Worried about potential repair costs? An extended warranty can provide peace of mind.
Chart based on 81 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
Not sure if related but during the repairs to the battery cable, the shifter also went bad - the car couldn't consistently tell if it was in D or not so the battery kept draining and having issues. They ended up replacing the battery a second time before figuring this problem out.
slapping noise in right front wheel hub assembly, diagnosed as gap by design that allows part on shaft to slap against hub when turning. Ford did design a washer to fill this gap if desired by owner to eliminate noise, but not necessary. Will not do any damage to wheel hub.
58000 mi
Noise from left front, wheel bearing replaced under warranty
89000 mi
US $175
Noise from back of car, Replaced right rear wheel bearing.
Drive train module has a bad input, and needs to be replaced. Part is on backlog, but the car is safe to drive. Paid $250 as part of extended warranty. Unkown total cost.
Noticed Oil leaking when I changed the oil. Took it into the Ford Dealership. Power Transfer Unit was bad and needed to be replaced. Covered under warranty. Noticed Oil leaking when I changed the oil. Took it into the Ford Dealership. Power Transfer Unit was bad and needed to be replaced. Covered under warranty.
PCM Power Control Module failed and needed to be replaced. Triggered check engine light. Dealer fixed under 80k mi powertrain warranty. My cost was for replacement key.
Transmission would not disengage from Drive when shifting to other gears. Fixed itself, but took to dealer. They performed PCM update and tested system. Has not occurred since.
150000 mi
Pull code on Check Engine light.
112840 mi
C $2000
steering knuckle siezed, required entire steering column and connected parts to be replaced. Apparently a "feature" in ford's design, most other cars the knuckle is replaceable on it's own.
12000 mi
Rough downshifting when re-accelerating from low speeds. Parts replaced as per mfr bulletin on transmission. Remains to be seen if problem is corrected.
53000 mi
Noisy 1/2 shaft bearing. Replaced
73000 mi
US $250
Jerky transmission. Low on fluid (no leaks though) and SW updated.
PTU - transfer box 4wd system leaking thick black oil; dealer wanted to replace PTU. I repaired by flushing out ptu, solved the problem temporarily at least. Seems to be widespread issue on AWD flex.
91000 mi
PTU/front differential leaking thick black fluid from vent hole. Unit is un-serviceable, dealership recommends replacing PTU for $2000. I flushed and refilled with new fluid and problem is solved for the time being. Cost -$20 in fluid and 2 hours on my back under the car.
69920 mi
C $2000
PTU leaking. Clogged.
90520 mi
C $574
driver CV axel
24000 mi
Intermittent transmission slipping.Has happened several times since I've owned the (new) vehicle. Slips out of gear and then back in. Reminds me of the Windstar I had (eventually dropped 4 transmissions). so done with Ford
30000 mi
Transmission started doing slipping more frequently, then I started having odd electrical/transmission problems such as the rear lights not going on when going in reverse (same 1st sign as previous Ford). I decided to get rid of it while the going was goo
105400 mi
C $1000
New hose
106400 mi
C $2000
DVT problem - the usual Ford AWD problem.
3500 mi
2nd time in for slow electrical drain. Dealership reports that car has bad battery due to numerous power drains. Also concern with slight slip in transmission.
20300 mi
Tranmission slipping. Intermittent problem. I was informed that I have a computer with my trans that learns how I drive. I was told they updated the program that teaches the trans when to shift.
29000 mi
Car began running rough, making loud noise and was not drivaeble. Taken to dealer, where they replaced the PTO (power take off) box at no charge. Luckily it was covered under warranty. Other than this repair, it's been a great car!
Took in for recall of trans lines, replaced. One of the new trans lines broke at a seam leaving Flex not moving and spilling trans fluid.
14000 mi
Transmission appears to slip intermittently when turning..Dealer could not replicate
73000 mi
US $100
Wheel bearings (both up front) one was worn and damaged, the other was loose.
15000 mi
Tranny is always in the wrong gear. It seems as though it is always upshifting to save gas, at the expense of power. Though my gas mileage sucks! Tranny also gets confused when moving up and down the gears and hesitates w/ loss of power.
94900 mi
US $100
started slipping from startup when cold then slamming into gear. Dealer "broke" alignment tool during new sensor replacement resulting in 5 additional days out of service waiting for replacement tool from ford
Replace left front cv shaft due to torn boot and contamination
27000 mi
Trans sluggish/shifting problems, reflashed memory
74700 mi
US $130
PTU (Front transfer case) need replacement
6820 mi
The Flex had a hesitation and slam at about 60 km/h. This has been a very intermittent problem but previously it was minor. However, a severe slam happened. It's a known problem and Ford has a service advisory. The valve body was replaced.
32240 mi
Transfer case / PTU seal was leaking. Seals replaced under warranty. Noticable improvement in transmission smoothness after repair.
46500 mi
The power-take off unit was leaking. The unit was replaced under warranty. I didn't realize it but this this is the second failure of this unit. The previous failure was repaired under a broader dealer service trip.
53940 mi
Power take off unit seal was leaking. Noticed during service repaired under warranty
51860 mi
C $2863
Grinding noise - constant. Front PTU replaced.
89200 mi
US $410
Half shaft seal leak on the PTU for the Awd system. This leak was on the right side.
Abrupt engagement of gears. Could not be replicated and has not reocurred.
40000 mi
The local firestone shop recommended looking into having the transmission repaired. Can't remember the issue.
42780 mi
TSB re-flash for hard shifting
70000 mi
US $100
Rough shifting. Leaking near air conditioning evaporator. Repaired overnight.
68000 mi
Transmission started slipping at low RPMs. Dealer repaired under warranty. This should not be happening at 67k miles. Seriously disappointed with Ford. This will be my last Ford.
70300 mi
Transmission slipping again at 1250 RPM, light acceleration. Same problem as last report, even after repair. Dealer unable to duplicate problem on test drive. Problem is intermittant and less frequent as before, but still happening.
Gear makes big hit while shifting down or up at lower gears
13000 mi
Drive train made a horrible metallic snap noise upon first acceleration from park. Dealer found nothing wrong.
36580 mi
axle seal leak
3100 mi
Power Transfer Unit (PTU) for AWD system has a known seal leak. Transmission fluid leaks onto hot exhaust manifold and smelly smoke permeates cabin when vehicle comes to a stop. First attempt to repair leak was not successful, despite a TSB.
5580 mi
Second attempt to repair leaking seal in PTU. No problems after this fix...no gear oil leaking onto exhaust manifold ergo no nasty smell anymore!
32000 mi
CV boot problem. Right front axle removed and replaced.
78000 mi
US $1260
PTU replaced
145000 mi
US $600
updated software
43700 mi
Known TSB for transmission seal replaced under powertrain warranty
60140 mi
C $400
Replaced toque converter Wheel bearing replaced
57040 mi
Boot torn. Axle replace under warranty.
57000 mi
2 seals leaking affecting AWD. Caught early before a leakage on driveway.
39040 mi
PTU unit leaking oil on exhaust and smelling like burning gear oil. Replaced right axle and resealed unit. In extreme cold there would be a whining sound coming from the transmission area. Especially around 60 to 65km per hour. Turns out there was a TSB regarding the transmission cooler line rubbing against the frame transfering the noise.
