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Ford · Known Issues

2013 Ford Flex Problems: 15 Known Issues

2013 model year · 1,120+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 1,120+ owner reports, the 2013 Ford Flex has 15 documented known issues, with 6 rated critical. The most serious are Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage ($1,500-$7,000 repair), Electric Power Steering (EPS) Failure and Assist Loss ($300-$1,300 repair), Timing Chain, Guide and VCT Phaser Wear Causes Cold-Start Rattle on the 3.5 Cyclone ($1,800-$4,000 repair), Brake Booster Check Valve Failure ($50-$600 repair), Torque Converter Clutch Shudder and TCC Solenoid Contamination in the 6F50/6F55 ($1,200-$4,500 repair) and Electronic Throttle Body Failure Causes Limp Mode (P2111/P2112/P2119) ($300-$700 repair). The most commonly reported issue is Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage with 480 owner reports. Across all issues with published estimates, repair costs range from $30 to $7,000. DIY maintenance guides at au7o.io.

In This Article

  • Flex Engine4
  • Flex Suspension2
  • Flex Brakes1
  • Flex Transmission1
  • Flex Body/Panels2
  • Flex Electrical2
  • Flex Drivetrain1
  • Flex Exterior1
  • Flex HVAC1
  • Recalls8
  • FAQ
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In This Article

  • Engine4
  • Suspension2
  • Brakes1
  • Transmission1
  • Body/Panels2
  • Electrical2
  • Drivetrain1
  • Exterior1
  • HVAC1
  • Recalls8
  • FAQ

All 15 Known Issues

NHTSA Recalls8 recalls

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER

Ford Motor Company (Ford) is recalling certain model year 2016 Ford Taurus, 2016-2017 Ford Flex, Lincoln MKT, 2017 Ford Explorer and Ford Explorer Police Interceptor Utility vehicles equipped with 3.5L GTDI engines. Improperly brazed turbocharger oil supply tubes may leak oil on engine components.

Campaign #16V92500022/12/2016

SUSPENSION:REAR

Ford Motor Company (Ford) is recalling certain 2013-2018 Lincoln MKT and Ford Flex and Taurus vehicles with the Police Interceptor or SHO Performance Pack. The rear suspension toe links may fracture due to stress on the rear suspension.

Campaign #20V07200010/02/2020

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

Ford Motor Company (Ford) is recalling certain 2015-2019 Flex, 2015 Explorer, Lincoln MKT, Lincoln MKZ, 2015-2016 C-Max, Escape, Taurus, 2016 Fusion, 2018-2019 Taurus, 2019 Lincoln MKT, Fiesta, and 2020 Mustang vehicles. The rearview camera may display a distorted, intermittent, or blank image when the vehicle is in reverse.

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Frequently Asked Questions

What are the most common Ford Flex problems?

According to Au7o's analysis of 1,120+ owner reports, the 2013 Ford Flex has 15 documented issues. The most frequently reported are: Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage, Electric Power Steering (EPS) Failure and Assist Loss, Timing Chain, Guide and VCT Phaser Wear Causes Cold-Start Rattle on the 3.5 Cyclone. Of these, 6 are rated critical and should be addressed promptly.

Is the Ford Flex reliable?

The 2013 Ford Flex has 15 known issues documented across 1,120+ owner reports. 6 issues are rated critical: Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage and Electric Power Steering (EPS) Failure and Assist Loss and Timing Chain, Guide and VCT Phaser Wear Causes Cold-Start Rattle on the 3.5 Cyclone and Brake Booster Check Valve Failure and Torque Converter Clutch Shudder and TCC Solenoid Contamination in the 6F50/6F55 and Electronic Throttle Body Failure Causes Limp Mode (P2111/P2112/P2119). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Flex problems?

Repair costs for known Ford Flex issues range from $0 to $7,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage, typically costs $1,500-$7,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2009-2019 Ford Flex Internal Water Pump Failure Causes Coolant-Oil Mixing and Catastrophic Engine Damage?

The 3.5L Duratec and 3.5L EcoBoost V6 engines in the Ford Flex have a critical design flaw: the water pump is driven by the timing chain and mounted internally inside the engine. When the water pump seal fails, coolant leaks directly into the engine oil, creating a milky sludge t… Repairs typically run $1,500-$7,000. Severity: high.

What is the 2009-2013 Ford Flex Electric Power Steering (EPS) Failure and Assist Loss?

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 1,120+ owner reports, NHTSA recalls, TSBs, and automotive forums.

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ALL YEARS20192018201720162015201420132012201120102009
Community reported
480 owners

On the 2009-2019 Ford Flex, the 3.5L Duratec and 3.5L EcoBoost V6 engines in the Ford Flex have a critical design flaw: the water pump is driven by the timing chain and mounted internally inside the engine. When the water pump seal fails, coolant leaks directly into the engine oil, creating a milky sludge that destroys engine bearings in a matter of miles. Because the pump is internal, there is no external leak to warn the owner — the first symptom is often catastrophic engine failure. This is one of the most expensive and common failures on high-mileage Flex vehicles, with repair quotes ranging from $5,000 to $7,000+ for engine replacement.

Common Symptoms

  • Milky or frothy substance on oil dipstick or under oil fill cap
  • Sweet smell from engine oil indicating coolant contamination
  • Coolant level dropping with no visible external leak
  • Engine overheating
  • Low oil pressure warning light
  • Knocking or ticking sound from engine indicating bearing damage
  • White or sweet-smelling exhaust

How to Fix

Proactively replace the water pump and timing chain as preventive maintenance between 100,000-120,000 miles ($1,500-$2,500 labor-intensive job). Check oil regularly for milky appearance or coolant smell — catching it early can save the engine. If coolant is found in the oil, stop driving immediately and have it towed. Use only Ford-approved coolant to minimize seal degradation. Consider extended warranty coverage when purchasing a high-mileage Flex.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Engine Water Pump
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    Fitment confirmed against the ShowMeTheParts catalog for this vehicle's year and engine.

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Typical repair cost:$1,500 - $7,000

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Based on 480 owner reports

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Community Reported
High Confidence480 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2009-2019 Ford Flex, separate from the internal water pump, the 3.5L Cyclone's timing drive itself wears. The primary and secondary chain guides and the hydraulic tensioners lose their ability to hold tension when oil pressure bleeds down overnight, so the first two or three seconds after a cold start produce a loud rattle from the front of the engine. Owners report worn tensioner teeth at mileages as low as 56,000, and cases where the noise was ignored until metal debris from a chain sprocket circulated through the oil and forced an engine replacement. Extended oil change intervals and low oil level accelerate the wear because the tensioners are oil-fed. Once cam-to-crank timing drifts far enough, the PCM sets correlation codes and driveability suffers.

Common Symptoms

  • Loud rattle for 1-3 seconds on cold start
  • Chain or whining noise from the front of the engine
  • Check engine light with cam/crank correlation codes
  • Rough running or reduced power
  • Metal or plastic debris in the oil filter

How to Fix

Treat a cold-start rattle as urgent, not cosmetic. Check oil level and condition first and cut the oil change interval to 5,000 miles with the correct-viscosity full synthetic. Pull a valve cover and inspect the guides for grooving, and check the oil pan and filter for plastic guide fragments or metal. The correct repair is a complete front-cover-off job: both timing chains, all guides, both tensioners, the crank and cam sprockets, and the VCT phasers, done as a set - replacing only one component reliably brings the noise back. Since the front cover is already off, replace the internal water pump at the same time.

Typical repair cost:$1,800 - $4,000

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

On the 2009-2016 Ford Flex, the electronic throttle body on the 3.5L/3.7L Cyclone V6 uses a plastic-geared motor and integrated throttle position sensors. Contamination, gear wear and sensor drift cause the PCM to lose confidence in commanded vs. actual plate position, triggering failsafe cooling mode. The vehicle drops to a fixed low-power limp mode with the wrench light on, often at highway speed, which is why owners describe it as a safety issue rather than a driveability annoyance. Ford acknowledged the pattern with customer satisfaction/warranty extension programs (13N03, 16B32) and a TSB covering 2015-2016 3.5L vehicles built on or before 31 May 2016. The failure is frequently intermittent at first: the wrench light appears, the vehicle is restarted, and normal power returns until the next episode.

Common Symptoms

  • Sudden loss of power / limp mode while driving
  • Wrench (powertrain malfunction) light on dash
  • Erratic or surging idle
  • Engine stalls at stops
  • Reduced throttle response that clears after restart

How to Fix

Confirm with stored P2111/P2112/P2119 (and often P2135 for TPS correlation). Cleaning the bore rarely gives a lasting fix once the gears or sensors are worn - the real repair is replacing the electronic throttle body with the updated Motorcraft part and then completing the throttle body relearn/KAM reset so the PCM adapts to the new unit. Check for the applicable Ford program by VIN before paying out of pocket; also verify the accelerator pedal position sensor, since a failing pedal sensor produces overlapping symptoms.

Typical repair cost:$300 - $700

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

On the 2010-2019 Ford Flex 3.5L EcoBoost V6, the 3.5L EcoBoost in the Flex (SHO-derived, EcoBoost/Limited AWD models) is direct-injected only, so no fuel ever washes across the back of the intake valves. Oil vapor pulled through the PCV system and exhaust residue from valve overlap bake onto the valve stems and seats. As the deposits thicken they disrupt the low-velocity airflow at idle first, producing a rough or lopey cold idle, then progress to misfires under load, hesitation, lost boost response and reduced fuel economy. It is a mileage-driven wear item, not a defect that appears suddenly, and is typically noticeable somewhere past 60,000-80,000 miles depending on driving pattern and oil change discipline.

Common Symptoms

  • Rough or unstable idle, worst when cold
  • Misfire under load or during acceleration
  • Hesitation and reduced boost response
  • Drop in fuel economy
  • Check engine light with cylinder misfire codes

How to Fix

Confirm with a borescope through a removed intake runner before spending money - misfire codes alone do not prove carbon. The effective cleaning is mechanical: remove the intake manifold and walnut-shell blast the intake ports and valve backs, then replace the intake gaskets and spark plugs while everything is open. Chemical intake cleaners and fuel additives cannot reach the valves on a DI-only engine. To slow reaccumulation, fit a quality oil catch can on the PCV line, use a full synthetic that resists volatility, and keep oil changes at 5,000 miles. Plan on repeating the service roughly every 40,000-60,000 miles.

Typical repair cost:$500 - $1,200

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026
Community reported
290 owners

On the 2009-2013 Ford Flex, the 2009-2013 Ford Flex uses an electric power steering system that is prone to sudden failure, leaving the driver with extremely heavy steering that requires significant effort to turn. The power steering control module can overheat or fail internally, and the steering motor itself can burn out. The failure often occurs without warning, typically during low-speed maneuvers like parking lot turns. This was one of the top NHTSA complaint categories for the Flex.

Common Symptoms

  • Steering suddenly becomes very heavy and difficult to turn
  • Power steering warning light illuminates on dashboard
  • Steering assist intermittently cuts in and out
  • Grinding or whining noise from the steering column
  • Steering feels normal at highway speed but fails at low speed

How to Fix

Have the power steering control module and motor tested at a Ford dealer or independent shop with Ford-specific scan tools. The steering column assembly with motor costs $400-$800 for the part, plus $300-$500 labor. Some owners have had success with aftermarket rebuilt units for $200-$400. Ford issued a TSB with a software update that can help in some cases — ask the dealer to check for applicable TSBs.

Typical repair cost:$300 - $1,300

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Based on 290 owner reports

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Community Reported
High Confidence290 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2009-2019 Ford Flex, sealed hub bearing assemblies on the Flex wear out and produce a speed-dependent noise that owners consistently describe as starting like a hum and progressing to a sound like aggressive snow tires, usually first noticed above 40 mph and changing pitch when the vehicle is loaded up in a turn. It affects both front and rear (including rear hubs on AWD cars). What makes this repair worse than on other vehicles is corrosion: the bearing race seizes to the knuckle/spindle, so the whole spindle often has to come off the car and the bearing pressed out, turning a routine job into a multi-hour fight.

Common Symptoms

  • Humming or growling that increases with speed
  • Noise changes pitch when turning or changing lanes
  • Roar resembling aggressive tire tread above 40 mph
  • Play felt when rocking the wheel at 12 and 6 o'clock
  • ABS or traction control light in severe cases

How to Fix

Isolate the noisy corner with a stethoscope or by loading the vehicle in sweeping turns - noise that worsens turning one way usually points to the opposite-side bearing. Replace the complete hub/bearing assembly. Anticipate corrosion: soak the hub in penetrant, use a hub puller or the forum technique of long fine-thread grade 5/8 bolts through the flange to press it out, and apply anti-seize to the knuckle bore on reassembly. Torque the axle nut to specification with a new nut, and check the ABS sensor tone ring while the hub is out.

Typical repair cost:$230 - $600

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

On the 2009-2019 Ford Flex, the brake booster check valve fails, allowing vacuum to leak and causing a hard brake pedal and longer stopping distances. Some owners report a hissing sound from the brake area when pressing the pedal.

Common Symptoms

  • Hard brake pedal
  • Hissing from brake area
  • Longer stopping distance
  • Engine idle changes when braking

How to Fix

Replace the brake booster check valve and grommet. Test vacuum at the booster — should hold 15+ inches of vacuum. If the booster diaphragm is damaged, the entire booster needs replacement.

Typical repair cost:$50 - $600

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Medium Confidence

On the 2009-2019 Ford Flex, owners report a shudder or vibration that feels like driving over rumble strips, typically in 3rd through 6th gear at light throttle or on gentle inclines - exactly when the transmission control module tries to hold the torque converter clutch in partial (EMCC) lockup. FORScan logging shows the TCM commanding roughly 20 RPM of converter slip while actual slip wanders randomly between 0 and 200 RPM, which is the signature of a glazing converter clutch lining or a TCC/pressure control solenoid that has been contaminated by clutch material and metal debris. Because the shudder mimics an engine misfire, many owners chase spark plugs, coils and motor mounts first. Left alone, the debris circulates through the valve body and takes out other solenoids and eventually the transmission.

Common Symptoms

  • Shudder or vibration at steady cruise, 35-60 mph
  • Rumble-strip feeling under light load or on inclines
  • Jerky or surging low-speed shifts
  • Hesitation when accelerating from a stop
  • Metal shavings in the transmission pan

How to Fix

Confirm the fault is the converter and not a misfire by logging TCC slip with FORScan while the shudder occurs. Early cases often respond to a full fluid exchange with the correct Mercon LV plus a friction modifier, but that is a temporary measure. The durable repair is replacing the torque converter, flushing the cooler lines, and replacing the TCC/pressure control solenoids or the valve body if the pan shows metal. Dealers commonly quote a complete remanufactured transmission; an independent transmission shop replacing converter plus solenoids costs far less. Change the transmission fluid every 50-60k miles rather than treating it as fill-for-life.

Typical repair cost:$1,200 - $4,500

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2009-2019 Ford Flex, the multi-panel Vista Roof is not sealed against water - it relies on a drip tray and four drain tubes that route water down the A- and C-pillars. On the Flex those tubes are prone to being crimped, kinked or, in some documented warranty cases, never connected at the factory at all. Owners also found the rear drains act as collectors: when the vehicle sits nose-up in prolonged rain, the collector fills and overflows onto the top of the headliner, where water tracks forward and appears at the driver's A-pillar, the overhead DVD player, or the rear side windows. Because the water enters far from where it drips out, dealers frequently mis-diagnose it as a glass seal problem and reseal the roof repeatedly without success. Standing water leads to stained headliners, mildew smell, wet carpets and corroded connectors for overhead electronics.

Common Symptoms

  • Water dripping from the overhead console or DVD player
  • Wet headliner or A-pillar trim after heavy rain
  • Damp front or rear carpet
  • Musty or mildew smell in the cabin
  • Water stains around the rear vista glass

How to Fix

Do not start by resealing the glass. Pull the A-pillar trim, locate the front drain outlets and flush the tubes with low-pressure air or water from the roof end to confirm flow at all four corners. Straighten or replace crimped tubing and verify the rear collector tubes are actually attached to their nipples - some owners have permanently fixed the leak by re-routing or extending the rear drains. Clear leaf debris from the drip tray, replace a damaged tray seal, and dry the headliner fully before reinstalling trim to prevent mold.

Typical repair cost:$150 - $900

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High ConfidenceVerifiedReviewed Aug 2026

On the 2009-2019 Ford Flex, on power-liftgate Flexes the gate is raised by two electric struts working with the drive motor and control module. The gas charge and internal drive in the struts weakens with age and cold weather, so the gate opens slowly, stops partway, reverses as though it detected an obstruction, or refuses to move while the module beeps. Because a weak strut forces the motor to work outside its designed load, owners repeatedly report that the module faults out or the motor burns up secondary to the real problem - the struts. Owners who replaced the motor alone often saw the fault return until the struts were also replaced. A fully dead system with no sound at all from the fob, dash switch or gate button is instead a fuse, wiring, or liftgate control module problem.

Common Symptoms

  • Liftgate opens partway then stops or reverses
  • Beeping from the liftgate with no movement
  • Gate will not stay up on its own
  • Power liftgate dead from fob, dash and gate switch
  • Motor runs but the gate does not lift

How to Fix

Diagnose in the right order. If the gate moves at all, replace both motorized struts as a pair rather than chasing the motor - many owners report the fault clearing permanently once the struts are renewed and the motor stops being overloaded. If nothing happens at all, check the liftgate fuse and the wiring loom in the flex conduit between the body and the gate, where broken conductors are common, before condemning the module. After any component replacement, reset the system by disconnecting the battery for about 20 seconds, manually closing and latching the gate, then cycling it open with the fob so the module relearns its travel limits. A replacement module must be programmed to the vehicle.

Typical repair cost:$200 - $900

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

On the 2013-2019 Ford Flex, flexes equipped with MyFord Touch (SYNC 2, roughly 2013 onward) suffer failures of the Accessory Protocol Interface Module, the computer mounted behind the 8-inch center screen that runs the infotainment OS. Symptoms escalate from slow response and Bluetooth dropouts to spontaneous reboots mid-drive, a permanently black screen, or a display that lights up but ignores touch input because the digitizer has delaminated. Because HVAC, audio, rear camera display and phone functions are routed through this screen, an APIM failure takes out several unrelated systems at once - most importantly the backup camera image. Ford issued repeated software updates and TSBs over the SYNC 2 era, but the hardware failures persisted, and out-of-warranty owners are quoted large sums for a dealer module.

Common Symptoms

  • Touchscreen goes black or does not respond to touch
  • System reboots repeatedly while driving
  • Backup camera image will not display
  • Bluetooth and USB audio drop out
  • Climate and audio controls unavailable from the screen

How to Fix

First try a master reset and a current SYNC 2 software update installed from USB using the Ford Owner site - a meaningful share of freezing and reboot complaints are software. If the screen stays black, reboots continuously, or the touch layer is dead, the APIM (and sometimes the separate front display/digitizer) must be replaced. A replacement APIM has to be programmed to the VIN and to the vehicle's option content; this can be done at a dealer, with FORScan by a competent DIYer, or by buying a unit pre-programmed to your VIN, which is typically a fraction of dealer pricing. Some owners instead retrofit an aftermarket head unit.

Typical repair cost:$300 - $1,400

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Medium ConfidenceVerifiedReviewed Aug 2026

On the 2009-2019 Ford Flex, the door ajar warning stays illuminated even with all doors closed, draining the battery if interior lights stay on overnight. Caused by faulty door latch switches that corrode or stick.

Common Symptoms

  • Door ajar warning on with doors closed
  • Interior lights stay on
  • Battery drain overnight
  • Dome light won't turn off

How to Fix

Spray electrical contact cleaner into the door latch mechanism. Replace the door latch assembly if cleaning doesn't resolve it. Check each door individually to identify which sensor is faulty.

Typical repair cost:$30 - $250

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Community reported
350 owners

On the 2009-2019 Ford Flex, aWD-equipped Ford Flex models suffer from chronic Power Transfer Unit (PTU) seal leaks and eventual PTU failure. The PTU transfers power from the transaxle to the rear driveshaft and is sealed with halfshaft seals that deteriorate over time. When the seals leak, the PTU fluid level drops, causing the unit to overheat and produce metal shavings that destroy the internal gears. Ford issued a TSB acknowledging the problem but never recalled the part. The PTU has no dipstick and the fluid is considered "lifetime" by Ford, meaning most owners never check or change it — leading to premature failure.

Common Symptoms

  • Brown or dark fluid leak near the front axle area
  • Burning oil smell from under the vehicle after driving
  • Grinding or whining noise from the front of the drivetrain
  • AWD malfunction warning light or message
  • Vibration at highway speeds from the drivetrain
  • Metal shavings or black sludge in PTU fluid

How to Fix

Change the PTU fluid every 30,000-40,000 miles regardless of Ford's "lifetime" fluid claim. Have a shop inspect the PTU seals at every oil change for leaks. If the PTU is leaking, replace the seals promptly ($300-$600) before the unit is damaged. If the PTU has already failed (grinding noise, AWD malfunction), replacement costs $1,200-$2,500. An independent transmission shop can flush the fluid at a fraction of the dealer cost.

Typical repair cost:$300 - $2,500

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Based on 350 owner reports

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High Confidence350 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2011-2019 Ford Flex, the black B-pillar applique bonded to the trailing edge of the driver and front passenger doors can separate and fly off. NHTSA opened an investigation in August 2025 after complaints on 2019 Flex vehicles and then widened it to 2011-2018 Flexes that use similar trim, and Ford recalled roughly 71,000 2017-2019 units under campaign 25SB8. Ford's own analysis blamed a repositioned two-way locator on the trim that increased outward reaction force, combined with assembly-plant operators inconsistently using hand rollers to set the adhesive bond. Ford had logged more than 1,600 warranty claims for this part. A detached panel is a road-debris hazard for following traffic; before it lets go, owners hear wind noise and rattling and can see the top of the trim lifting away from the door when they get in or out.

Common Symptoms

  • B-pillar trim lifting away from the top of the front door
  • Wind noise at highway speed
  • Rattling or flapping from the door area
  • Trim piece missing after driving

How to Fix

Check your VIN against the NHTSA recall lookup - 2017-2019 vehicles are covered by 25SB8 and Ford will inspect and secure or replace the applique at no charge. Owners of 2011-2016 vehicles not covered by the recall should inspect the top edge of the trim on both front doors; if it has lifted, the panel can be re-bonded with automotive-grade acrylic foam tape after cleaning both surfaces with adhesion promoter and firmly rolling the panel down. Do not drive with a partially detached panel.

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Typical repair cost:$0 - $250

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On the 2009-2019 Ford Flex, the Flex uses several small plastic-geared HVAC actuators (driver blend, passenger blend, mode/panel-floor-defrost, and recirculation) behind the dash, plus additional units for the rear climate zone. The position feedback potentiometer inside the actuator degrades and stops reporting true door position, so the control module keeps driving the motor past the door stops until the nylon gear teeth skip and strip. The result is the classic rhythmic clicking or ticking from behind the dash, usually loudest right after startup or when temperature is changed. Owners of dual-zone Flexes typically notice one side blows hot while the other blows cold, or that airflow is stuck on defrost. This is one of the most frequently repeated HVAC complaints across the entire 2009-2019 run.

Common Symptoms

  • Rhythmic clicking or ticking behind the dash
  • One side blows hot while the other blows cold
  • Air stuck on defrost or floor regardless of mode setting
  • Temperature does not change when the dial is adjusted
  • Recirculation does not engage

How to Fix

Identify which actuator has failed before buying parts - a scan tool that can command each actuator, or simply listening while cycling temperature and mode, will isolate it. Replace the failed actuator (driver-side and recirculation units are typically under an hour; the passenger blend and rear-unit actuators can require significant dash disassembly). After installation the HVAC module must relearn actuator travel, done by disconnecting the battery for a few minutes or performing the module self-calibration on startup. Confirm the blend door shaft itself is not broken before blaming the actuator again.

Typical repair cost:$120 - $700

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026
Campaign #25V695000
13/10/2025

STRUCTURE:BODY

Ford Motor Company (Ford) is recalling certain 2017-2019 Flex vehicles. The driver and front passenger B-Pillar door trim may detach while driving.

Campaign #25V73200024/10/2025

ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

Ford Motor Company (Ford) is recalling certain 2018 Ford Edge, Lincoln MKX, 2019 Ford Flex, and Lincoln MKT vehicles. The power supply cables at the starter and the alternator may not have been properly secured, possibly resulting in an electrical arc.

Campaign #18V54800020/08/2018

+ 3 more recalls. Check all on NHTSA.gov

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

get a full repair guide

The 2009-2013 Ford Flex uses an electric power steering system that is prone to sudden failure, leaving the driver with extremely heavy steering that requires significant effort to turn. The power steering control module can overheat or fail internally, and the steering motor its… Repairs typically run $300-$1,300. Severity: high.

What is the 2009-2019 Ford Flex Timing Chain, Guide and VCT Phaser Wear Causes Cold-Start Rattle on the 3.5 Cyclone?

Separate from the internal water pump, the 3.5L Cyclone's timing drive itself wears. The primary and secondary chain guides and the hydraulic tensioners lose their ability to hold tension when oil pressure bleeds down overnight, so the first two or three seconds after a cold star… Repairs typically run $1,800-$4,000. Severity: high.

What is the 2009-2019 Ford Flex Brake Booster Check Valve Failure?

The brake booster check valve fails, allowing vacuum to leak and causing a hard brake pedal and longer stopping distances. Some owners report a hissing sound from the brake area when pressing the pedal. Repairs typically run $50-$600. Severity: high.

What is the 2009-2019 Ford Flex Torque Converter Clutch Shudder and TCC Solenoid Contamination in the 6F50/6F55?

Owners report a shudder or vibration that feels like driving over rumble strips, typically in 3rd through 6th gear at light throttle or on gentle inclines - exactly when the transmission control module tries to hold the torque converter clutch in partial (EMCC) lockup. FORScan lo… Repairs typically run $1,200-$4,500. Severity: high.

What is the 2009-2016 Ford Flex Electronic Throttle Body Failure Causes Limp Mode (P2111/P2112/P2119)?

The electronic throttle body on the 3.5L/3.7L Cyclone V6 uses a plastic-geared motor and integrated throttle position sensors. Contamination, gear wear and sensor drift cause the PCM to lose confidence in commanded vs. actual plate position, triggering failsafe cooling mode. The… Repairs typically run $300-$700. Severity: high.

What is the 2009-2019 Ford Flex Power Transfer Unit (PTU) Seal Leaks and AWD System Failure?

AWD-equipped Ford Flex models suffer from chronic Power Transfer Unit (PTU) seal leaks and eventual PTU failure. The PTU transfers power from the transaxle to the rear driveshaft and is sealed with halfshaft seals that deteriorate over time. When the seals leak, the PTU fluid lev… Repairs typically run $300-$2,500. Severity: medium.

What is the 2009-2019 Ford Flex Vista Roof Drain Tube Blockage and Disconnection Floods the Headliner?

The multi-panel Vista Roof is not sealed against water - it relies on a drip tray and four drain tubes that route water down the A- and C-pillars. On the Flex those tubes are prone to being crimped, kinked or, in some documented warranty cases, never connected at the factory at a… Repairs typically run $150-$900. Severity: medium.

What is the 2013-2019 Ford Flex MyFord Touch / SYNC 2 APIM Module Failure - Black Screen, Reboots, Unresponsive Touch?

Flexes equipped with MyFord Touch (SYNC 2, roughly 2013 onward) suffer failures of the Accessory Protocol Interface Module, the computer mounted behind the 8-inch center screen that runs the infotainment OS. Symptoms escalate from slow response and Bluetooth dropouts to spontaneo… Repairs typically run $300-$1,400. Severity: medium.

What is the 2011-2019 Ford Flex Front B-Pillar Door Trim Applique Detaches From the Doors (Recall 25SB8)?

The black B-pillar applique bonded to the trailing edge of the driver and front passenger doors can separate and fly off. NHTSA opened an investigation in August 2025 after complaints on 2019 Flex vehicles and then widened it to 2011-2018 Flexes that use similar trim, and Ford re… Repairs typically run $0-$250. Severity: medium.

What is the 2009-2019 Ford Flex Front and Rear Wheel Hub Bearing Failure With Corrosion-Welded Hubs?

Sealed hub bearing assemblies on the Flex wear out and produce a speed-dependent noise that owners consistently describe as starting like a hum and progressing to a sound like aggressive snow tires, usually first noticed above 40 mph and changing pitch when the vehicle is loaded… Repairs typically run $230-$600. Severity: medium.

What is the 2010-2019 Ford Flex Intake Valve Carbon Buildup on the Direct-Injected 3.5 EcoBoost?

The 3.5L EcoBoost in the Flex (SHO-derived, EcoBoost/Limited AWD models) is direct-injected only, so no fuel ever washes across the back of the intake valves. Oil vapor pulled through the PCV system and exhaust residue from valve overlap bake onto the valve stems and seats. As th… Repairs typically run $500-$1,200. Severity: medium.

What is the 2009-2019 Ford Flex Power Liftgate Motorized Struts Weaken and Overload the Lift Motor?

On power-liftgate Flexes the gate is raised by two electric struts working with the drive motor and control module. The gas charge and internal drive in the struts weakens with age and cold weather, so the gate opens slowly, stops partway, reverses as though it detected an obstru… Repairs typically run $200-$900. Severity: low.

What is the 2009-2019 Ford Flex Door Ajar Warning Stays On?

The door ajar warning stays illuminated even with all doors closed, draining the battery if interior lights stay on overnight. Caused by faulty door latch switches that corrode or stick. Repairs typically run $30-$250. Severity: low.

What is the 2009-2019 Ford Flex HVAC Blend Door Actuator Gear Stripping Causes Clicking and Split Cabin Temperatures?

The Flex uses several small plastic-geared HVAC actuators (driver blend, passenger blend, mode/panel-floor-defrost, and recirculation) behind the dash, plus additional units for the rear climate zone. The position feedback potentiometer inside the actuator degrades and stops repo… Repairs typically run $120-$700. Severity: low.