Sills and chips got both rusty. Sills were extremely expensive to replace. The part cost 188 euros for a piece and whole process cost almost 1000 euros.
Constant adjusting of tappets which were caused by worn-out camshaft. New camshaft cost 280 euros and with work it cost 750 euros to replace. Nice.
Muffler rusted.
Sway beam had to be replaced.
Nice car to drive. Very stable and good-looking.
However the quality of Ford left something to hope for. I got tired of my old 15 year old Fiat Tipo and it`s constant repairs, but Ford Ka was worse. And the spare parts were more expensive.
My next car will be made in Japan.
I also have a ford ka 2000 plate and I have had a lot worse than you wrong with it within the 1year I was replacing the wheel springs then my camshaft (i think) not long after that the stearing froze n I had to get that fixed too my sills went rusty and ford told me it was a common problem I would not recomend any one to bye a ford ka. I have spent about £2000 on repairs in the last 2years. I have just traded it in and got a suzuki jimny mode. klass car would recomend.