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Ford Problems

RepairPal has identified the most common problems for 50 Ford models based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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541
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 defective thick film ignition (TFI) module can cause the engine to stall while driving, or the engine may not start. A failed TFI module will require replacement.

Valve seats (components in the cylinder head that help seal the valve) can fall out. When this happens, it causes rough running and creates noise. Replacement of the cylinder head is commonly required to fix this problem.

A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.

Adhesive for foam blocks in the headliner can fail leading to poor fitment of the headliner and a possible rattle around the sunroof area. The foam blocks attach the headliner to the mounting brackets. Access the headliner and re-secure the foam blocks to the brackets using cable ties / zip ties.

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.

Software enhancements are available to remedy inconsistency and confusion about the Diesel Particulate Filter (DPF) cleaning cycle - “Regeneration” mode. The Powertrain Control Module (PCM) will need to be reprogrammed to add several enhancements, including a more reasonable driving experience during the cleaning cycle and instrument cluster notifications of the cleaning status.

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.