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Expensive Ford Flex repairs by problem area

Engine (27%)

Transmission and Drivetrain (12%)

Brakes and Traction Control (10%)

Suspension and Steering (36%)

Electrical and Air Conditioning (13%)

Paint, Rust, Leaks, Rattles, and Trim (1%)

Other (0%)

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Chart based on 105 repairs.

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Ford Flex repair cost distribution

$2500+ (21%)

$1000 - $2499 (79%)

$500 - $999 (0%)

$100 - $499 (0%)

< $100 (0%)

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Chart based on 72 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

93000 mi

US $1200

right front boot wheel bearing

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52620 mi

US $2050

Replace both front struts. Replace both rear shocks.

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56110 mi C $275	Fuel Pump Drive Module replaced
67580 mi C $1130	2 wheel bearing replaced
79670 mi C $250	Replaced leaking seal

107704 mi US $735	replaced left catalytic converter
132000 mi US $502	replaced right rear wheel bearings
320758 mi US $1062	replaced alternator and washer fluid pump
432000 mi US $806	Replaced fan blower motor

133000 mi US $537	Replace both front upper control arms and bushings
144000 mi US $1300	Replace rear shocks, replace front struts

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97400 mi

US $1200

Right rear wheel bearing making noise, issue confirmed and wheel bearing replaced, While troubleshooting wheel bearing, it was noticed the rear brakes were completely worn down and the front brakes did not have much life left. Replaced pads and rotors front and rear.

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52080 mi

C $1100

Rear brakes making noise, replaced pads and rotor. Also found leaking rear shock, replaced both rear shocks.

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.
119000 mi US $170	Rear backup camera was failing intermittently. I replaced the rear camera.
119000 mi US $133	A message kept displaying in the instrument cluster that the passenger door was ajar even though the door was fully closed. I replaced the faulty door latch.

48000 mi US $300	Door switch on rear passenger door failed
71000 mi US $1333	Front left wheel bearing failed Failure of coil pack cylinder 1 Failure of door switch right rear passenger door.
78000 mi US $481	Rear hatch actuator failed. Replace actuator

56500 mi US $1000	Axle bearings Rear limited chrome flex panel began to bubble
83000 mi US $300	Fuel pump modulator quit
92000 mi US $400	Spark plug failure
100000 mi US $5600	Water pump failure Timing chain

54800 mi

US $2000

Adaptive Cruise Control Module failed

32000 mi US $150	Car would not start. Battery died. Replaced battery.
69000 mi US $3198	Collision Warning/ABS/Traction Control warning lights come on intermittently. Replaced ABS/HCU module, and brake pedal switch. Clunking in front end. Replaced front sway bar end links. Leaking rear shock absorbers. Replaced.

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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.
68954 mi US $2681	Rear camera and navigation not working/working intermittently. Diagnosis plus replacement of rear camera and APIM module.
71000 mi US $3200	Water pump broke, overheat. Replaced water pump, required removal of timing chain - water pump integrated into engine.

118000 mi

US $2000

Tie rod and wheel bearing replacement. Spark plug replacement.

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90000 mi

US $3200

transfer case replacement AWD

101000 mi

US $3400

Water pump failed, but at 99,000 miles there were multiple parts about to fail as well.

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78740 mi

C $2000

Power steering pump and steering rack replacement

110000 mi

US $1250

Front and rear suspension bushing replacement

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92000 mi US $450	Wheel making significant noise
96000 mi US $500	All 4 wheel bearings have gone in the past 3,000 miles.
98000 mi US $440	Needed new front axle after boot on u joint broke. CHeaper to get new axle than new u joint.
104000 mi US $1000	Needed 2 new real shocks, a new front strut and new real brake pads and rotors
118000 mi US $300	Vacuum

41800 mi US $1000	Replaced hubs + bearings(4),replaced brake rotors + pads.Also installed new coil springs, struts/shocks
62000 mi US $185	Service engine light came on twice in the last two weeks, once engine died . Dealer could not diagnose ?
89000 mi US $350	Replaced pass side half shaft. Ford dealer failed to support half shaft axles when sub frame was removed to replace long block and turbos. Also new tie rod ends, rotors, brakes, struts.

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.
95800 mi US $200	The my driver and passenger side climate control started doing the opposite of each other. If on A/C driver's side would blow cold and passenger side would blow hot. Mechanic replaced the actuator and fixed the issue.
137000 mi US $5000	Had to replace the timing chain. Seriously not thrilled.

72300 mi US $200	Replaced leaking rear differential vent per TSB Dual zone climate inop
94000 mi US $175	Dual zone climate non operative
103900 mi US $9335	Replaced both rear knuckles because of worn ball joints. Also decided to replace wheel bearings and rear shocks while I was at it.
131700 mi US $350	Stuck rear caliper. Replaced both calipers, lines, pads, and rotors for both sides.

115000 mi

US $1000

Replace Fuel injector. Replace high pressure fuel pump.

62000 mi US $1500	Pto was leaking. Was just over the factory 60k warranty and it needed to be replaced.
81000 mi US $10400	Connector rod disintegrated and blew through the block. Replaced with NEW long block and NEW turbos
90000 mi US $1100	Had 1 caliper hanging up and another getting close. Decided to do the HD brake upgrade. New calipers, brackets, rotors, pads and SS brake lines at all 4 corners. Brake fluid flush as well.
98000 mi US $400	Replaced front struts, rear shocks and sway bar end links. Had rattle over bumps and leaking shocksstruts

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26660 mi C $310	Back brakes seized, not sliding on slider bolts. Calipers fine. front drivers side bearing squealing gas cover not seating correctly, scraping paint
39680 mi C $200	sunroof drain plugged (even though never under a tree or anything), not covered under warranty as had hit 60k. Had to rerun the drain hoses.
56600 mi C $1100	rear bearing died, ended up wearing the tire so badly the set required replacement. rear caliper refused to disengage, required replacement (along with rotors/pads, price not included)
76880 mi C $1300	steering rack failed - leaking steering fluid. Entire rack replaced
91140 mi C $500	bottom inch of back hatch rusted away. other rust spots eating away at car significantly, paint bubbling in spots. Had several areas redone, new metal put in.
96720 mi C $1000	brakes, transmission fluid, filters, oil change.
99200 mi C $100	steering rack failed - second time on this vehicle, new parts used on first repair as well! replaced rear brakes and rotors
101060 mi C $500	high pressure hose to the steering rack rusted out. repairs a month ago apparently didnt notice the hose needed replacing - argued and got the cost of part $150 covered, but labour for 3+ hours and fluids still needed
110360 mi C $2500	fourth repair/replace to steering system in 18 months. This time the knuckle that connects the rack to the steering column had siezed, and in these vehicles its all one big piece.
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.
114700 mi C $400	abs sensor dead on rear right wheel. No traction control or abs available caliper siezed, was removed and rehabilitated, and put back in
151900 mi C $750	[alternator] was overcharging the battery, causing everything electrical to shutdown/malfunction bushing, control arm was shot. car was sliding in the snow
155000 mi C $200	super loud bearings at back ac blowing hot air, not cooling at all

55000 mi US $250	Had to replace starter. It kept cranking after the car started. I decided to also replace the battery since it is 6 years old...it checked out okay but decided to replace due to age
62000 mi US $1000	Had to replace front passenger control arm $800 but it wasn't Ford's fault. My daughter who was learning how to drive hit a curb. I also decided to change the transmission fluid and radiator fluid while at the dealership

51000 mi US $1400	Condenser needed replacing. The repair apparently needed them to remove the front bumper (!)
131714 mi US $2600	Water pump leaked over Timing Belt. Replaced Pump, Timing Chain, guides and tensioner.

73000 mi US $100	After a recharge, system blew no cold air. Dealer replaced compressor and 2 other elements of the AC system. Covered by $100 deductible with ESP.
84000 mi US $1079	Replace rear pads and rotors. Resurface, sand pads, lubricated and adjust all brake components and reassemble front brakes. Replace rear shocks Left turn signal replaced. Probably didn't take more than ten minutes.

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.

187000 mi US $1500	Front struts and rear shocks replaced
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

58000 mi US $250	Blower motor control unit required replacement. Common problem, lots of examples on Internet. Parts and Labor $250.
40000 mi US $600	Replaced Starter Motor. Starter continued to run long after engine had turned over for variable periods of time.
62000 mi US $1700	Condenser cracked, A/C blowing only warm air Replaced core.

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.

81000 mi

US $1000

Leaking A/C condenser was replaced with a vac and re-charge of refrigerant

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69920 mi C $600	PTU leaking. Clogged. blew a power steering hose
83700 mi C $120	Key jammed in ignition. Switch in gear shift faulty
90520 mi C $1024	rear rotors and brake pads driver CV axel

38600 mi US $750	Replaced front driver side wheel bearing. Rumbling noise
63000 mi US $1500	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.

105400 mi C $1000	New hose
106400 mi C $2000	DVT problem - the usual Ford AWD problem.
124000 mi C $1600	back rotors, all pads

75640 mi

C $1000

Seal leaking in Rack and Pinion. Had to replace complete unit.

100000 mi US $500	Rear brake pads and rotors replace.
101000 mi US $1200	Passenger side sway bar needed replacement. Both front replaced

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30480 mi C $302	Rear driver side factory DVD headrest monitor failed. Was replaced under pro-rated warranty coverage and costs shared with dealer and Ford.
60760 mi C $1500	Front strut upper mounts and front struts replaced, mostly due to mileage. Rear rotors and pads replaced.

75640 mi C $300	Noisy wheel. Bearing replaced. Did snow tires at same time
86460 mi C $300	Replace actuator motor for heater doors.
111600 mi C $2300	Replaced most of front end. Just well worn.

46000 mi US $250	Factory passenger side headrest DVD player stopped working. Replaced with takeout unit from other flex.
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.
56100 mi US $2100	Power take off unit failed. Expensive hard part failed much too early in my opinion.

55000 mi US $700	Replaced rotors and pads. Suspension alignment rods as well. Cabin air filter changed
80000 mi US $1580	O2 sensors and network. Brake discs and pads.
112300 mi US $1400	Broken motor mount, reprogram computer

93500 mi US $2200	Needed new transfer case/internals. $1,700.00 Needed rear control arms. $400.00 Above repairs required a 4 wheel alignment.$80.00
113000 mi US $1500	Replaced rear rotors, calipers and pads. Also switched back to stock struts/shocks from Megan coilovers.

22000 mi US $160	"protective" panel under engine falling off and needed to be replaced
27200 mi US $100	Replaced all rear brake components
49000 mi US $800	Replaced all rear braking components. Both pads rotors & calipers. Second time!!! The right wheel components were rusted together the left components were headed in same direction.
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!

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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.

48000 mi US $100	Left rear brake was heating up. They performed a TSB fix which included hardware but not the brake material. When I went in to pick it up they told me it included the brake pads too.
65000 mi US $100	Cluster light came on for airbag. Two loose wire connections found on passenger side airbags. Cleaned connections and plugged in at a cost of $100 deductable from extended warranty.
73000 mi US $100	Wheel bearings (both up front) one was worn and damaged, the other was loose.
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	Tie rod was loose (replaced) and alignment done. Oil change also done on this trip. 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).

159000 mi

US $1000

Replaced condensor Replaced bushing for control arm

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.
130200 mi C $500	Serious front-end noise. Inspected by my shop and repaired the faulty part.
139500 mi C $300	The damper between the front split heat/cool control was not functional. Service was required and a component was replaced. An actuator was replaced.

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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.
79580 mi C $120	Battery died
109600 mi C $1200	Front left and right bearings replaced

51860 mi

C $2863

Grinding noise - constant. Front PTU replaced. Rear toe links found loose when mounting new tires. Replaced.

37200 mi C $1100	Tie rods and stabilizer bars replaced
53940 mi C $3000	Knocking noise from front of car; steering wheel vibration; loose steering and suspension. Had to replace control arm, bushings, bracket.
60140 mi C $4000	Major repair on steering and front suspension.

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64300 mi

US $1800

no front heat

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80000 mi US $260	AC leak, and regulator switch
86000 mi US $198	Loose left inner tie rod replaced. Four wheel alignment an additional $110
94700 mi US $350	left front wheel hub replaced. car had been making a grinding noise
101000 mi US $389	Fuel sensor
107500 mi US $1706	Had cold air blowing out of passenger side, warm air on driver's side. Sometimes warm air from both sides.
122600 mi US $2410	front end wanders, steering wheel off center, steering column squeaks when turning. They replaced steering gear, including spindle rod, and intermediate steering shaft. replaced both outer tie rods, and right rear toe adjustment link. Four wheel alignment.
127000 mi US $2000	Power steering pump broke, spilling fluid everywhere, rendering power steering inoperable. Was able to drive car home, and then to the dealer.

12000 mi US $500	Repaired right front door lock by reinstalling door trim correctly.
112000 mi US $1100	Cooling fans failed cuasing the car to over heat. The car was towed to the dealer.

42000 mi US $215	sunroof seal was leaking and water was running down driver side A pillar onto seat and floor board Took to dealer and had repaired they also had to replace the Tweeter for the radio that was in the A pillar, it got wet. water leaking in to car at driver side A-pillar [ again ] causing headliner to get wet at top corner of driver side A-pillar and driver side carpet to be saturated with rain water. called dealer. they have to order parts.
43300 mi US $100	water leaking into interior at driver side A pillar [top]. Dealer said it was coming in from around windshield rubber seal[top driver corner]. pulled windshield out , replaced rubber seal. Drove to NV from MI. in much rain and snow, no leak.
81000 mi US $1347	4 new tires installed (Michelin). Rear tie rod ends worn and replaced. Told by dealer rep if not replaced (tie rod ends)rear tires could not be aligned properly.

77000 mi

US $1156

cooling fan assembly was replaced.

92000 mi

US $1300

Rack and pinion

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.

39000 mi US $200	Heard knocking on passenger side front when changing temperature in car. Air mixing door was malfunctioning.
46000 mi US $100	Automatic Rear Liftgate would not stay open, but instead chime rapidly and close again. Diagnosed as liftgate struts were not supporting enough, so struts were replaced.
70000 mi US $100	Rough shifting. Leaking near air conditioning evaporator. Repaired overnight.
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.

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54560 mi C $1400	Both O2 sensors malfunctioned
55180 mi C $1130	Replaced cracked A/C condenser
60140 mi C $400	Replaced toque converter Wheel bearing replaced
68820 mi C $1200	Engine fan failing - replace fan unit
C $250	Rear door actuator door motor replaced
73660 mi C $250	Calliper frozen

78000 mi US $1260	PTU replaced
145000 mi US $600	updated software
168000 mi US $125	Replace actuator

47120 mi C $1800	Rear door power lift repaired. Still not working. Changed locking mechanism and controller. They want to change lift motor now.
53320 mi C $800	Rear tie-rod replaced, both sides Rear sway bar linkage broke

47120 mi C $1400	Brakes seized on calipers, totally destroyed rotors and pads
48360 mi C $400	Loud noise vibration type sound worse when turning wheels left to right
54240 mi C $230	Lower door gasket torn away from lower door trim due winter freezing ice build up
60140 mi C $250	Noise or thunk would occur after rolling over a bump at slow speeds or turning. Dealer assessed the issue and ordered the part to make repair. Lower driver side sway bar end links and bushing.

97960 mi

C $1250

AC pressure valve and rad fan assembly

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Expensive Ford Flex repairs by problem area

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