Generations
Mk1 — First Generation
2006–2014
1.6 Duratec, 1.8 TDCi, 2.0 TDCi, 2.0 Duratec, 2.2 TDCi, 2.3 Petrol
Mk2 — Second Generation
2015–2021
1.5 EcoBoost, 1.6 TDCi, 2.0 TDCi
Top issues to watch for
The most serious Ford S Max problems ranked by severity. We track 9 known issues — here are the ones you need to know about first.
Major
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.
What happens if ignoredComplete 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.
Specialist
£1,800–£3,500
Main dealer
£2,500–£4,500
Parts only
£1,200–£2,000
Major
DPF blockage and failure
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.
What happens if ignoredComplete 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.
Independent garage
£800–£1,200
Specialist
£900–£1,400
Main dealer
£1,200–£1,800
Parts only
£500–£800
Major
Dual mass flywheel failure
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.
What happens if ignoredDMF 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.
Independent garage
£600–£900
Specialist
£700–£1,000
Main dealer
£800–£1,200
Parts only
£300–£450
Major
Rear spring failure
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.
What happens if ignoredFractured 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.
Independent garage
£120–£200
Specialist
£150–£250
Main dealer
£200–£350
Parts only
£40–£80
5 more known issues tracked
Including further major faults, wear items, electrical niggles, and generation-specific problems. Check a specific car to see which issues apply to its age and mileage.
Check a specific car →MOT failure hotspots
Based on DVSA MOT test data. These are the items where the Ford S Max fails at a significantly higher rate than the average car.
Light unit fault
Lights & Electrics · 0-20k miles
MOT failure rate: 39x the fleet average
Sample: 4,746 tests
Emissions failure
Exhaust & Emissions · 0-20k miles
MOT failure rate: 36x the fleet average
Sample: 4,074 tests
Brake hoses perished or damaged
Brakes · 40-60k miles
MOT failure rate: 35x the fleet average
Sample: 18,465 tests
Coil springs broken
Suspension · 0-20k miles
MOT failure rate: 35x the fleet average
Sample: 4,074 tests
Seat mounting fault
Seatbelts & Airbags · 20-40k miles
MOT failure rate: 34x the fleet average
Sample: 9,642 tests
Anti-roll bar links worn
Suspension · 0-20k miles
MOT failure rate: 32x the fleet average
Sample: 1,534 tests
Technical service bulletins & recalls
Official manufacturer notices issued to dealerships. If a car hasn't had recall work done, it needs doing — check with the dealer network.
14-0017
PowerShift Transmission Shudder/Judder
Ford acknowledges PowerShift transmission shudder during low-speed manoeuvres and provides software updates and clutch replacement procedures. Check whether any software updates have been applied and request service history documentation.
Buying a Ford S Max?
Check a specific car's service history to see if it's been looked after — franchised dealer records with dates, mileage, and work done.
Check service history£6.99 · Full refund if no records found
Related
Ford S Max reliability FAQs
What are the most common problems with the Ford S Max?
The Ford S Max has 9 known issues across 2 severity levels. The most common problems relate to PowerShift transmission failure and DPF blockage and failure.
Is the Ford S Max reliable?
The Ford S Max has 0 dangerous and 5 major known issues. No dangerous issues are tracked, which is a positive sign.
How much does it cost to fix Ford S Max problems?
Costs vary by issue. Independent garages are typically 30-50% cheaper than main dealers for most repairs.
Which Ford S Max generation is most reliable?
The Mk1 (2006–2014) has the fewest dangerous issues (0). However, condition and service history matter more than generation — a well-maintained earlier car can be more reliable than a neglected newer one.