Fault File
All models / All cars / MPVs / Ford S-MAX

Ford S-MAX

All generations and engines together · 57,536 MOT tests in the 2025 data · typical mileage at age 7: 70k

First-time failure at age 7
20.3%
Across 3,627 tests. The average across all tracked models is 19.5%.
Rank at age 7
151 of 239
1 = lowest failure rate among the models tracked.
Typical mileage at age 7
70k miles
Check the mileage view below; low-mileage models can look better by age than they are.

Generation

Split by first-registration year. Cars registered in a changeover year can belong to either generation.

How this model wears

Ford S-MAXClass average, all tracked models

Known issues

Measured

Computed from DVSA MOT results, all of Great Britain, 2025. Nothing here is opinion.

What testers flag

Share of tests where each item was recorded. The dark tick is the class average across all tracked models; bars are scaled within each group.

Faults with the car itself

The rows that judge the model rather than its keeper. 17,252 tests in this band.

A suspension pin, bush or joint excessively worn
Advisory
5.0%class 5.9%
Fluid leaking excessively and likely to harm the environment or to pose a safety risk to other road users
Advisory
4.3%class 2.0%
A headlamp or light source missing, inoperative or more than ½ not functioning in the case of LED
Fail
1.4%class 0.8%
A lamp missing, inoperative or in the case of a multiple light source more than 1/2 not functioning
Fail
1.1%class 1.3%
Seat belt buckle missing, damaged or not functioning as intended
Advisory
0.9%class 0.0%
Excessive fluctuation in brake effort through each wheel revolution.
Advisory
0.8%class 0.6%

Wear, upkeep and luck

Tyres, pads and stone chips say more about how the car was driven and maintained than about how it was built.

Tyre tread depth not in accordance with the requirements
Advisory
42.4%class 22.9%
A brake lining or pad worn below 1.5mm
Advisory
20.4%class 8.7%
A tyre seriously damaged
Advisory
11.3%class 13.4%
Brake disc or drum excessively weakened, insecure or fractured
Advisory
9.7%class 10.1%
Child Seat fitted not allowing full inspection of adult belt
Advisory
9.7%class 2.2%
A brake lining or pad worn below 1.5mm
Fail
4.6%class 1.6%
A rear registration plate lamp or light source missing or inoperative in the case of multiple lamps or light sources
Minor
4.4%class 1.2%
A tyre pressure monitoring system malfunctioning or obviously inoperative
Fail
4.4%class 0.9%

Unconfirmed issues

Reported

Owner folklore from forums and the motoring press. Most of it never shows up in an MOT, which is why this section exists at all.

PowerShift automatic gearbox judder and failure

Automatics only

The 6-speed Getrag PowerShift dual-clutch automatic (mostly paired with the 2.0 TDCi diesel) is the fault owners and traders talk about most. Symptoms are judder or a wheelspin-like shudder pulling away from a stop, sometimes with a gearbox warning light. Failures of the clutch damper or the mechatronic unit have shown up from around 20,000 miles and get more common past 60,000-80,000, with fixes running £1,800-£2,400 for a clutch damper and £3,500-£5,500 for a full transmission. Ford specifies an oil and filter change every 3 years/36,000 miles on this box; owners who can show that on the history are a much safer bet.

Reported 20-90k miles, worse if the 3yr/36k service was skipped · sources: Honest John, owner reports on Honest John Mk2 review

Dual mass flywheel and clutch wear on diesels

Emerging

Diesel S-MAXes, manual and PowerShift alike, have a recurring pattern of the dual mass flywheel wearing out early and taking the clutch with it, more so on cars driven hard or used for towing. Owners describe the clutch going soft or the pedal feeling odd from around 25,000-55,000 miles. A DMF and clutch replacement typically runs £1,500-£1,600. It's not the subject of a recall, just a widely repeated complaint.

Reported 25-55k miles · sources: Honest John Mk1 review

Front tyre and wheel bearing wear

Partly in the MOT data

Owners and reviewers separately flag heavy, sometimes uneven front tyre wear and front wheel bearings going noisy from around 38,000-40,000 miles. That lines up with suspension being the standout measured MOT fault for this car: a big MPV body with a lot of front-end load will chew through bushes, bearings and tracking faster than the class average. Budget for an alignment check and a listen for bearing rumble on any test drive, and expect this to show up as an advisory sooner than on a smaller car.

Reported 35-40k miles onward · sources: Honest John, Auto Express long-term review

Panoramic roof leaks

Emerging

Cars fitted with the optional panoramic glass roof have a repeated history of leaks from the drain channels and blind mechanism, sometimes appearing within a year or two of the car being new and recurring even after a warranty repair. A buyer would notice damp headlining, water stains around the roof edges, or a musty smell. Fixing the mechanism and reseating the seals is roughly £500 in labour on top of parts.

Reported from 1-2 years old · sources: Honest John

Blocked scuttle drains flooding the wiring loom

Emerging

Leaves and debris block the drain wells under the windscreen scuttle, and water backs up into the wiper motor and the alarm sounder module, then into the wiring loom. It shows as random alarm triggers, damp footwells, or a wet smell, and if the loom gets soaked the repair bill jumps to £2,000-£3,000. It's cheap to prevent, an annual clear-out of the drain channels, but plenty of owners find out the hard way.

Reported at various ages · sources: Honest John

2.5-litre Volvo petrol timing belt failure

2.5 petrol only

Early Mk1 cars fitted with the five-cylinder 2.5-litre Volvo-derived turbo petrol have a history of timing belt and tensioner failures well short of the usual interval, in some cases reported from around 28,000-50,000 miles, and because it's an interference engine a snapped belt means a full rebuild. Rebuild costs of around £6,000 have been reported. This engine was a minority fitment even when new, so it mostly matters if you're looking at an early, higher-spec petrol S-MAX.

Reported 28-50k miles · sources: Honest John Mk1 review

Viewing one? Ask this

Built from the two sections above.

From cold, pull away gently in D and feel for judder or a shudder through the pedals. That's the classic PowerShift clutch-damper symptom, not just a cold gearbox.
Ask for service history showing a gearbox oil and filter change at 3 years or 36,000 miles on automatics. No record of it is the single biggest red flag on a PowerShift car.
On a manual, dip the clutch and pull away under load, listen and feel for slip or softness. Early signs of dual mass flywheel and clutch wear, expensive to leave.
Check front tyres for uneven or inner-edge wear and rock each front wheel for play. Points to the alignment and wheel bearing wear this model is prone to.
On panoramic roof cars, check the headlining and roof edges for damp staining. A leak here has usually been going on longer than the seller admits.
Lift the bonnet and check the scuttle drain channels under the wipers are clear, and sniff the footwells for damp. Blocked drains flood the wiring loom and can run to thousands in repairs.
If it's an early petrol, confirm which engine it has and ask for cambelt history. The 2.5 Volvo unit has a history of early belt failure that wrecks the engine.

Others in its class

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How it compares

Head to head with the other popular cars in its class on reliability and common faults.