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.
Transfer case / PTU seal was leaking. Seals replaced under warranty. Noticable improvement in transmission smoothness after repair.
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.
Drive train made a horrible metallic snap noise upon first acceleration from park. Dealer found nothing wrong.
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.
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!
466 TrueDelta members own (or used to own) a 2000 or newer Ford Flex. 58 of these members
(12.4%) have reported transmission repairs for their car.
A total of 68 transmission repairs to Ford Flexes--an average of 0.1 per
vehicle--have been reported.