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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

If you experience difficulty starting the engine when cold, stalling at idle, or hesitations during acceleration, it may be the idle air bypass valve. This valve helps the vehicle idle steady when the accelerator pedal is not pressed.

A severe lack of power may develop because the hose from the turbocharger to the intake manifold can come loose, resulting in loss of boost pressure to the engine.

Excessive clearance between the plastic wheel cladding and the wheel can cause a clicking noise from the wheel area while the car is moving. If the plastic cladding is loose, the wheel will need to be replaced.

The 2004-2010 Ford F-250 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.

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.

The magnet for the camshaft position sensor may fall out of its mount and damage the synchronizers. This causes long crank times when starting the engine and may cause the Check Engine Light to illuminate. If this happens, both the magnets and the synchronizers need to be replaced.

If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing differential clutch kit. An updated differential clutch kit available.

While driving the Ford Five-Hundred, operators may notice harsh shifting or slippage of the transmission. This may not illuminate the check engine light

This is caused by software issues in many cases, however, internal transmission failure may be the culprit as well. In some instances, the failure has been attributed to the ‘sealed-for-life’ nature of the transmission, as the transmission fluid may break down before the transmission is taken out of service.

 

The manufacturer of the transmission, which is a third party, has issued many software updates, but when these updates fail to correct concerns, the transmission must be removed, disassembled, inspected, and repaired. 

From 2006-2012, the Ford Fusion was built with a six-speed automatic transmission built by a third-party manufacturer, as is the case with most transmissions.

For this specific automatic transmission, there is a common complaint regarding the harshness of shifts, as well as slight slippage when the transmission is hot.

In most cases, these issues arise from faulty software, which does not account for all variables as the transmission warms to normal operating temperature. In other cases, the valve body or shift solenoids are found to be faulty.

Software updates and software patches have been developed for these transmissions, and that is normally sufficient to correct drivability issues. If resetting the transmission controller and updating the transmission proves insufficient to correct concerns, the transmission will likely require rebuild or replacement before performance is returned to normal.

These transmissions were built and sold as ‘sealed for life’, but many have found that the automatic transmission fluid is not reliable for the complete service life of the vehicle.

A ticking noise may develop from the engine due to a cracked exhaust manifold. Damaged exhaust manifolds will require replacement to correct this issue.

The Ford Expedition has known issues with the V8 engine ejecting spark plugs. This will make a tapping or knocking noise, plus the engine will begin to misfire at all speeds. The check engine light will also illuminate.

The threads on the cylinder head are too short and soft, allowing pressure from combustion to overwhelm and destroy the threads. 

When the spark plug ejects, the cylinder head becomes damaged, necessitating repair of the spark plug port threads, or replacement of the cylinder head and cylinder head gasket. 

Ford has recommended a method of repair for the cylinder head that prevents the spark plug from ejecting under future use. Replacement of all spark plugs is not necessary, but an updated spark plug design can help prevent this from happening in the future. 

There is a technical service bulletin for the V8 engine.

The 1997-2001 Ford Ford Crown Victoria, with a 100% plastic intake manifold, is known for engine overheating, even with normal use, and a coolant leak from the front of the manifold. This will often trigger the check engine light and low engine coolant warning light.

The engine coolant leak is from a factory defect, which causes cracking on the front coolant passage of the intake manifold. In a very short time, this leak will lead to engine overheating issues, especially while the vehicle is idling.   

Between 1999 and 2001, Ford released an updated version of this engine, known as the 'PI' version with a metal coolant passage on the front of the intake manifold, to prevent future issues.

There is no factory authorized repair for the intake manifold, and replacement is required to correct the engine coolant leak and overheating issues.

 

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.