Ford's sport-styled MPV in its second generation, offering seven seats with genuinely engaging driving dynamics. The 2.0 TDCi was the dominant engine choice. At the 2015 European launch the diesel line-up ran 120, 150 and 180 PS single-turbo versions plus a 210 PS bi-turbo, with six-speed manual or PowerShift and optional all-wheel drive. In 2018 the EcoBlue engine replaced the Duratorq rather than rebadging it, bringing 120, 150, 190 and 240 PS, an eight-speed automatic, and revised internals including a wet timing belt. This report covers the mainstream 150-190 PS versions. Production ended in April 2023 with no direct successor. The engine is generally durable, parts are reasonably priced, and independent garage support is excellent across Europe.· more· less
Engaging handling for an MPVStrong diesel economy, 5-6 l/100 km
Wet timing belt on EcoBlue modelsPowerShift gearbox issues (if equipped)
Buy if: You want a practical 7-seat diesel with good driving dynamics and can verify timing belt/chain history and gearbox condition.
Avoid if: You mostly do short urban trips (DPF problems), the car has a PowerShift gearbox with unknown service history, or the wet belt has not been replaced on a high-mileage EcoBlue model.
Price & maintenance
Used price
€16,400
median asking price, typically 130,000 km
Typical range€12,900 – €20,800
Kilometres drivenAll
Maintenance cost
€800 – €1,500/year
at 15,000 km/year
Fixed costsservice, tyres, brakes€500 – €850 /yr
Risk bufferunplanned repairs€300 – €650 /yr
Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Ownership costs
Maintenance assumes 15,000 km a year. Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Used price
€16,400
Typically €12,900 – €20,800, at around 130,000 km.
Diesel particulate filter blocks when the car is used predominantly for short urban trips · more· less
The S-MAX Mk2 2.0 TDCi uses an active DPF system that requires sustained motorway driving for regeneration. Consistent short-trip use prevents regeneration from completing, causing progressive soot accumulation. Symptoms include DPF warning light, reduced power (limp mode), and increased fuel consumption. A common cheap fix is replacing the failed DPF differential pressure sensor hoses (rubber hoses that become brittle from heat), which costs under €100. Professional DPF cleaning runs €250-500. If the filter is beyond recovery, replacement costs €1,000-1,800 depending on OEM vs aftermarket. Prevention is straightforward: a 30-minute motorway drive every 300-400 km of urban use.
EGR valve clogging
€350 - 6002 of 8
Carbon buildup in the exhaust gas recirculation valve causes rough running and warning lights · more· less
The EGR valve on the 2.0 TDCi accumulates carbon deposits over time, particularly on cars used for urban driving. Symptoms include rough idle, power loss, check engine light, and sometimes the engine going into limp mode. Cleaning the valve (€100-200 at a specialist) can resolve the issue, but if the valve is seized or the housing is damaged, full replacement is needed. Ford dealer replacement costs around €350-600. The issue typically becomes noticeable between 80,000 and 130,000 km. Regular motorway driving and using quality fuel help slow the buildup.
Wet timing belt degradation (EcoBlue models, 2018+)
€1,000 - 2,5003 of 8
Oil-bathed timing belt can fray and shed material, contaminating the oil system · more· less
From 2018 onward, the S-MAX switched to the 2.0 EcoBlue engine which uses a wet timing belt running inside the engine, lubricated by engine oil. This belt can degrade prematurely if the engine oil is contaminated or not changed on schedule, shedding rubber particles into the oil that can block the oil pickup and cause catastrophic engine damage. Ford originally set the replacement interval at 10 years or 200,000 km, but independent specialists strongly recommend replacement at 6-7 years or 100,000-130,000 km. Replacement costs €1,000-1,500 at an independent specialist and €1,500-2,500 at a Ford dealer, as the job takes 10-12 hours of labor. Pre-2018 TDCi models use a conventional timing belt that is simpler and cheaper to replace.
PowerShift 6DCT450 gearbox issues (if equipped)
€1,200 - 3,0004 of 8
Dual-clutch automatic gearbox can develop clutch slip, mechatronic faults, and jerky shifts · more· less
The S-MAX Mk2 was available with a 6-speed PowerShift (6DCT450) wet-clutch automatic. While more reliable than the smaller dry-clutch DQ200/6DCT250 units that caused Ford's class-action lawsuits, the 6DCT450 still has documented issues. The plastic clutch spring damper guides are a known weak point, transferring all engine torque to the damper springs and eventually fracturing. Solenoid failures occur when gearbox oil is not changed regularly (recommended every 50,000-60,000 km), as debris from clutch and gear wear circulates and blocks solenoids. Symptoms include jerky shifts, banging into gear, transmission warning lights, and hesitation from standstill. Clutch replacement costs €1,200-1,800, while a full rebuild can reach €2,500-3,000. Manual gearbox cars do not have this issue.
Turbocharger failure
€1,200 - 2,5005 of 8
Turbo actuator sticks or turbo internals wear, typically after 150,000 km · more· less
Turbocharger problems can occur on higher-mileage S-MAX models, typically after 150,000-200,000 km. The electronic turbo actuator can stick due to carbon buildup or wear, causing loss of boost and limp mode. Ford does not sell the actuator separately, so a sticking actuator often means full turbo replacement. Specialist repair of the actuator alone costs €200-500, but if the turbo internals are worn, a remanufactured turbo fitted at an independent garage costs €800-1,200, while a new OEM unit at a Ford dealer can reach €2,000-2,500. Using quality engine oil and allowing proper warm-up/cool-down extends turbo life.
Injector seal leaks
€150 - 8006 of 8
Fuel injector seals degrade, causing diesel weeping and carbon buildup around injectors · more· less
The 2.0 TDCi is known for fuel injector seal degradation over time. When the copper washer seals fail, diesel and exhaust gases escape past the seal during compression, creating a sticky black carbon buildup around the injectors sometimes called 'black death' in the diesel community. Early signs include a diesel smell in the engine bay and visible black residue around injector wells. If caught early, replacing the copper washers is a straightforward job costing €150-300. If left unchecked, the carbon buildup can damage the cylinder head seat, requiring machining (€400-800). A frequently repeated claim about a February to September 2019 injector recall does not hold up for this car: the contemporaneous European action was a service action covering Transit, Transit Custom and Ranger, not the S-MAX.
Rear suspension toe link bolt corrosion
€200 - 5007 of 8
Original rear toe link bolts corrode and can fracture, especially in salt-spray regions · more· less
Ford issued recall 20S75 covering S-MAX and Galaxy models built between 2015 and 2020. The rear suspension toe link bolts are prone to excessive corrosion, particularly in countries that use road salt heavily during winter. Over time, the corrosion reduces the bolt's load capacity, potentially leading to fracture. A fractured toe link while driving causes sudden changes in rear wheel alignment and can seriously affect vehicle handling. The recall fix replaces the original bolts with corrosion-resistant alternatives on both sides. Verify the recall has been completed before purchase. If not covered by recall, replacement costs €200-500 at a workshop including alignment.
Dual-mass flywheel and clutch wear (manual)
€800 - 1,6008 of 8
DMF wears faster in the heavy S-MAX body, typically requiring replacement between 120,000-180,000 km · more· less
The S-MAX is a heavy vehicle (1,650-1,800 kg) and the 2.0 TDCi produces strong torque, which accelerates wear on the dual-mass flywheel and clutch assembly compared to lighter models using the same engine. Symptoms of a failing DMF include rattling at idle (especially when warm), vibration during gear changes, and eventual clutch slip. Replacement of both the DMF and clutch together costs €800-1,200 at an independent garage and €1,200-1,600 at a Ford dealer. The job typically takes 4-6 hours. This is more of a wear item than a surprise failure, but the interval is shorter than many owners expect for a diesel engine.
Reasonably reliable, but emissions equipment and timing belt need attention
The Ford S-MAX Mk2 2.0 TDCi is a capable family MPV with an engine that can cover high mileage when properly maintained. The main concerns are common diesel issues (DPF, EGR) plus the wet timing belt on post-2018 EcoBlue models and potential PowerShift gearbox problems on automatic variants. Manual gearbox cars with documented motorway use and regular servicing are the lowest-risk choice. Always verify the rear toe link bolt recall has been completed.
Service history
Complete Ford dealer or specialist records are essential. Verify oil change intervals (maximum 20,000 km or 12 months). Check for gearbox oil changes on PowerShift models.
Tires
Check tread depth, tire age (date codes on sidewall), and uneven wear patterns. Heavier MPV body means tires wear faster on the inside edges if alignment is off.
Cold start
Start the engine completely cold. Listen for any unusual rattling, knocking, or excessive diesel clatter in the first 30 seconds.
Test drive
Drive for minimum 30 minutes including motorway speeds. Monitor for warning lights, unusual vibrations, and power delivery hesitation.
Specific for this vehicle
Check for DPF warning lights during test drive
Drive for at least 20 minutes at various speeds. A DPF warning light or sudden power loss indicates a clogged filter. Ask the owner about typical driving patterns — predominantly short-trip cars are higher risk.
Verify rear toe link bolt recall (20S75) completed
All 2015-2020 models are covered. Contact Ford with the VIN to confirm. Check rear suspension for any signs of excessive corrosion on bolts and links.
Inspect timing belt history (EcoBlue 2018+ models)
If the car has an EcoBlue engine (2018+), check when the wet timing belt was last replaced. If the car exceeds 100,000 km or 6 years without belt replacement, factor in €1,000-2,500 for this service.
+ 3 more checksShow less
Test the automatic gearbox thoroughly (if fitted)
Identify which unit the car has first: pre-2018 TDCi automatics use the six-speed PowerShift, while 2018-on EcoBlue automatics use Ford's eight-speed. Drive for 15+ minutes in stop-and-go traffic. Feel for jerky shifts, hesitation from standstill, or clunking. Check for any transmission warning messages on the dashboard.
Check around fuel injectors for black carbon deposits
Open the engine cover and look around the injector wells for black sticky carbon residue. This indicates failed injector seals that need attention.
Listen for DMF rattle at warm idle (manual models)
With the engine warm, listen for a metallic rattle at idle that changes when you slightly depress or release the clutch. This indicates dual-mass flywheel wear.
Recalls and Technical Service Bulletins
Rear suspension toe link bolt corrosion (2015-2020, recall 20S75)Critical - verify completed
Takata airbag inflator replacement (recall 20S32; Ford France scopes S-MAX II production to January 2014 - March 2017, other countries are VIN-specific)Verify by VIN
Air conditioning clutch pulley (recall 18S23, Safety Gate A12/1331/18, production 1 September 2014 - 20 April 2018)Verify completed
Defective retaining clip on the fuel pressure and temperature sensor, risk of fuel leakage (2.0 Duratorq TDCi, production 31 October 2014 - 31 January 2016)Verify completed
Adaptive LED headlamp software error (2014-2016, if equipped)Verify completed
eCall telematic control unit software update (2019-2021, recall 21C12)Verify completed
Contact a Ford dealer with the VIN to verify all recalls have been completed. The rear toe link bolt recall (20S75) is particularly important for safety, and cars built between 31 October 2014 and 31 January 2016 should have had the fuel sensor retaining clip campaign carried out. Takata scope varies by country, so ask the dealer to check the VIN rather than relying on a model year.
Warranty Status
Factory warranty (2 years)Expired on all used S-MAX Mk2 models
Extended warrantyAvailable through Ford dealers and third-party providers
Rust perforation warranty (12 years)May still apply on 2014-2023 models
All used Ford S-MAX Mk2 models are outside their original 2-year factory warranty. Ford's 12-year rust perforation warranty may still apply on newer examples. Third-party extended warranties are available but check exclusions carefully — PowerShift gearbox and DPF issues are commonly excluded.
Sources: Research draws on model-specific owner forums and owner communities, recall information from official authorities, German automotive press, and multiple workshop cost references cross-checked against each other.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.
