Ford S-Max
2.5L Duratec FHEV (full hybrid) in the S-Max and Galaxy. Toyota-style hybrid architecture with a planetary gearset. Reliable, but the eCVT gearbox is vulnerable at very high mileages.
Modern Diesel Van
190 hp EcoBlue with automatic: composed and efficient in the S-Max Mk2.
Engine Weaknesses 7
The eCVT hybrid gearbox (electric drive + planetary gear set) can fail at very high mileages or from leaking shaft seals. Servicing as a sealed unit is very expensive.
Symptoms: Judder or rattling when pulling away, gearbox fault message, loss of drive.
The 2.3 EcoBoost 206 kW (Focus ST) is prone to head gasket failure from high thermal stress. Spirited driving significantly accelerates wear.
Symptoms: Coolant loss without external leak, white exhaust clouds on cold start, overheating warning.
The DC-DC converter that steps down HV battery voltage to 12V can fail and cause the 12V electrical system to collapse. Reported sporadically on the C-Max/Kuga Hybrid with Atkinson engine.
Symptoms: All warning lights illuminate simultaneously; vehicle immobilised; 12V battery no longer charged; system errors on SYNC display.
Ni-MH or Li-Ion hybrid battery degrades over time. At very high mileages or on older vehicles the buffer capacity drops, causing the combustion engine to start more frequently.
Symptoms: Hybrid battery warning, increased fuel consumption, engine starts more often.
The 2.5L Duratec shows known coolant losses through hoses and seals. In FHEV operation frequent start-stop cycles increase thermal variation.
Symptoms: Coolant level drops regularly, occasional temperature warning.
The clutch on the Focus ST 2.3 EcoBoost wears prematurely under sporty driving. The engine's high torque overwhelms the clutch disc if not driven optimally.
Symptoms: Clutch slipping under load, increased effort when selecting gears, burning smell.
The lithium-ion battery in the Ford Hybrid loses capacity through cycle ageing. Particularly on the plug-in hybrid (Energi), electric range drops noticeably below 15 km after 5–7 years.
Symptoms: Electric range below 50% of new value; more frequent combustion engine starts; battery health warnings; longer charging times.
Vehicle Weaknesses 8
The 1.5- and 2.0-litre EcoBoost engines in the S-Max II are susceptible to hairline cracks in the engine block, causing coolant loss and in the worst case engine damage. Particularly affected are model years before mid-2019.
The 6-speed Powershift dual-clutch gearbox in the S-Max II is prone to clutch wear, juddering when pulling away, sticking in gears and limp mode activation. Repair costs are considerable.
Ford recalled over 200,000 Galaxy and S-Max vehicles in Europe because the original bolts securing the rear trailing arms can fracture from severe corrosion. If they break the rear axle can fail — acute accident risk.
Corrosion occurs at the rear axle of the S-Max II on track rod ends and axle bolts. Ford recalled affected vehicles. On untreated examples, fracture and loss of driving safety are a risk.
The adaptive headlight control unit in the S-Max II occasionally fails, disabling automatic beam levelling. The failure is listed as a common finding in TÜV reports.
On the Ford S-Max II, rust forms at the tailgate — particularly on lower folded edges and hinge holes — with increasing age. Tow bars are also affected, as corrosion protection around the mounting point often deteriorates.
The Sync 3 infotainment system freezes during temperature fluctuations or after extended standstill and needs to be restarted. Bluetooth connections drop and voice control responds unreliably, particularly on newer vehicles after OTA updates.
TÜV statistics and driver reports confirm above-average brake disc wear on the S-Max II at both front and rear axles. Brake hoses also become brittle with age, which can lead to loss of braking effect.
Reports & Tests
442 owner complaints filed with NHTSA (2015–2023). Most reported: Backup Camera/Sensors (145), Other (88), Electrical (61).