@FocusynRS here is my Ford customer service case number from when I had a similar issue. CAS-11643232
Let me know if I can be of any more help.
This is a discussion on What's that weird burning smell? Getting screwed by FoMoCo for a defective clutch! within the Focus RS TroubleShooting forums, part of the Focus RS Garage category; Hmm this has me worried. I notice my car is smelly after I pull it into the garage sometimes after I've been getting on it. ...
Hmm this has me worried. I notice my car is smelly after I pull it into the garage sometimes after I've been getting on it. Driving roads aren't great around here, so it's only a few hard shifts/brake events at a time, but having never owned a true performance car before (or any new car from mile zero for that matter), I chalked it up to all the grippier friction compounds from the performance application, so nbd.
Now I'm questioning all that. In unfortunately can't 100 percent rule out driver mod, as I've only got about 70k miles under my belt on a manual, but by a twist of fate, when my Mazda died, they had to drop the engine/transmission, so I got a sneak peek of my clutch after 65k miles of my usage habits. Everything looked uniform to me and there was certainly quite a bit of friction material left, without knowing what it looked like originally I'd have to guess it was about half way through its life. In my mind I shifted that car hard but not "abusively".
My shift habits were basically this (and I've continued with the RS):
-I never flat foot shift
-I never ride the clutch (have a dead pedal for a reason)
-I was usually heavy-ish on the throttle on takeoff, but the whole clutch event lasts about a second (this has actually changed a bit with the RS, as I've grown lazy and taken advantage of it's takeoff assist, so I typically apply little to no throttle at all on takeoff in the RS)
-up shift events are probably "street-aggressive", but not "race-aggressive". I never wait for the revs to drop to the value appropriate for the next gear; as soon as the lever is in the next position I am getting back on the throttle/off the clutch. Whole thing takes about a second total (with a third to a half of that being clutch reengagement), and revs fall smoothly from the old gear to new with no stutters or hang-ups as the revs fall. In my mind this is aggressive, but still proper and not abusive by any means.
-down shifts are always double clutched, and include heel-toe if necessary. I still don't always get the rev matching right, but I'm fairly proficient and tend to over rev rather than under rev my throttle blips as I perceive that to be better for the clutch. Clutch re-enagement is snappy but not abrupt, probably about a third of a second to reengage.
So thoughts - driver mod or should I be taking this thing in to get looked at? If you answer driver mod, I've given you plenty of ammo so please point to a specific poor habit if you think there is one.
On order: FW RS2 with Forged Wheels
Also sorry to hear about your issue. My immediate (selfish) reaction after reading your post was to worry about my own car, but I seriously hope Ford steps up and does the right thing for you.
While I might lack tens of years of driving experience, I did manage to successfully get a new clutch under warranty for my buddy's Jetta GLI after only 20k miles - it was a huge uphill battle with the warranty department, but eventually we won so stick to your guns and hopefully things will work out. Of course part of the pressure plate was actually broken in that case, and somehow they "didn't notice", but still, I've got hope for your situation.
On order: FW RS2 with Forged Wheels
I have the same clutch smell after backing into my garage. 1300 miles.
Next time I drive it, I'll make sure it's not the brake pads.