Ford S-Max
2.5T 5-cylinder 162 kW/220 hp, S-Max I (WA6 2006-2010)
Sportiest Van
220 hp five-cylinder turbo in the S-Max: Ford built the sportiest van. Corners like a saloon, sounds like a sports car.
Engine Weaknesses 7
The 2.5L Duratec-ST HUWA (S-Max Mk1, Mondeo Mk4 ST) with 220 hp puts the turbocharger under heavy load. Bearing-wear oil leaks and falling boost pressure are known from 130,000 km.
Symptoms: Whistling from the turbo, boost pressure drop, blue smoke at high revs
The 2.5 Duratec-ST has a timing belt with a 200,000 km or 10-year change interval. Used cars often have no documented evidence of this service. A snapped belt causes immediate valvetrain destruction.
Symptoms: Normally no warning; on a very old belt occasional faint rattle; after snap: immediate engine stop and destruction.
The 2.5 Duratec-ST shows hesitation at part-throttle at higher mileages from fouled injectors or a faulty fuel pressure regulator.
Symptoms: Hesitation at 1,500–2,500 rpm, rough idle, poor throttle response
The water pump on the 2.5 Duratec-ST HUWA (Volvo B5254 derivative) develops leaks at higher mileages. Coolant loss can lead to overheating and cylinder head damage.
Symptoms: Coolant leak at the pump, dropping coolant level, elevated engine temperature
The DPF on the Kuga 2.0 EcoBlue blocks in short-trip use through incomplete regeneration. Oil dilution from post-injection further degrades the lubricating properties.
Symptoms: DPF warning light; power loss; oil level rises at standstill through oil dilution; increased fuel consumption in town.
The Duratec HE 2.0 tends towards increasing oil consumption from around 150,000 km, worsened by short trips and delayed oil changes. Typical: 0.5–1 litre per 1,000 km. Shorten the oil change interval to 10,000 km.
Symptoms: Regular oil loss without visible leak, blue smoke on cold start, slight oil smell inside the cabin
The inductive crankshaft position sensor on the Duratec 2.0 can fail without warning and stall the engine. Resistance above 300 ohms indicates a fault. Parts cost is low, but dangerous driving situations can result.
Symptoms: Engine stalls without warning, will not restart or only restarts after cooling down, engine management light, no immobiliser fault
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 TÃœV 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).