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Old 05-17-2013, 08:42 AM   #21
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Originally Posted by c5karl View Post
I was ready to give Ford a pass on this. It's impossible to build one car per minute, or whatever the assembly line speed is, without the occasional screw being dropped. But three coming into the same dealership with the same problem? They need to look into why this is happening.

Makes me think of a conversation I had a while ago with a friend's buddy who worked at the assembly facility in Ft. Worth where they built F-14s. He said when completed jets came off the line, they made sure to fly upside down for an extended period of time during the test flight. A handful of loose screws and bolts and clips would fall into the top of the canopy and be scooped up before delivery to the Navy.
They absolutely need to investigate this - with Visteon, the HVAC supplier. Ford does not build the HVAC assembly (the entire module that contains dozens of screws and other parts). They arrive pre-assembled at MAP and Ford assembles them into the vehicle. The thing with Tier-1 suppliers is that they have guaranteed quality so Ford does not inspect. With something like an HVAC it would be impossible to inspect as the assembly is large, complex, and can't be accessed without being disassembled.

There is clearly an issue with Visteon's quality check if this many are slipping through.
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Old 05-17-2013, 09:05 AM   #22
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I always knew that someone at Ford had a screw loose.
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Old 05-17-2013, 01:17 PM   #23
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Originally Posted by bobakman View Post
Just got my Focus back from the dealer and it was a screw as well that was the cause of the plugged drain. The service adviser stated that mine was the third one recently that has had the same issue.

Thanks for keeping us in the loop, Bob. If you need any assistance in the future, just send a PM my way.


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Old 05-18-2013, 01:09 PM   #24
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Reading about this made me nervous. I added factory air conditioning to my first car ('79 Bobcat wagon), and forgot to drill the hole for the drain. The memory of that experience still haunts me, so I went out today to make sure this car doesn't have that problem.

I took some pictures in case people want to check this out for themselves. It was necessary to remove the passenger-side footwell console cover, but there was the drain tube plain as day (my index finger is touching it):

It pulls out with little force:

And here's the whole tube, including the exit into the center tunnel:

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