| 1 | 0 | 3 | 4 | 3 | 4 |
2009 Ford Flex repairs by problem area
Engine (14%)
Transmission and Drivetrain (7%)
Brakes and Traction Control (9%)
Suspension and Steering (13%)
Electrical and Air Conditioning (25%)
Paint, Rust, Leaks, Rattles, and Trim (26%)
Other (6%)
Chart based on 382 repairs.
2009 Ford Flex engine repair cost distribution
$2500+ (0%)
$1000 - $2499 (14%)
$500 - $999 (8%)
$100 - $499 (24%)
< $100 (53%)
Chart based on 49 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2009 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic FWD
| 38300 mi US $200 |
Radiator cooling fans. |
| 14000 mi | Two problems. 1st was a sound at cold start which sounded like the starter was engaged too long. 2nd was an engine light. Diagnosis - Cam Phasers. Job took 2 days b/c dealer didn't start work on 1st day. Cam Phaser repair solved 1st problem |
| 47500 mi US $10 |
Wire broke on oxygen sensor. Sensor replaced under my factory extended warranty. No charge |
| 105000 mi | HEGO sensor-Upper failed. Damaged earlier while working on front suspension. |
| 74000 mi US $1400 |
Phaser had to be replaced. This required removing the intake and other parts on top of the engine. Replaced several other parts while in there. |
| 148300 mi US $496 |
Oxygen sensor failure resulting in CEL |
| 101000 mi US $389 |
Fuel sensor |
| 65300 mi US $189 |
Fuel Pump seal o-ring at tank improperly installed allowing tank to leak on fill up. Took car to dealer to have it looked at and they missed it. Took it to local firestone and they caught it. |
| 67200 mi | oxygen sensor failure |
| 77000 mi US $1156 |
cooling fan assembly was replaced. |
| 32000 mi | Check engine light came on - car in shop for 2 days, sensors were replaced Check engine light reappeared day after replacing 2 separate sensors. Replaced computer. |
| 90000 mi US $600 |
Had to replace engine fan assembly because one of the fans in assembly was not working to cool a/c condenser |
| 5000 mi | Hard shift/ transmission bucking TSB 09-23-6 |
| 10300 mi | Intermittent transmission bang. No condition found, no faults noted. |
| 16000 mi | pcm reflash |
| 22500 mi | Gasket on fuel door |
| 25900 mi | after driving 2/3 miles car was acting as if it would stall. throwing codes p0016/p0012 performed tsb 11-6-1 Replaced right and left side cam phasers. |
| 148000 mi US $550 |
Valve cover gaskets needed replacement for leaking oil |
| 22300 mi | Leaking Freeze Plugs and Water Pump replaced |
| 7000 mi | Also fuel system fill does not require a fuel cap and a check engine light code is occuring due to a malfunction. Problem repaired. Problem has reoccured in less than a week. |
| 112000 mi US $1100 |
Cooling fans failed cuasing the car to over heat. The car was towed to the dealer. |
| 12000 mi | ECM failed car would not run |
| 27000 mi | Car had a rough idle with RPM's surging up and down. Throttle body replaced under warranty. |
| 73000 mi | Engine was shuddering at low RPMs at 50 mph. Dealer found ignition coil and wires on cylinder 3 bad. Replaced wires, coil and spark plug. |
| 14260 mi C $250 |
Tranny reflash |
| 60760 mi | serpentine drive belt squeaking, dealer replaced n/c for Ford Maintenance Plan. |
| 71660 mi C $113 |
Coolant smell from engine area. Ford Dealer inspected and found no problems, invoice for 1 hour of inspection time. |
| 96100 mi C $232 |
CEL came on, scanned codes and confirmed O2 sensor on bank 1, sensor 1 was failing. Replaced both upstream O2 Sensors myself. |
| 25000 mi | Engine light came on and stayed on. Required a new cooling fan and one oxygen sensor for catalytic converter. Work covered under extended warranty purchased at end of Jan 2012. Estimated value of repairs $1,000. Unusual for less than 25k mi |
| 28000 mi | This repair was after car returned from 6 mo checkup. After driving 1 mile, care nearly failed. Managed to limp back to dealer where I learned that computer and 2 coils had burned out. Am upset that this was not picked up at time of 6 mo ch. |
| 68000 mi US $107 |
Vehicle was overheating. Electrical cooling fan was malfunctioning and was replaced under extended vehicle warranty. |
| 125000 mi US $500 |
Water pump failed, hydrolocking the cylinders and cracking the block. Car scrapped. |
| 75000 mi US $1250 |
Cracked COP, engine computer damaged. Spark plugs, computer, and 3 COPs replaced. |
| 92000 mi US $1890 |
Trouble light reported low efficiency of catalytic converter. Converter bed was damaged so it and oxygen sensor replaced. While idling, suddenly dumped coolant and indicated high temperature. Radiator support broken, and fan motor failed. Motor part of larger assembly which was replaced. |
2009 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic AWD
| 2500 mi | Car ran out of gas two other times, brought into dealership given run around took car on cross country trip had to refill every 110 miles Brought car in for the fourth time to dealership it took two weeks but found pump connecting two tanks malfunction |
| 12000 mi | Wife driving at high speed car shut down, dealership could not find or fix problem. Car in shop 5 weeks. Ford decided to give us a new car |
| 130200 mi C $435 |
Fuel pump module failed right at the mechanic workshop while testing the car after replacement of power steering pressure hose it originally came in for. Module was replaced free of charge |
| 99000 mi US $300 |
Fan controller replaced |
| 93000 mi C $500 |
Replaced noisy fan |
| 37200 mi | squeeling from belt area, replaced idler pulley, tensioner pulley and belt |
| 43000 mi US $120 |
O2 sensor replaced and new tires |
| 8000 mi | replaced the defective throttle body |
| 18000 mi | replaced throttle body, this is the 2nd throttle body replacement |
| 4000 mi | Strange shifting at idle and low speeds. |
| 23560 mi | Oil seal replacement to stop leak. |
| 40000 mi US $275 |
Check Engine light for ODC P0605 ECM ROM |
| 27000 mi | Problem with adequate heat. Last year, first noticed in winter, heater core replaced per Ford TSB. Did not solve problem. Took vehicle back last month...recent Ford TSB recommended flush of coolant system and update computer...helped a bit |
| 29000 mi | Still having same problem with inadequate heat. In contact with Ford..engineering rec a specific remedy. Dealership attempted (with their most experienced mechanic)....did not solve problem. Then was told field engineer from Ford would exam |
| 31000 mi | Repair number 4 attempted at dealership, this time with supervision of Ford field engineer...problem ultimately not fixed. Working with Ford (they have not been the best to deal with on this) but may invoke "Lemon Law" |
| 31500 mi | Experienced rough up shift or down shift from the automatic transmission seemed as if it would stay in the gear too long and then drop into gear with a harsh revving noise and a pull feeling from torque. occured when doing rolling stops |
| 54560 mi C $1400 |
Both O2 sensors malfunctioned |
| 68820 mi C $1200 |
Engine fan failing - replace fan unit |
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