Ford S Max MOT Failures
An analysis of 415,154 real DVSA MOT tests on the Ford S Max — what fails, how often, and how that compares to every other car on UK roads. Generations covered: Mk1 (2006–2014), Mk2 (2015–2021).
Where the Ford S Max fails its MOT
The single biggest MOT failure point on the Ford S Max is emissions failure — this model is 36 times more likely to fail on this item than the average car on UK roads. That makes it a significant weak point for anyone buying or owning this model. Across 415,154 MOT tests, 0.65% of all Ford S Max tests recorded this as a failure.
Exhaust and emissions failures often point to catalytic converter degradation, lambda sensor faults, or — in diesel models — DPF problems. These can be expensive to fix and will cause an immediate MOT failure.
Other notable weak points include light unit fault (39x the fleet average), headlight fault (23x the fleet average), coil springs broken (35x the fleet average), and seat mounting fault (34x the fleet average). These ratios compare the Ford S Max's failure rate on each item against the national average for all cars tested — a ratio of 10x means this model fails ten times more often than a typical car.
The failures span 6 categories: Exhaust & Emissions, Lights & Electrics, Suspension, Seatbelts & Airbags, Brakes and others. If you're inspecting a Ford S Max before purchase, these are the areas to focus on — and if any have been flagged as advisories on a previous MOT, they're likely to become failures in the near future.
How failures change with mileage
The Ford S Max's weak points shift as the car covers more miles. Understanding these patterns helps you know what to expect — and what to budget for — at each stage of ownership.
Under 60,000 miles
At this mileage, most failures are either design-related or caused by age rather than wear. Components like bushes and drop links may not have been replaced yet, and original-fit parts can deteriorate even on low-mileage cars that spend a lot of time sitting.
For the Ford S Max specifically, the DVSA data shows the most common failures at this mileage are light unit fault (39x the average) and emissions failure (36x). brake hoses perished or damaged (35x) and coil springs broken (35x) also appear frequently.
60,000 to 100,000 miles
This is where routine wear items start to show up. Brake components, tyres, and exhaust parts have done serious work by this point. Cars that have been well serviced will show fewer of these failures — this mileage band is where good maintenance really separates the well-kept from the neglected.
For the Ford S Max specifically, the DVSA data shows the most common failures at this mileage are suspension pin, bush or joint (24x the average) and power steering fault (21x). brake hoses perished or damaged (19x) and registration plate lamp not securely attached (17x) also appear frequently.
Over 100,000 miles
High-mileage cars accumulate failures across multiple systems. The key question isn't whether things will need doing — they will — but whether the car has been maintained well enough to keep on top of them. Look for a consistent service history and recent MOT passes with minimal advisories.
For the Ford S Max specifically, the DVSA data shows the most common failures at this mileage are headlight fault (23x the average) and emissions failure (19x). suspension pin, bush or joint (19x) and parking brake inefficient (16x) also appear frequently.
The shift from light unit fault at lower mileages to headlight fault at higher mileages is typical — early failures tend to be design or factory-related, while high-mileage failures reflect accumulated mechanical wear. A car that's been well maintained will usually dodge the worst of both.
Known issues beyond the MOT
An MOT only tests roadworthiness at a single point in time — it won't catch developing faults, intermittent problems, or issues that haven't yet reached the failure threshold. These are the issues that Ford S Max specialists and owners flag most frequently, drawn from manufacturer technical bulletins, workshop data, and verified owner reports.
PowerShift transmission failure Major
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. Affects Mk1, Mk2.
DPF blockage and failure Major
The diesel particulate filter (DPF) on Ford TDCi engines becomes blocked with soot during short-journey driving patterns common to MPV usage. Affects Mk1, Mk2; typical independent garage repair cost is £800–£1,200.
Dual mass flywheel failure Major
The dual mass flywheel (DMF) on diesel S-Max variants uses internal springs to smooth engine vibrations before they reach the clutch and gearbox. Affects Mk1, Mk2; typical independent garage repair cost is £600–£900.
Rear spring failure Major
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. Affects Mk1, Mk2; typical independent garage repair cost is £120–£200.
For the complete picture — including repair costs across independent, specialist, and dealer garages — see the full Ford S Max common problems breakdown.
What to check before buying a Ford S Max
Based on the MOT failure data and known issues above, here's what to prioritise when inspecting a Ford S Max:
Exhaust & Emissions — check for emissions failure. Lights & Electrics — check for light unit fault, headlight fault. Suspension — check for coil springs broken, suspension pin, bush or joint.
Beyond the MOT items, ask specifically about powershift transmission failure and dpf blockage and failure. These won't show up on a standard MOT but can be expensive to fix — A specialist pre-purchase inspection is worth the investment on this model.
Always check the car's full MOT history for patterns — recurring advisories often become failures within 12 months. And verify the service history to confirm maintenance has been kept up to schedule. Enter any reg into our free car check to see the complete picture.
Looking at a specific Ford S Max?
Enter the reg to see its full MOT history, mileage records, write-off status, and finance checks.
Ford S Max MOT FAQs
What are the most common MOT failures on a Ford S Max?
Based on 415,154 DVSA MOT tests, the most common failure is emissions failure — at 36x the national fleet average. Other frequent failures include light unit fault and headlight fault.
Is the Ford S Max reliable based on MOT data?
The Ford S Max has 22 MOT failure categories above the fleet average. Specialists also flag powershift transmission failure as a concern. A pre-purchase inspection and service history check are recommended.
What MOT failures should I expect at high mileage?
Above 100,000 miles, the Ford S Max most commonly fails on headlight fault and emissions failure. Under 60,000 miles, the main issues are light unit fault and emissions failure.
How do I check a Ford S Max's MOT history?
Enter the registration number into our free car check above. You'll see every MOT test result, advisories and failures, mileage readings, write-off status, and finance checks.
MOT failure data sourced from DVSA bulk test records via data.gov.uk. Ratios compare this model's failure rate against the national fleet average. Known issues sourced from manufacturer bulletins, specialist workshops, and verified owner reports.