel rail pressure and misfires · more· less
The camshaft-driven high-pressure fuel pump pressurizes fuel to 2,000+ PSI for direct injection. Failure symptoms include hard starting (extended cranking), rough idle, misfires, and P0087 code (fuel rail pressure too low). At idle, failed pump shows only 80-100 PSI instead of proper pressure. Can be misdiagnosed - also check low-pressure pump, fuel filter, and inlet screens. OEM replacement €500-700 plus 3-4 hours labor. Aftermarket upgrades available for tuned cars: Bosch HPFP upgrade flows 40% more (€400-600), Nostrum HPFP flows 63% more and is E85-compatible (€800-1,200). Most failures occur on tuned cars running high ethanol content or very high power levels. Stock cars rarely experience HPFP failure.
Engine mount and gearbox mount wear€200 - €600
Rubber mounts degrade from hard launches - knocking in 1st-3rd gear · more· less
Symptoms include knocking during gear changes (especially 1st-3rd), excessive engine movement, and wheel hop during hard acceleration. The lower "dogbone" gearbox mount is most common failure point. OEM Ford gearbox mount €200-320, engine mounts €120-180 each. Labor is 0.5-1.5 hours per mount depending on location. Upgraded polyurethane mounts available from Powerflex, AIRTEC (€90-150 each) offering longer life and reduced movement but transmit more vibration. Track-oriented drivers report mounts lasting only 30,000-50,000 km. Street-driven cars see 80,000-120,000 km. Uprated mounts can be fitted in 30 minutes with basic tools. Softer 70A bushings for engine/diff mounts, firmer 80A for suspension areas.
Wheel bearing/hub replacement€350 - €650
Ford doesn't sell front bearings separately for RS - whole hub needed · more· less
The RS uses different hubs than the ST (related to RevoKnuckle design). Ford does not supply individual front wheel bearings - complete hub assembly required at €290-350 per side. Symptoms include groaning/grinding from wheels (worse during turns), vibration through steering, loose handling, car pulling to one side, and possible AWD system shutdown. Rear bearings can be replaced separately (€100-150 per side). Total replacement cost per corner: front €400-550, rear €200-350 including labor. Damaged ABS sensor rings or dirty sensors can cause AWD to disable - clean sensors and rings before replacing bearings. Failure typically occurs at 80,000-120,000 km. Track use and aggressive cornering accelerate wear.
Oil consumption€50 - €200
Turbo engines run rich under boost - 1 quart per 3,000 km considered normal · more· less
Ford EcoBoost engines are harder on oil than naturally aspirated engines. By design, the engine runs extremely rich under boost causing fuel contamination and increased oil burn-off. Ford considers 1 quart (0.95L) every 1,500-2,000 km within normal specification. Most owners report 0.5L consumption every 3,000-5,000 km. Check oil level every 1,000 km - low oil can damage turbo bearings. Use quality low-NOACK synthetic oil (Castrol Edge, Mobil 1, Motul) and change every 8,000 km maximum. Heavy-footed drivers should change at 5,000 km. Oil capacity is 5.7L. Excessive consumption (more than 1L per 2,000 km) or blue smoke indicates worn piston rings, valve seals, or turbo oil seal failure.
Spark plugs and ignition coils€200 - €400
3-year replacement interval, costs reasonable for a performance car · more· less
Ford specifies spark plug replacement every 3 years regardless of mileage. OEM iridium plugs can last 100,000 km but gap widens after 50,000 km affecting performance. Tuned cars should replace at 50,000 km maximum. Spark plugs cost €15-25 each (4 cylinders = €60-100), labor 1-2 hours (€80-160). Full service with plugs at dealer €350-500, independent €250-350. Ignition coils typically last 100,000+ km but can fail prematurely. Symptoms: rough idle, misfires, reduced power. Coil failure often caused by worn spark plugs. Replace coils individually as they fail - no need to replace all at once. OEM coil €60-90 each, aftermarket €40-60. If misfires occur, replace spark plugs first before condemning coils.
High-performance thrills come with high-performance bills
The Focus RS Mk3 is one of the most capable and engaging hot hatches ever made, but ownership costs reflect its performance nature. The head gasket recall is the biggest concern for 2016-2017 cars - verify completion before purchase. The complex AWD system requires careful maintenance and doesn't tolerate aggressive track use or significant power upgrades well. Consumables (brakes, tires, clutch) wear quickly under spirited driving. Budget €1,500-2,500 annually beyond routine maintenance for a well-used example. This is not a car for buyers seeking Honda Civic reliability or Toyota running costs - but for enthusiasts willing to maintain it properly, it delivers an unmatched driving experience.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete service records essential. Look for oil changes every 8,000-10,000 km max, PTU/RDU fluid changes, and brake fluid changes every 2 years.
Cold start
Must start completely cold. Listen for timing chain rattle, turbo noises, exhaust leaks. Check for white smoke indicating head gasket issues.
Test drive minimum 30 minutes
Include highway speeds, hard acceleration, and full-temperature operation. AWD issues often only appear when hot.
Body condition and accident damage
Check roof above rear doors for denting (bodyshell flex), inner wings for creases, paint match. Many were crashed during drift mode antics.
Specific for this vehicle
Verify head gasket recall FSA17B32 completed
Critical for 2016-2017 cars. Check door jamb build date - if before 10/17, recall applies. Register on Ford ETIS with VIN to check recall status. Feel for revision C gasket tab on front of engine block.
Check for coolant leaks before and after test drive
Look under car and around hose underneath coolant tank. Wait 10-15 minutes after test drive and recheck. Sweet smell in exhaust indicates head gasket leak.
Test AWD system thoroughly
Try all drive modes (Normal, Sport, Track, Drift). Watch for "AWD service needed" or "AWD off" warnings. System should feel engaged and responsive. FWD feeling indicates RDU problems.
Check for PTU and RDU oil leaks
Inspect PTU at front (between engine and transmission) and RDU at rear axle. Minor weeping is somewhat normal, but active leaks require attention.
Test clutch engagement and feel for slip
Clutch should engage 7-10 cm from floor. Try pulling away in 3rd/4th gear - should bog engine down. If revs rise without speed increase, clutch is slipping.
Listen for boost leaks during acceleration
Any loud whistling or screaming under boost indicates charge pipe leak. Check all clamps and pipes, especially under intercooler near oil filter.
Inspect brake discs and pads
Check pad thickness and disc condition. Warping or excessive wear indicates hard use. Squealing acceptable, grinding is not.
Check rear wheel arches for paint bubbling
Look where arches meet bumper - bubbling indicates water ingress and rust.
Test for modifications and tuning
Check for aftermarket intercooler, intake, exhaust, access port/tuner. Modifications void warranty and stress components. Mountune upgrades maintain warranty.
Verify Sync 3 and desirable options
Sync 3 standard from September 2016 build (much better than Sync 2). Lux Pack, Shell/Recaro seats, and Premium Audio are desirable.
Check interior for excessive wear
Seats, steering wheel, shifter, carpets should match mileage. Check floor mats underneath for water (leak indicator). Test all buttons and switches.
Check rubber seals on door bottoms
Common Mk3 Focus fault - seals hang loose. Not serious but indicates lack of attention to detail.
Recalls and Technical Service Bulletins
Head gasket FSA17B32 (built before 6 July 2017)CRITICAL - Verify completed
Canister Purge Valve CPV (18S32)May affect some RS cars
Oil pump drive belt (23S64, 2016-2018)Check if applies to your VIN
Floor pan weld (17S03, 2016 cars)Safety recall - verify completion
Contact Ford with VIN to verify all recalls completed. Register on Ford ETIS (https://www.etis.ford.com) for complete recall history. The head gasket recall is absolutely critical for 2016-2017 cars and must be verified before purchase.
Warranty Status
Factory warranty (3 years)Expired on all Mk3 RS cars
Ford Protect extended warranty (4th/5th year)€320 for years 4-5 combined
Maximum coverage availableUp to 10 years / 160,000 km
All Focus RS Mk3 cars are now outside original 3-year warranty. Ford Protect extended warranty available through dealers or myfordprotect.co.uk for cars up to 10 years old / 100,000 miles. Germany offers up to 7 years / 150,000 km coverage. Read terms carefully - some items like oil leaks may be excluded. Mountune upgrades do not void Ford Protect warranty. Third-party warranties available but read exclusions carefully.
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.