Ford Kuga

Contaminated battery cells from Samsung SDI (Hungary) caused fires in at least 4 vehicles. Ford halted sales in 2020 and recalled all Kuga PHEVs built before 26 June 2020. Complete battery replacement.

Symptoms: Heat development without warning, fire, possibly preceded by charging errors or warning messages.

Second recall wave: repeated charge/discharge cycles damage the internal battery separator, leading to internal short circuits and fire risk. 26,000 vehicles affected. Charging ban until repair.

Symptoms: Warning messages on the dashboard, loss of electric motor power, in extreme cases fire even after parking.

The 2.2 TDCi BGDA shows typical variable turbine geometry wear. Oil carbon deposits on the vanes restrict turbo response and cause power loss.

Symptoms: Power loss at low rpm, limp mode triggered by ECU, dark exhaust smoke under acceleration.

The 2.5L Duratec combustion engine in the PHEV tends to coolant loss at hoses and heat-cycle stress from frequent start/stop cycles in PHEV mode.

Symptoms: Coolant level drops, occasional temperature warning in combustion-engine-only operation.

The EGR valve on the 2.2 TDCi clogs with soot deposits from the exhaust gas. Short-trip driving significantly accelerates coking. First failure typically around 75,000 km.

Symptoms: Rough idle, power loss at low rpm, check engine light, increased fuel consumption.

The 2.5 Turbo Duratec in the Focus ST and Mondeo ST tends to fluctuating boost pressure from a worn or leaking wastegate diaphragm. Boost pressure swings occur from as early as 80,000 km; turbo bearing damage follows with continued use.

Symptoms: Irregular, fluctuating boost pressure during full-throttle acceleration, overboost fault codes, occasional power drop

On the highly stressed 2.5 Turbo Duratec the crankcase breather blocks with deposits. Overpressure builds up, forcing oil past shaft seals and promoting oil loss and turbocharger damage.

Symptoms: Oil traces at the air filter box, smoke from the oil filler cap, increased oil consumption, oil leaks at shaft seals

The Kuga PHEV (plug-in hybrid) was recalled multiple times for fire risk. Faulty charge regulation or defective battery cells can cause overheating and vehicle fire. Multiple separate recall actions up to 2025.

The 1.5-litre EcoBoost engine in the Kuga III — despite revisions from mid-2019 — still occasionally suffers from hairline cracks in the engine block. Coolant enters the combustion chamber or oil circuit.

In 2022 Ford recalled over 36,000 German Kuga PHEV and FHEV vehicles because a defective connecting rod bearing can damage the engine block. Oil can reach hot exhaust components — significant fire risk. As an immediate measure the grille was modified rather than replacing the bearing.

A software fault in the park module of the Kuga PHEV and FHEV hybrid gearbox can cause the vehicle to unexpectedly shift into neutral and roll away. Ford recalled approx. 3,600 German vehicles for a software update.

The 8-speed automatic gearbox in the Kuga III shifts harshly under certain conditions and exhibits vibrations when engaging reverse or on hill starts. Software updates only partially improve the situation.

On the Kuga PHEV, the 12-volt starter battery deep-discharges during extended standing because the control unit doesn't regulate standby current draw optimally. Vehicles that aren't moved or charged regularly can be left stranded.