The MPV that drives like a car
Ford's sporty seven-seater MPV, sold from 2006 to 2024 with no direct replacement. Won Car of the Year in 2007 and remains the driver's choice among MPVs. Mk1 models (2006-2014) start from around £3,000; Mk2 examples (2015-2024) from £10,000-£25,000. The 2.0 TDCi diesel in Titanium trim dominates the used market. Strong towing capacity (up to 2,000kg) makes it popular with caravan owners.
We track 9 known issues across the Ford S-MAX range, with 5 classified as significant. Knowing which variants and configurations to approach with caution can save you from expensive surprises after purchase.
Found a Ford S-MAX? Enter the reg to see which of our 9 known issues apply to that exact car, plus full MOT history and mileage checks.
Mk1 (2006–2014) — Petrol options included the 1.6 Duratec, 2.0 Duratec, 2.3 Petrol, 2.5 Duratec, with 1.8 TDCi, 2.0 TDCi, 2.2 TDCi on the diesel side. We track 9 known issues on this generation, with 5 classified as significant. The most significant concern is PowerShift transmission failure.
Mk2 (2015–2021) — Petrol options included the 1.5 EcoBoost, with 1.6 TDCi, 2.0 TDCi on the diesel side. We track 9 known issues on this generation, with 5 classified as significant. The most significant concern is PowerShift transmission failure.
Ford's six-speed PowerShift dual-clutch transmission uses a dry clutch design that is prone to premature wear and juddering during low-speed manoeuvres. The system relies on precise electronic control of clutch engagement, and software calibration issues combined with clutch wear create shuddering, gear selection delays, and complete transmission failure. This is Ford's most documented transmission problem across multiple model ranges. Later software updates improved operation but did not eliminate the fundamental clutch wear issue.
Complete transmission failure requires replacement of the entire PowerShift unit. Ford stopped manufacturing replacement units for older S-Max models, making repairs expensive and potentially impossible. Repair costs typically exceed the vehicle's market value on higher mileage examples. The car remains driveable with minor juddering but should not be used for extended periods once symptoms develop.
Test the automatic gearbox extensively in slow traffic, car parks and on hill starts. Feel for any juddering, hesitation or clunking during gear changes. Try repeated low-speed manoeuvres as this is where problems are most apparent.
The diesel particulate filter (DPF) on Ford TDCi engines becomes blocked with soot during short-journey driving patterns common to MPV usage. The system requires regular high-temperature regeneration cycles that cannot complete during urban driving. Blocked DPF triggers warning lights, reduces power significantly, and can cause complete engine shutdown in limp mode. Replacement DPF units are expensive and aftermarket removal is illegal for MOT testing since 2014.
Complete DPF failure requires replacement at £1,000-£1,500 fitted cost. Continued driving with a blocked DPF can damage the turbocharger and exhaust system. The car will enter limp mode limiting speed to 30mph and making it undriveable for normal use. DPF removal is illegal and will result in MOT failure.
Ask about the car's typical usage — short urban journeys prevent DPF regeneration. Check for DPF warning lights and ask about any previous regeneration issues. A forced regeneration at a garage costs far less than a DPF replacement.
The dual mass flywheel (DMF) on diesel S-Max variants uses internal springs to smooth engine vibrations before they reach the clutch and gearbox. These springs weaken over time and the DMF develops internal play, creating rattling noises during idle and gear changes. Ford's diesel engines produce significant torque that accelerates DMF wear compared to petrol variants. Failure typically coincides with clutch replacement, adding significantly to repair costs.
DMF replacement is labour-intensive as it requires complete gearbox removal. Total costs including clutch replacement typically reach £800-£1,000 at independent garages. The car remains driveable with DMF noise but continued use will damage the new clutch if replaced without addressing the DMF. Failure to replace both together significantly shortens clutch life.
Check each gear engages smoothly without crunching. Feel the clutch bite point — very high or very low can indicate wear. Listen for bearing noise when the clutch is depressed.
MOT data shows S-Max models fail at 497.6x the national fleet average for spring fractures, with the highest failure rate on 2.0L diesel variants in the 0-20,000 mile range suggesting premature failure on newer examples. The rear coil springs are under high load due to the vehicle's weight and seven-seat configuration, leading to stress fractures near the spring ends. Fractured springs affect handling and can damage tyres through uneven loading.
Fractured rear springs create dangerous handling characteristics and uneven tyre wear. The broken spring end can puncture the tyre or damage other suspension components. This is an MOT failure item and the vehicle should not be driven with known spring damage. Replacement typically costs £150-£300 per side including labour.
Listen for knocking, clunking or rattling over bumps during the test drive. Inspect the underside for corroded or cracked suspension components. Check the MOT history for suspension-related advisories, which often predict future failures.
MOT data shows S-Max diesel variants fail at 497.6x the national fleet average for excessive smoke opacity, indicating widespread issues with the diesel exhaust system. This typically relates to DPF problems, failed EGR valves, or worn injectors that cause incomplete combustion. The issue is most severe on 2.0L diesel variants and affects both generations, suggesting a systemic problem with Ford's TDCi emission control systems.
Excessive smoke emission will result in MOT failure and the vehicle cannot be legally driven on public roads. The underlying causes typically require expensive repairs including DPF replacement, EGR valve cleaning, or injector replacement. Costs can reach £1,000-£2,000 depending on the specific fault. Temporary emission additive treatments may mask the problem but do not resolve the underlying mechanical issue.
Ask about the car's typical usage — short urban journeys prevent DPF regeneration. Check for DPF warning lights and ask about any previous regeneration issues. A forced regeneration at a garage costs far less than a DPF replacement.
For the full breakdown of all 9 tracked issues with repair costs, see the Ford S-MAX common problems page.
Based on 433k real DVSA MOT tests, the Ford S-MAX fails more often than average on several items. The biggest outlier is light unit fault at 39x the fleet average, followed by emissions failure (36x).
When viewing a specific car, check its MOT history for recurring advisories in these categories. See the full Ford S-MAX MOT failure breakdown for data at every mileage point.
Routine servicing (oil and filter change every 13k miles) typically costs £80–£120 at an independent garage.
See the full Ford S-MAX service schedule for every interval and cost breakdown.
The Ford S-MAX is a solid choice on the used market, though not without its quirks. The issues we track are well-understood and largely avoidable if you know what to look for. A thorough inspection and complete service history go a long way. 2015-2019 Mk2 in Titanium trim with the 148bhp 2.0 TDCi and manual gearbox is the safest bet. The 2019 facelift brought further refinements. For Mk1, post-2010 facelift models with the revised 2.0 TDCi are more reliable — but avoid the Powershift auto and choose the manual. Mk1 models before the May 2007 update lack ESC as standard. If budget-focused, a 2012-2014 Mk1 Titanium with full service history offers enormous value.
Before committing, check the car's full MOT history, verify the service record is complete, and if possible arrange a specialist inspection. Enter any registration into our free report to see the complete picture.
Get Car Wise maintains a database of known mechanical issues for every popular car on UK roads, tracking the faults that owners, specialists and DVSA data reveal.
When you run a report on a specific Ford S-MAX, we cross-reference the exact variant, engine and age against our database of 9 known issues. Combined with full MOT history analysis, mileage verification and DVLA data, you get a complete picture before viewing.
Enter the registration for MOT history, mileage verification, known faults for that exact variant, and a Get Car Wise Score.
This guide was compiled from independent expert reviews, DVSA MOT data, specialist workshops and our own database of 9 known Ford S-MAX issues. We are not affiliated with any source listed.