Ford S-Max
2.2 TDCi 129 kW/175 hp, S-Max I (WA6 2006-2010)
Strong Van
175 hp diesel in the S-Max: composed, even fully laden.
Engine Weaknesses 7
Failed injectors cause over-fuelling of individual cylinders and piston damage (crack in piston crown). The 2.2L Duratorq has a high rate of engine failures from this damage pattern, especially on early build years. Ford recommends premium diesel for this engine.
Symptoms: Knocking sounds, severe power loss, white or black smoke, engine failure
On the Ranger 2.2 TDCi the oil pump can fail causing immediate pressure loss. The result is crankshaft bearing and turbocharger damage. Unusual noises from the engine bay are the first sign.
Symptoms: Knocking from engine, oil pressure warning light, power loss, turbo noise
The high-pressure pump of the 2.2 Duratorq TDCi can fail. Metal debris from the pump contaminates the entire injection system and damages all injectors. Repair requires pump, all injectors and system flushing.
Symptoms: Sudden power loss; engine won't start or stalls; fuel pressure too low per OBD; smoke; black residue in fuel system.
The high-pressure pump on the 1.8 TDCi fails frequently between 150,000 and 220,000 km. Metal debris contaminates the fuel system and injectors, often requiring the entire common-rail system to be renewed.
Symptoms: Engine dies suddenly, flashing glow plug light, poor throttle response, engine won't restart, blue smoke
In short-trip Transit Connect operation the DPF clogs because it cannot reach regeneration temperature. Forced dealer regeneration or replacement every 100,000 km is frequently needed.
Symptoms: DPF warning light after city driving; power loss and increased consumption; oil level rising from DPF post-injection.
The rubber damper in the crankshaft pulley of the 1.8 TDCi wears from around 100,000 km and generates noise. Continued use risks the auxiliary belt being shed and failure of the alternator and power steering.
Symptoms: Ticking or knocking noise at idle from the auxiliary belt area, louder on cold start, vibration at idle
The EGR valve of the 2.2 TDCi clogs with short-trip use. Frequently seen in Transit and Ranger as a result of predominantly city driving. Cleaning significantly extends service life.
Symptoms: Power loss, misfires, increased fuel consumption, check engine light
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).