IsItAGoodCar
Reliability Guide

Common Problems with the
2009 Ford S-MAX Mk1

We've identified 5 known issues that can affect the 2009 Ford S-MAX Mk1. 2 of these are serious faults that could be expensive to repair.

5
Known Issues
2
Serious
3
Moderate
0
Minor

All Known Issues

Steering Rack Failure

SeriousSteering

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

Est. Repair Cost: £500–£1,000
Warning Signs:

Heavy steering, Whining noise from the power steering pump, Loss of fluid from the reservoir

What to Inspect:
  • Check the power steering fluid level
  • Look for swollen rubber boots on the ends of the steering rack
Verified by IsItAGoodCar Research Team

Dual Mass Flywheel (DMF) Wear

SeriousGearbox & Transmission

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.

Est. Repair Cost: £800-£1,500
Warning Signs:

Metallic rattle at idle with clutch pedal up, Judder when moving off, Vibration through clutch pedal

What to Inspect:
  • Listen for rattle that stops when clutch is depressed
  • Test for judder pulling away uphill
  • Check for smooth gear changes when warm
Verified by IsItAGoodCar Research Team

DPF Clogging and Vaporiser Failure

ModerateExhaust & Emissions

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.

Est. Repair Cost: £250-£1,500
Warning Signs:

DPF warning light, Reduced power or limp mode, Engine malfunction message, Frequent regeneration fan noise

What to Inspect:
  • Scan for P244B or P2463 fault codes
  • Check DPF soot load via diagnostics
  • Ask about usual driving pattern
Verified by IsItAGoodCar Research Team

Power Folding Seat Mechanism Failure

ModerateBodywork & Rust

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.

Est. Repair Cost: £200-£600
Warning Signs:

Seats will not fold or unfold electrically, Grinding noise from seat motor, One side folds but the other does not

What to Inspect:
  • Fold and unfold all seats during inspection
  • Listen for motor noise and smooth operation
  • Check seat-folding wiring harness for damage
Verified by IsItAGoodCar Research Team

Coolant Leaks (Thermostat and Hoses)

ModerateCooling System

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.

Est. Repair Cost: £80-£900
Warning Signs:

Low coolant warning, Sweet smell from engine bay, Pink staining around hoses or expansion tank

What to Inspect:
  • Inspect expansion tank and thermostat area from cold
  • Check for unexplained coolant top-ups
  • Verify recall completion for 1.6 EcoBoost models
Verified by IsItAGoodCar Research Team

Buying Tips for 2009 Ford S-MAX Mk1

  • Avoid the Powershift dual-clutch automatic transmission unless it has bulletproof evidence of fluid changes every 3 years/37,500 miles.
  • Check the interior thoroughly; the S-MAX was designed for families, so broken trim, stained seats, and worn seat-folding mechanisms are common.
  • Listen for knocking from the front suspension and check the tyres for uneven wear; the heavy S-MAX eats through lower arm bushes and tyres.
  • On 2.0 TDCi models, verify the DPF isn't clogged; look out for warning lights or poor performance if the car has only done school runs.
  • Test the air conditioning to ensure it blows cold out of all vents, as replacing the condenser or compressor is an expensive job.
  • Check the manual handbrake cables (or electronic parking brake on high specs) to ensure they release fully, as rear calipers are prone to sticking.
20082010
Check a 2009 Ford S-MAX Mk1 by Registration