Ford Flex - Known Issues / Defects

List last updated January 18,2010

For more information, search in the Ford Flex forums. We have linked each issue to a corresponding forum discussion thread where appropriate.

Ford Flex Issues

In no particular order, here are a list of known Flex issues experienced by our members. If you have experienced any of these issues, please tell us about it in the Ford Flex forum. Typically we don't list issues here unless there has been more than one (1) report.

Broken front console latch
Panel gaps not consistent and/or larger than expected
Brake "grinding" noise - See TSB #09-13-3 which basically says that on Flexes built before May 26/09 to resolve, replace the front brake pads, apply grease to the backing plates, and resurface the rotors. The updated Brake Kit part number is AG1Z-2001-C. UPDATE: This TSB was updated on September 9,2009, so be sure the dealer is using the new TSB
Flex Died While Driving Down the Road - Reflashing the PCM fixes this most of the time. No known TSB number as of yet
Slight pulsation in brake pedal when brakes applied - typical fix is for dealer to resurface the front brake rotors
Air conditioning gets less cold, then not cold at all (see also: this thread) - Fix likely is to replace the O-ring at the A/C compressor and recharge the refrigerant
Uncomfortable steering wheel position - Fix is basically to buy a 2010 model with tilt & telescopic wheel (sorry!)
Large (uncomfortable) front headrests - A common complaint, some owners are fixing this by replacing the headrests with those from the Taurus X
Leaking Vista Roof
Squeaks from DVD headliner area
Power door lock not working - There is a TSB regarding this, it has to do with the lock rod not being seated correctly in the door grommets. TSB #09-01-03
Interior rattles - Various, could be loose clip in headliner, etc.
Transmission clunk (low-speed) or harsh 1-2 shift - There is a TSB #09-2-7, fix is to reflash the PCM. For vehicles built before December 12/08 (early, early 2009 Flex models)
Wheel bearing failure - issue: low "hum" coming from the vehicle, really noticeable @ 40 MPH, fix: replace wheel bearing (mine was left rear), voila, no more humming.
USB - No Audio but shows tracks - First try unplugging and plugging the device back in. If the problem persists, see the dealer, or you could also try pulling fuse #14 for 30+ seconds, that may help.
Too much road noise through microphone (2009 Sync models) - Fix is TSB #09-13-5. Fix is to replace the microphone (Sync Microphone Service Kit)
Power Mirror (passenger side) not keeping memory preset - current fix is to manually put passenger side mirror back to proper spot.
Outside pillar trim loose, falling off or dimpled. Dealer will fix these for you, sometimes the pieces just aren't "clicked" in all the way.
Radiator springs a leak - You'll notice A/C gets hot, temp guage goes to red, and then into "limp home" mode
The plastic plate behind the door handles is loose / falls out
Leaky PTU Seal (Power Transfer Unit) AWD models - Fix is TSB #09-08-10, replacement of the PTU seal. Owners will notice a funny smell, but no visible leaks on the ground underneath the Flex. The reason being is the fluid that leaks is burned on the exhaust pipe, also affects Ford Edge models.
Remote Start Shuts down when door is opened