2000 Ford Focus - Runs rough when wet

Capt_A

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Nov 13, 2007
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I have a 2000 Ford Focus with 142k miles. When it rains, or when I wash the car, it runs very rough. Once the weather clears or the car dries out, it runs fine. I've replaced the plugs, wires, fuel filter, etc. Then I found a TSB on this phenomenon -

Make : FORD
Manufacturer : FORD MOTOR COMPANY
Service Bulletin Num : 17505
NHTSA Item Number: 10007338
Component: ENGINE AND ENGINE COOLING:ENGINE
Summary:
RUNS ROUGH AND/OR MALFUNCTION INDICATOR LAMP (MIL) ON CONDITION WITH DIAGNOSTIC TROUBLE CODES (DTCS) P402 AND/OR P0403 (EGR FLOW EXCESSIVE DETECTED/EGR CONTROL CIRCUIT) IN WET WEATHER OR IN A CAR WASH. *TT

and

Water leak: Rough engine running in wet weather caused by water leaking onto wiring from gap near center joint in cowl grille. (2000-02)


The Ford Dealer wants a ton of money (and the car for a couple of days) to repair this, when the problem is caused by poor initial design. Do you know of any way that I, a minimally mechanically inclined person, can repair this?

Thanks...
Andrew
 

EricC

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Nov 14, 2006
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25 bucks for a subscription to AllDataDIY and a tube of RTV should take care of it.
 
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