Thanks for the replies. I'd like to keep this discussion alive for awhile to get more input. The more research I have done on both vehicles, the more problems I have uncovered. I like to check forums so that actual owners can provide a "real world" sample of experiences. This is a good forum to check on the Focus:
http://www.focusfanatics.com/forum/showthread.php?t=125090
I've also been to Edmunds.com to check reviews. Granted, there are many really good reviews on both vehicles. But the sample size I am looking at is very small, so I assume I'll get a small number of negative AND a small number of positive reviews. What I am focusing on (no pun intended) are the negative reviews because I am looking for failure patterns. Even if the sample size is small, it may be useful if I see patterns.
What I have found so far in a week's worth of research is that both cars have a set of pattern problems, both cars are cheap, and it becomes a pick your poison scenario with them. For example, I have researched and found:
Ford Focus problems:
ignition system - faulty key cylinders / stuck keys
brake system - warped rotors, sticking brake calipers, brake noise/squealing, excessive brake pad wear, etc.
transmission - complete failures, loss of individual gears, fluid leakage, shift linkage/cable problems, etc.
electrical - blown fuses, lighting failures, control module failures, etc.
fuel - fuel pump issues
chassis - water leaking from somewhere and onto the floor mats
cooling system - plastic thermostat housing cracking and breaking, A/C compressor failures, A/C compressor cut-out during acceleration, etc.
engine - stalling, surging, rough idle, vibration
fit and finish - interior parts breaking, cheap build
safety recalls - numerous for the 2000 model
Chevy Cobalt problems:
ignition system - faulty key cylinders / stuck keys
brake system - warped rotors, sticking brake calipers, brake noise/squealing, excessive brake pad wear, etc.
transmission - complete failures, loss of individual gears
electrical - blown fuses, lighting failures, control module failures, CD player/radio failures, trip computer faulty MPG readings, cruise control failures, faulty fuel guages, fuel tank sending units, electric power steering failures
fuel system - faulty fuel tanks
chassis - water leaking from somewhere and onto the floor mats
cooling system - mold in A/C system
engine - stalling, surging, rough idle, plastic timing gears
fit and finish - cheap plastic everywhere, breaking plastic parts, broken knobs and buttons, cheap fabric apholstery, fading paint and door panels, clear coat breakdown
Both cars have disappointed me so badly that I've stopped my research of the two vehicles at this point. Unfortunately, since all vehicles have some issues, so this process of looking for a vehicle may turn into choosing the lesser of two evils - or in this case, the car with the fewest pattern failures.
My own experience tells me that you can't go wrong with a Honda but it is really hard to find one in the same price range that isn't cancered or beat on and I don't really want to have to go as far back as 2001-2002 years to get a Honda sedan in the $5-6k range in my area.
Nonetheless, it's off to look at some other sedans and I will post back with what I find.
The basic criteria I am looking for is:
1. reliable - few if any serious failures (my CRX is an example of this - still on the road since 1984)
2. economical - 30+ mpg (my CRX is an example of this - still getting 35-42mpg)
3. reasonably safe - airbags, ABS
4. enough room for adults or kids in the back seat
5. $5-6k starting point