2021 Ford Transit Problems: 11 Known Issues

On the 2015-2024 Ford Transit EcoBoost 3.5, the Ford Transit 350/350 HD with the 3.5L EcoBoost twin-turbocharged V6 experiences turbocharger failures from inadequate lubrication, carbon buildup in the turbo housings, wastegate actuator failure, and turbo bearing wear.

On the 2015-2022 Ford Transit 3.5L EcoBoost V6, on the twin-turbo 3.5L EcoBoost (GTDI) Transit, a turbocharger wastegate that does not move freely, or a wastegate actuator that leaks, stops the engine from controlling boost pressure. Ford's TSB 15-0115 (July 2015, superseding TSB 15-0107) covers 2015 Transit vans that set code P0234 (overboost), code P0299 (underboost), or both. It also covers 2011-2015 F-150s and the 2015 Expedition and Navigator. The bulletin lists the drivability symptoms as surging and noises described as an air rush, hiss, whoosh, whistle, grinding, growling or scraping. Either turbo can be affected: the bulletin lists replacement parts and labor for the left, the right, or both turbochargers. The bulletin names only 2015 Transit models, so on a 2016 or later van a dealer has to confirm whether the same diagnosis applies.

On the 2017-2023 Ford Transit, the 2017-2023 Ford Transit with the 2.0L EcoBlue diesel engine (available in some markets) and the 3.5L EcoBoost V6 experience fuel injector failures causing rough running, misfires, poor idle, reduced performance, and excessive smoke on cold start. Ford issued a service action for 2.0L EcoBlue vehicles built between February and September 2019 after a batch of high-pressure fuel injectors (reported as Continental-supplied) failed to meet quality standards, causing misfire and reduced engine performance. FordTransitUSAForum.com documents injector failure on 3.5L EcoBoost Transit models as well, where direct injection fuel deposits cause injector spray pattern degradation. RepairPal estimates individual injector replacement between $266 and $627 depending on Transit model, but multiple injectors often need replacement simultaneously, and contaminated fuel systems can cost significantly more.

On the 2020-2024 Ford Transit, later Transits equipped with the 10R80 10-speed automatic have documented owner complaints of harsh 1-2/2-3 shifts, delayed engagement, and occasional shudder. Ford TSB 24-2254 covers 2020-2023 Transits built on or before Aug 15, 2022 with harsh/delayed engagement or shifts, attributing it to axial movement of the CDF clutch cylinder sleeve causing hydraulic circuit leaks. Drivers often describe banging into gear, flare, or hesitation when pulling into traffic.

On the 2018-2023 Ford Transit 2.0L EcoBlue, ecoBlue diesel Transits have documented owner reports of check engine lights and emissions system warnings related to SCR/DEF operation, commonly tied to NOx sensor faults or SCR efficiency monitoring. When the system detects persistent faults, it may trigger reduced power or countdown-to-no-start strategies depending on market/calibration. These issues are frequently accompanied by emissions-related DTCs and can be intermittent before becoming persistent.

On the 2015-2024 Ford Transit, ford Transit vans are well-known for water infiltration through the roof, particularly in medium-roof and high-roof configurations. Water intrudes through multiple paths: (1) factory roof plug holes (the 2015 roof has 16 plugged holes for optional roof rack and ancillary hardware), (2) roof rack mounting holes where Ford applies only primer circles without top-coat paint, (3) push-pin trim clips along the roof/wall junction, and (4) blocked windshield gutter channels that direct water into the engine bay instead of away from the vehicle. The rust issue is compounded by thin steel roofs and inadequate factory corrosion protection. The FordTransitUSAForum has extensive documentation of roof rust appearing within 3-5 years on vans operating in salt-belt states (Northeast, Midwest). For conversion van owners, water leaks can ruin expensive interior buildouts.

On the 2015-2024 Ford Transit, nHTSA complaints and fleet/owner reports commonly cite the Transit sliding door becoming difficult to open/close, popping, grinding, or failing to latch. Wear in the center roller/hinge and track hardware can cause misalignment, especially on high-use cargo vans. The problem often worsens over time and can lead to the door not fully closing or reopening after latching.

On the 2015-2024 Ford Transit, the Ford Transit rear-wheel-drive models develop axle shaft oil seal leaks at the rear differential, allowing gear oil to weep past the axle seals onto the brake backing plates and brake shoes/pads. The leak is often slow enough to go unnoticed until a rear brake inspection reveals oil-soaked components. In severe cases, contaminated rear brakes cause pulling to one side under braking, which is a significant safety concern for loaded vans.

On the 2015-2023 Ford Transit, long-wheelbase and extended-length Transit models (T-250, T-350, T-350 HD) with two-piece driveshafts develop carrier bearing (center support bearing) failure. The rubber isolator deteriorates and the bearing wears, causing vibrations at highway speeds (50-70 mph) and a prominent clunking noise when shifting between drive and reverse.

On the 2015-2022 Ford Transit, the Ford Transit uses a MacPherson strut front suspension with lower control arm bushings that are known to wear or crack prematurely, especially in high-mileage commercial fleets or when the vehicle is operated at or near maximum payload regularly. Worn bushings cause the front axle geometry to shift, leading to rapid and uneven tire wear, vague steering, and a pronounced clunking noise over bumps. This is a documented issue in NHTSA complaints and Transit owner forums, particularly on 2015–2020 models used for delivery service.

On the 2015-2022 Ford Transit, ford Transit vans experience premature alternator failure, often between 50,000-80,000 miles. Symptoms often start as intermittent battery warnings before progressing to a no-start condition.