Ford Problems

RepairPal has identified the most common problems with the Ford as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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Known Problems

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. Our technicians tell us the valve and sensor must be replaced together to correct this concern.

The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.

A leaking axle shaft seal and / or PTU cover seal can cause transmission (red) or Power Transfer Unit (PTU) (brown) fluid leaks at the axle area. The axle shaft seal and / or PTU cover seal may be leaking and should be replaced as required.

Defective materials can cause the center console latch to break. The latch on the console lid should be replaced.

Failure is very common in the ignition module, causing intermittent stalling or a "No start" condition.

A defective crankshaft pulley can cause a clicking, or clanging noise from the engine when it is running. The center hub can become loose and the pulley should be replaced with the revised design.

An abnormal noise may develop from the transfer case. At this time parts are not available to repair internal damage to this type of transfer case, replacement is the only option. It is not uncommon for irregular tire wear to cause a similar noise. Diagnoses should be performed to confirm the actual cause of the driveline noise. Tire noise can be reduced by rotating the tires at least every 5000 miles.

The Check Engine Light may illuminate, the engine may run rough and have misfires on acceleration. Commonly the ignition coils and/or the ignition coil boots are the cause of this problem. The rubber boot that insulates the coil to the spark plug can dry and crack allowing arcing. Inspect the coils and boots, and replace them as needed. Our technicians also recommend replacing the coil boots any time the spark plugs are replaced.

The 2008-2012 Ford Escape with manual temperature and fan controls may have problems with the the blower motor only blowing air on certain settings. Most commonly the fan will only run on the highest setting. This is a well documented problem, and is caused by a failing blower motor resistor.

Correcting the problem is straight forward, and requires replacement of the small resistor. The resistor is normally found behind the glove box, next to the blower motor.

The cooler for the EGR valve can leak coolant internally, which causes white smoke to come from the tail pipe. Hot exhaust gases are cooled by the EGR cooler before being circled back into the engine.

A coolant leak from the radiator can be caused by a defective thermostat bypass. This can cause pressure spikes in the cooling system, which leads to radiator failure. The thermostat assembly and radiator should be replaced.

There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.