Common Problems with the
2006 Ford S-MAX Mk1

The power steering rack can leak fluid internally into the track rod end boots, eventually running the pump dry and ruining the rack.

The S-Max heavy body puts extra strain on the DMF. Symptoms include rattling at idle especially cold, vibration through the pedals and difficulty engaging gears. Some owners report failure as early as 60,000 miles on cars used in stop-start traffic.

Short urban journeys prevent DPF regeneration. The fuel vaporiser can fail and the differential pressure sensor is a common secondary failure. Without the vaporiser working the DPF cannot regenerate and will eventually clog completely.

The 2nd and 3rd-row seats fold flat electrically via motors in the seat bases. These motors can fail, the mechanisms can jam and the wiring in the seat channels can fracture. A non-folding third row reduces the car key practical advantage.

The thermostat housing, expansion tank and coolant hoses are common leak points as the car ages. Gradual coolant loss can lead to overheating if not caught early. The 1.6 EcoBoost models are also subject to the cylinder-head cracking recall.