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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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Known Problems

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.

Bulletin 13N02 - This program extends the coverage of the brake booster to ten years of service or 150,000 miles from the warranty start of the vehicle, whichever occurs first. This is a one time repair program.

In some of the affected vehicles, it is possible for the brake booster to develop a small tear in the diaphragm under certain driving and environmental conditions. If this occurs, the driver may hear a hissing noise while depressing the pedal and may also experience a "spongy" pedal feel without a noticeable effect on braking performance. If the vehicle is not serviced, the tear will eventually expand and the pedal effort required to stop the vehicle will gradually increase. However, in all cases, the fundamental vehicle braking system remains functional.

Ford Escape four wheel drive models may develop an abnormal noise from the transfer case. This may sound like a bearing howling first, but will turn into a clicking noise at higher speeds.

The transfer case on these models is notoriously troublesome, and can become damage from normal use, and the sound of the failure is notably close to the noise heard from mud tires on pavement. 

To eliminate the noise, the vehicle should be inspected, and, if the transfer case has suffered internal damage, it must be replaced, not rebuilt. 

Changing the transfer case fluid on schedule may help, but many failures are before the first fluid change interval. 

The 2005-2009 Ford Mustang 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 Check Engine Light may come on due to failure of the Variable Camshaft Timing (VCT) solenoid. The VCT solenoid will need to be replaced to correct this concern.

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

An illuminated Check Engine Light and a rough running engine could indicate that one or more of the ignition coils has failed. Often times this is due to excessive spark plug gap. To fix this problem, the defective ignition coilsspark plugs, and all coil boots should be replaced.

The engine may misfire and/or buck while driving at freeway speeds with no fault code stored in the powertrain control module (PCM). This can be caused by an intermittent fault with the camshaft synchronizer assembly. This condition can be diagnosed by monitoring knock sensor data as per Ford service bulletin #05-22-12. Replacement of the synchronizer assembly will be required to correct this concern.

Drivers may notice the engine idling roughly, hesitation to accelerate, and even engine stalling on the Ford Mustang GT V8..

The mass air flow sensor (MAF) is prone to fail, and commonly is diagnosed as the faulty component when these issues arise.

When the Check Engine Light illuminates, and the diagnosis is a failed MAF, it will require replacement to correct the issue. 

Ensuring the air filter is installed properly, and sealed to the air filter housing, can help prevent MAF sensor issues. 

Squeaks and creaks heard while driving over bumps and turning can be caused be a couple common sources and should be carefully diagnosed. Possible weld issues on the lower control arms can cause the noise concerns and require repair kits for the lower control arms from Ford. A jounce bumper (bump stop) rubbing against dry strut plate can cause an abrasion noise from the strut area. In this case the strut assembly should be disassembled to lubricate the jounce bumper and then reinstalled.

Replace the worn wheel bearings.