| 1 | 0 | 3 | 4 | 3 | 4 |
Ford Flex repairs by problem area
Engine (15%)
Transmission and Drivetrain (9%)
Brakes and Traction Control (9%)
Suspension and Steering (17%)
Electrical and Air Conditioning (24%)
Paint, Rust, Leaks, Rattles, and Trim (20%)
Other (5%)
Chart based on 1093 repairs.
Ford Flex engine repair cost distribution
$2500+ (6%)
$1000 - $2499 (12%)
$500 - $999 (9%)
$100 - $499 (27%)
< $100 (46%)
Chart based on 140 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2018 Ford Flex 4dr SUV
turbocharged 365hp 3.5L V6 6-speed shiftable automatic AWD
| 52000 mi US $798 |
Battery went bad, which led to the positive battery terminal completely disintegrating which required replacement of the whole cable. |
2015 Ford Flex 4dr SUV
287-horsepower 3.5L V6 6-speed shiftable automatic FWD
| 91000 mi US $200 |
Had a vaccum hose and control unit replaced |
2014 Ford Flex 4dr SUV
turbocharged 365hp 3.5L V6 6-speed shiftable automatic AWD
| 31000 mi | Even though mine was not part of the fuel pump recall that is what was repaired/replaced. |
2014 Ford Flex 4dr SUV
287-horsepower 3.5L V6 6-speed shiftable automatic FWD
| 56110 mi C $275 |
Fuel Pump Drive Module replaced |
| 107704 mi US $735 |
replaced left catalytic converter |
2014 Ford Flex 4dr SUV
287-horsepower 3.5L V6 6-speed shiftable automatic AWD
| 10320 mi | Faulty O2 sensor replaced under warranty |
| 12400 mi | replace faulty O2 sensor under warranty 2nd time in 3 months. This time sensor failed because fuel was too lean. |
2013 Ford Flex 4dr SUV
turbocharged 365hp 3.5L V6 6-speed shiftable automatic AWD
| 71000 mi US $1333 |
Failure of coil pack cylinder 1 |
| 75950 mi C $300 |
Fuel pump recalled, replaced by dealer. |
| 83000 mi US $300 |
Fuel pump modulator quit |
| 92000 mi US $400 |
Spark plug failure |
| 100000 mi US $5600 |
Water pump failure Timing chain |
| 11800 mi | Car stopped running. Was a bad fuel module. |
| 25000 mi US $297 |
Running rough and stalling at stops. Replaced Purge Control Solenoid |
| 35000 mi | Error code P0161 Oxygen Sensor Bank 2 Sensor 2 replaced under warranty |
| 67000 mi | Turbo replaced on Ecoboost motor. Failed oil seal. |
| 38600 mi | Fuel Pump failed, there was a recall on this part, replaced for free by Ford |
| 117000 mi US $50 |
Phasers, Chamshaft, and Timing belt replaced due to fault. Code showed 'Camshaft Misalignment' problem. Necessitated partial engine rebuild. Paid under warranty. |
| 66000 mi US $4500 |
Excessive coolant consumption due to leaking water pump. Water pump was replaced. |
| 104000 mi US $2000 |
The water pump was leaking coolant. The vehicle was towed to the repair shop and a new water pump was installed with new coolant. |
| 63000 mi | Oil pump replacement |
2013 Ford Flex 4dr SUV
287-horsepower 3.5L V6 6-speed shiftable automatic FWD
| 38100 mi | Recall on o ring within fuel line. Smell of gasoline was constant. And, Ford did not notify us of the recall! |
| 90000 mi US $75 |
The gas cap (which the Flex does not have) developed an emissions problem. The fix was a 75.00 charge to us. |
| 161000 mi US $10 |
Idiot light came on, code said that an exhaust emissions part needed to be replaced. Paid 10 dollars for the evaluation. The light intermittently comes on. Have not noticed any problems nor mpg reduction. |
2013 Ford Flex 4dr SUV
287-horsepower 3.5L V6 6-speed shiftable automatic AWD
| 27000 mi | Fuel leak |
| 22940 mi C $812 |
the canister on the vacuum system of the gas tank was damaged during the winter and gave a check engine light. |
| 40000 mi US $172 |
Evap sensor replaced. Check engine light and scanned for code. |
| 32000 mi US $557 |
Replace ignition lock and key mechanism - was getting stripped out and manifested as being hard to start - wouldn't always engage on the first try or two. |
| 54570 mi US $360 |
Check engine light led to fail EVAP control purge valve and needing replacement. |
| 71000 mi US $3200 |
Water pump broke, overheat. Replaced water pump, required removal of timing chain - water pump integrated into engine. |
2012 Ford Flex 4dr SUV
turbocharged 355hp 3.5L V6 6-speed shiftable automatic AWD
| 101000 mi US $3400 |
Water pump failed, but at 99,000 miles there were multiple parts about to fail as well. |
2012 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic FWD
| 6000 mi | Needed to have a tension belt replaced. Sqeaked alot |
2012 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic AWD
| 17000 mi | serpentine belt replaced due to premature wear. |
| 65000 mi US $10 |
Air filter |
2011 Ford Flex 4dr SUV
turbocharged 355hp 3.5L V6 6-speed shiftable automatic AWD
| 82000 mi US $45 |
0442 Code, small evap leak, was the valve on the engine. |
| 81000 mi US $10400 |
Connector rod disintegrated and blew through the block. Replaced with NEW long block and NEW turbos |
| 84300 mi US $36 |
Replaced the canister evap solenoid. Cleared the CEL |
| 62000 mi US $185 |
Service engine light came on twice in the last two weeks, once engine died . Dealer could not diagnose ? |
| 67000 mi | Water pump failed, lead to oil contamination and catastrophic engine failure |
| 67800 mi | Catastrophic engine failure,ESP Warrenty covered engine replacement. Complete engine assemblies "no longer available "? New long block and new turbos installed with old engine parts.Car does not run well.MPG is under 14.Taking back in ASAP |
| 83000 mi US $45 |
Replaced oxygen sensor ( bank2 sensor1 ) after CEL came on . |
| 10000 mi | Bogging at accelaration from stop. Also deceleration at highway speed. Dealer could not replicate, but input from FordFlex.net & other indicated could be TRS or throttle body. Because they could not duplicate/confirm, they repaired both |
| 15200 mi | no heat on driver's or passenger side! Forced cold air blowing even when heat turned 'off' --Parts backordered for 3 1/2 weeks!!! |
| 105000 mi US $350 |
Thermostat and coolant replacement |
| 1000 mi | Injector stuck open, replaced PCM. Dumped the vehicle immediately after repair. |
| 68000 mi US $300 |
The coil on my #2 cylinder went bad, caused the engine to misfire and my check engine light to come on. I was able to drive the car to the mechanic, they diagnosed the issue and replaced the coil. No further problems. |
| 137000 mi US $5000 |
Had to replace the timing chain. Seriously not thrilled. |
| 84000 mi US $800 |
tune up, for first time |
| 118000 mi US $300 |
Vacuum |
| 115000 mi US $1000 |
Replace Fuel injector. Replace high pressure fuel pump. |
2011 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic FWD
| 193000 mi US $100 |
loud exhaust. front muffler had crack, flange between flex tube and front muffler had bolt that rusted out and broke. Easy fix. $100 for a aftermarket replacement front muffler |
| 1000 mi | Transmission slipped. Updated PCM programming. |
| 100000 mi US $6000 |
Early analysis suggests water pump bearing failed, allowing total loss of coolant. This was followed subsequently by overheating and a cracked block. The estimate of $6,000 was for replacement with a used engine, New of course would've been more closer to 10k. We opted not to fix vehicle and sold it for salvage value to the mechanic. |
| 17800 mi | leaking oil gasket |
| 15000 mi US $650 |
Car stalled numerous times, found throttle body malfunctioning. |
| 74000 mi US $1800 |
Throttle body malfunctioning, replaced under TSB at owner cost. Engine PCM damaged by malfunctioning throttle body, replaced under emissions warranty. |
| 37500 mi US $600 |
Replaced Starter Motor. Starter continued to run long after engine had turned over for variable periods of time. |
| 11000 mi | Engine overheated due to design defect in Fan Cooling system as outlined in a TSB. Ford was out of parts for a week, so we had to drive a rental (at Ford's expense) while it was in the shop. |
| 131714 mi US $2600 |
Water pump leaked over Timing Belt. Replaced Pump, Timing Chain, guides and tensioner. |
2010 Ford Flex 4dr SUV
turbocharged 355hp 3.5L V6 6-speed shiftable automatic AWD
| 39060 mi | Defective turbo chargers |
| 41540 mi | after replacing turbochargers there was an airlock in the cooling system that wasn't noticed till the heating season. The car would blow cold air at an idle but heat normally when driving along. Cooling system had air lock in it causing the passenger compartment heater to blow cold air at a stop but blow warm air once moving again. |
| 62000 mi | oil leak |
| 43080 mi C $100 |
No heat at idle, attempted rad flush of both heater cores but no success. Removed and replaced both heater cores. 11 hours of labour- gave us a courtesy loaner call- first warranty item that needed work. |
| 89000 mi US $210 |
Loss of power and whistling noise. Dealer found both Turbos were bad and replaced them. This was covered under an extended warranty plan from Allstate. The total cost was 2400.00 and my cost was the deductible of 210.00 |
| 129500 mi US $870 |
#5 fuel injector stuck open, CEL and lots of white smoke out of the tailpipe, smelled strongly of gas. |
| 129900 mi | after replacing #5 fuel injector, could smell gas under the hood after driving the car, especially if driven spiritedly. Fuel rail replaced. #4 fuel injector stuck open, shortly after the #5 fuel injector failed stuck open. The stop was originally going to eat the cost o the fuel rail, ate the cost of the second injector instead. |
| 31000 mi | Problem with hesitation and loss of power, spark plugs replaced under a tab, can provide if helpful. Warranty repair, no charge. |
| 58000 mi US $175 |
Diagnosed problem with ignition coil on cylinder 3. Took it to dealer to see if under warranty. They diagnosed again, came to same conclusion. Wanted $700 for diag, repair, and plugs. Declined, paid for diag. Replaced ignition coil cylinder 3 as well as all spark plugs myself. |
| 66000 mi US $1200 |
Gas odor rear of car. Gasket around one of two fuel pumps leaking small but evident amount of fuel. Both pumps replaced as labor was dominant cost to repair and the same whether one or both were replaced. Pumps had to be replaced as gaskets etc are one unit! If I did not love the car I would be very upset! |
| 1100 mi | - Rough Idle; Solid CEL (Check Engine Light) came on. Originally thought it was bad gas. Took to dealer replaced O2 sensor under warranty. Repair time 2 hours. |
| 9000 mi | Was having issue with poor fuel economy. |
| 34000 mi US $30 |
Flex was idling rough. I replaced the spark plugs (newer recommended #) and all is fine. |
| 4200 mi US $23 |
Evidently a defective bolt holding the hose on to the turbo intercooler broke. This resulted in the other bolt holding the hose to also break and a loss of power. Intercooler was also replaced due to possible damage. |
| 65200 mi | O2 sensor failed and replaced |
| 80000 mi US $1580 |
O2 sensors and network. Brake discs and pads. |
| 112300 mi US $1400 |
Broken motor mount, reprogram computer |
| 24800 mi | front turbo had a very slow leak. TSB was executed to replace all washers for oil and coolant lines to and from the turbo |
| 90000 mi US $100 |
water pump started leaking out the seep hole and coolant was going down ~0.5" / day. After 2-3 days of this we took the Flex in and the water pump was identified as being bad and needing to be replaced |
| 9000 mi | Extremely hard shifts; sometimes total loss of power; warnings on dash Dealership called Detroit. Fixed something(?). Running well now. |
| 11200 mi | At least seven occurences of harsh shifts since last reported, the most recent being violent bucking. Dealer said cannot replicate. Performed three TSBs, but since then I've had four minor drop-to-neutral-slam-into-gear occurrences. |
| 17000 mi | High pressure fuel pump replaced. |
| 48000 mi | Replaced high pressure fuel pump. |
| 16120 mi | After driving the Flex for a short period of time, the engine overheated and leaked coolant everwhere. The diagnosis was that the fan was not being told to kick on. Part was B/O for 24 days (also no Flex to drive during that time) |
| 60200 mi US $385 |
Cooling system heater hose Passenger side hvac blender door Coolant hose |
| 78000 mi US $158 |
Vehicle was running rough. Dealer found bad fuel injector on cylinder 2. |
| 44000 mi | Engine misses at idle. |
| 68000 mi US $100 |
Code P0442 - evap leak. Corrosion on the top surface of the fuel tank causing a vapor recovery system fault code. Tank needs to be replaced--back ordered. |
2010 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic FWD
| 91000 mi US $100 |
Evaporate system leaking and they are still having a hard time diagnosing it. Also had work done to the front suspension which is completed. |
| 107000 mi US $1200 |
The fuel system was evaluated for a fuel leak (not repaired). Vehicle has minor fuel leak on 'top' of tank and minor oil leak on front of engine (not repaired). |
| 24000 mi | Slow Oil drip - Replaced seal that required removal of transmission replace seal |
| 101680 mi C $1300 |
Failed waterpump resulted in coolant leaking into the crankcase. This resulted in reduced performance and loss of coolant fluid. Thankfully no damage to the engine. |
| 77000 mi | Error code related to throttle sensor. Researched, pulled throttle body and cleaned. Reset code and problem has not returned. |
| 165000 mi | Engine broke - coolant and oil mixture in oil pan. Required engine replacement. |
| 141000 mi US $189 |
engine hesitation, replaced one coil pack |
| 145600 mi US $250 |
Engine hesitation returned after less than a week. Replaced all coil packs. |
| 13000 mi | Wrench lite came on, ran VCR which stated take to dealer ASAP reduced power etc. Lite not on at dealer they said no event stored in computor. (BS) car got sunshine treatment. |
| 15000 mi | Replaced electronic throttle body |
| 89000 mi US $2500 |
Engine light, indicated cam phasers, $1,800 estimate. Mechanic suggested spending a little more, $2,500, to get an entire newer engine. |
| 58000 mi US $120 |
Exhaust gasket rusted and broke |
| 71000 mi | Oil in radiator fluid, and smell of radiator fluid in exhaust. |
2010 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic AWD
| 81980 mi C $200 |
O2 sensor left bank caused check engine light to come on. Reset check engine light. No issues. No replacement of sensor required. May have been due to fuel mix on heavy acceleration. |
| 42160 mi | The O2 sensor needed replacement after giving a warning light signal. Part had to be ordered in and repair time was over 2 days because of wait. Repair was covered by emissions warranty. |
| 8200 mi | Was stalling in park. Brought in and repaired per TSB 10-21-6: throttle body was replaced. Problem solved. |
| 41700 mi | Leaking green fluid from mid of vehicle. They were unable to reproduce the problem, seems to be intermittent. |
2009 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic FWD
| 68000 mi US $107 |
Vehicle was overheating. Electrical cooling fan was malfunctioning and was replaced under extended vehicle warranty. |
| 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. |
| 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 |
| 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. |
| 101000 mi US $389 |
Fuel sensor |
| 38300 mi US $200 |
Radiator cooling fans. |
| 22300 mi | Leaking Freeze Plugs and Water Pump replaced |
| 86700 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. |
| 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 |
| 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. |
| 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. |
| 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 |
| 14260 mi C $250 |
Tranny reflash |
| 12000 mi | ECM failed car would not run |
| 148000 mi US $550 |
Valve cover gaskets needed replacement for leaking oil |
| 125000 mi US $500 |
Water pump failed, hydrolocking the cylinders and cracking the block. Car scrapped. |
| 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. |
| 148300 mi US $496 |
Oxygen sensor failure resulting in CEL |
| 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. |
| 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. |
| 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. |
| 77000 mi US $1156 |
cooling fan assembly was replaced. |
2009 Ford Flex 4dr SUV
262-horsepower 3.5L V6 6-speed automatic AWD
| 4000 mi | Strange shifting at idle and low speeds. |
| 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 |
| 93000 mi C $500 |
Replaced noisy fan |
| 99000 mi US $300 |
Fan controller replaced |
| 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 |
| 43000 mi US $120 |
O2 sensor replaced and new tires |
| 54560 mi C $1400 |
Both O2 sensors malfunctioned |
| 68820 mi C $1200 |
Engine fan failing - replace fan unit |
| 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" |
| 37200 mi | squeeling from belt area, replaced idler pulley, tensioner pulley and belt |
| 45280 mi | Oil seal replacement to stop leak. |
| 40000 mi US $275 |
Check Engine light for ODC P0605 ECM ROM |
| 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 |
| 8000 mi | replaced the defective throttle body |
| 18000 mi | replaced throttle body, this is the 2nd throttle body replacement |
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