Ford S-Max
2.0 Duratec 107 kW/145 hp, S-Max I (WA6 2006-2010)
Sporty van
145 hp in the S-Max: Ford's sportiest van, but still a van.
Engine Weaknesses 6
The 2.0L Duratec-HE AOWA (S-Max MK1, Galaxy MK2) may show the known throttle plate problem on early intake manifolds. On the heavier family van, listen out for engine noises especially carefully.
Symptoms: Rattling from the intake, sudden power loss, possible engine damage
The chain tensioner on the 2.0 Duratec-HE AOWA wears at long oil change intervals. Watch for cold start rattling at mileages over 150,000 km.
Symptoms: Metallic rattling on cold start, stops after warm-up
At high mileages the 2.0 Duratec-HE AOWA in the Galaxy/S-Max shows increased oil consumption from degrading valve stem and piston ring seals.
Symptoms: Bluish smoke, oil level drops between changes
The EGR valve on the 2.0 EcoBlue becomes clogged with soot deposits. Fault codes for insufficient exhaust gas flow and limp mode significantly restrict the vehicle.
Symptoms: Check engine light on; power reduction (limp mode); increased fuel consumption; EGR flow insufficient fault codes.
The electronic throttle body on the 1.6 Duratec (e.g. Focus Mk2 petrol) commonly fails from 150,000 km through potentiometer wear or moisture. Fault codes P2108 and P2176 appear; OEM unit costs €550.
Symptoms: Sporadic engine warning, engine won't respond to throttle, idle fluctuations, intermittent stumble when pulling away
Individual ignition coils also fail repeatedly on the 1.6 Duratec. Reports of multiple consecutive failures. Replacing all coils and spark plugs together saves follow-up costs and prevents catalytic converter damage.
Symptoms: Hesitation and engine misfires under acceleration, backfiring sounds, check engine light, increased fuel consumption
Vehicle Weaknesses 7
An overflowing windscreen washer reservoir damages the wiring harness that runs below it. Cable insulation is attacked by the fluid, which can lead to engine stalling, AC failure and fault code P0003.
The central locking on the S-Max WA6 is known to be fault-prone: doors open spontaneously or cannot be opened, particularly the tailgate. In the worst case doors open while driving.
According to TÜV reports, the S-Max WA6 frequently has suspension, steering and driveshaft issues flagged. Broken front springs and worn driveshaft CV boots are typical.
The TPMS tyre pressure sensors on the S-Max WA6 corrode at the valve stem and mounting, causing seal failure. In the worst case the valve can fracture and cause sudden pressure loss, especially at higher speeds.
Rust blisters develop on the S-Max WA6 tailgate as the vehicle ages, caused by inadequate factory sealant at panel edges and folds. Vehicles without Titanium trim specification and its poorer underbody sealant are particularly affected.
Tie rod ends and anti-roll bar drop links on the S-Max WA6 show above-average wear that is regularly flagged at MOT inspections. Steering precision suffers noticeably, and advanced wear creates an accident risk.
The optional parking heater in the Ford S-Max WA6 is prone to ECU and glow pin failures. Owners report frequent breakdowns especially on older vehicles, with repair costs disproportionately high.
Reports & Tests
1440 owner complaints filed with NHTSA (2006–2015). Most reported: Steering (363), Electrical (331), Engine (166).