Ford Transit 1995 - 1998

Problem: The blower motor does not function on fan settings 1 or 2.

Solution: A common problem is the blower motor resistor contacts corroding and/or a damaged resistor. The solution is to fit a new blower motor resistor and wiring loom. Since 09/1998, the blower motor resistor has been fitted in a different position.

Ford Transit (rear-wheel drive) 2.4 Di upto 2002

Problem: Repeated premature clutch failure and possible damaged dual mass flywheel.

Solution: A revised final drive ratio (5.13) rear axle should be fitted. This will reduce the top speed of the vehicle, but will aid in situations such as a steep hill with full load, preventing repeat clutch failure.

Ford Transit

Problem: Premature discharged battery.

Solution: Additional electrical consumers can cause the battery to go flat, such as parking heating. Additional batteries are fitted as an option and in this case should be so if the battery is repeatedly going flat. This can be fitted under the driver's seat with an additional double battery cable.

Ford Transit with LPG fuel system

Problem: Engine missfire and loss of power.

Solution: A common problem is the breakdown of the ignition coils. This could be a result of incorrect spark plug gaps. This is due to the fact that LPG fuel systems require a higher voltage to create the spark due to the combustability nature of LPG. The solution is to fit revised spark plugs, ignition coils and HT leads. The ECM  and alternative fuel control module should also be re-calibrated.

Ford Tourneo Connect upto 2003

Problem: Random failure of the windscreen wipers.

Solution: A common problem is a faulty park position inside the wiper motor. A revised wiper motor should be fitted.

Ford Transit Tourneo upto 2003

Problem: Water ingress into vehicle.

Solution: There a few known problems:

A) Insufficient sealant applied between outer apron panel reinforcement and A-pillar may lead to water ingress in the footwell. Extra sealant should be applied.

B) Water entry due to excessive gap between the pollen filter housing and cowl panel can be rectified by applying extra sealant.

C) Water entering through the rubber seals of the back doors. This can be caused by incorrect adjustment of the door stop, a faulty cover plug or incorrectly installed rubber seal. These should all be inspected and rectified if necessary.

D) Water ingress from roof rack cover plugs. This can often be due to a damaged or missing plug seal. Remove the cover plug and check seal.

E) Ingress around the C-pillar of sliding door. This can be due to insufficient sealant between bodywork components. The area should be examined and additional sealant applied from the inside if needs be.

Ford Transit 2000 onwards without power steering cooler

Problem: Knocking noise when steering is nearing full lock.

Solution: The noise can be more apparent on rough road surfaces. The probable cause is resonance from the power steering fluid. To fix this specific problem a power steering fluid cooler and revised hoses should be fitted.

Ford Transit 2000 - 2003 front wheel drive manual gearbox VXT-75

Problem: The gear lever is very difficult to move.

Solution: A common problem is water ingress causing the upper bearing of the selector mechanism to become corroded. A dislodged vent hose or damaged seal for the upper bearing is the problem. A revised inner selector mechanism and revised transmission vent hose (made of ozone resistant material) should be fitted.

Ford Transit 2.0 2.4 Duratorq

Problem: The starter motor fails to engage especially in cold weather.

Solution: The probable cause is condensation in the starter motor, causing it not to engage. The condensation will freeze preventing current flow. A new starter motor with revised solenoid should be fitted. The revised starter motor has been fitted since 08/2003.

Ford Transit & Tourneo 2002 - 2003

Problem: The rear right hand door can no longer be opened.

Solution: The problem is most likely the door handle to unlatching rod coming loose. The solution is to fit a revised clip with a two sided retaining pin. The revised connection on the unlatching rod has been used since 05/2003.

Ford Transit 2002 - 2003 LPG

Problem: Erratic fuel gauge readings for LPG vehicles.

Solution: The probable cause is the LPG fuel gauge being wired to the fuel pump relay. This causes problems as the fuel pump relay will go through a cycle to prime the fuel rail. This will cause a brief break in the circuit. As the fuel gauge needs a constant voltage to function, the break in circuit will cause the gauge fluctuations. The solution is to rework the wiring to give the anti-slosh connector behind the instrument cluster a constant voltage.

Ford Transit front wheel drive bus

Problem: Knocking noise from area above fuel tank.

Solution: The problem could be fuel impacting on the fuel tank being transmitted through the floorplan. This could be especailly apparent during braking. The solution is to fit special noise vibration and harshness (NVH) pads around the fuel tank and floorpan area.

Ford Transit & Tourneo 2002 - 2003

Problem: When using the central locking (with key or remote), the sliding door does not lock or unlock.

Solution: A common problem is a failed door lock actuator. A revised lock actuator should be installed so it can function correctly with the central locking on the vehicle. The door contact switch should also be examined for damage along with the relevant wiring harnesses.

Ford Transit 2000 - 2002 FWD

Problem: Difficult to change gears.

Solution: The gearshift cables on these year Transits suffer from damage. Revised and modified gearshift cables should be fitted. Revised gearshift cables have been fitted since 08/2002.

Ford Transit 2000 to 2002

Problem: Fuses 3, 7, 9, 23, 24 in engine bay and fuses 49 and 51 in the passanger bay fuse box keep blowing.

Solution: These year Transits tend to suffer from damage to the wiring harness in the left-hand side member area. Remove the left-hand headlamp and check the wiring. The wiring should be repaired / replaced as necessary. Since 04/2002 an extra protective sleeve has been installed around the wiring harness for improved protection.

Ford Transit 2.0 Di 2001

Problem: Engine noises at idle and slipping clutch.

Solution: Due to the effects of heat, there is insufficient damping of engine vibrations by the dual mass flywheel. The solution is to fit a new clutch with conventional flywheel and fit a revised crankshaft pulley. A conventional flywheel has been fitted in production since 12/2001.

Ford Transit 2000 - 2001

Problem: Water in the front fog lamps.

Solution: Water or moisture may accumulate in the fog lamps due to inadequate drain holes. The solution is to fit revsied fog lamp boots that have extra drain holes. These have been fitted since 01/2002

Ford Transit 2000 - 2001 2.0 2.4 Di

Problem: Engine running problems, lack of power and / or failure to start.

Solution: The Transit with the 2.0 and 2.4 DuroTorq Di diesel engines suffer from a failing Bosch injection pump. The cam plate fails in the Bosch VP30 fuel injection pump. The solution is to fit a revised and modified injection pump. The fuel system should be thoroughly cleaned and checked for any metal particles in the fuel system. The revised injection pump has been installed since 12/2001.

Ford Transit LWB with dual rear wheels

Problem: Brake judder at high speeds.

Solution: The most likely cause is incorrectly manufactured wheel rims that have mounting surfaces that are not flush which cause the brake drums to become oval. The solution is to fit new wheel rims (part number VYC15-GA) that have been manufactured with machined mouting surfaces and new brake drums should be installed. The revised rims have been fitted since 07/2002.

Ford Transit 2000 - 2001

Problem: Booster heater no longer works or is noisey.

Solution: A common problem is moisture entering into the bearing of the lower motor through the booster heater intake hose. The solution is install a new blower motor, a revised housing and a modified intake hose for the blower motor. The intake hose will be located in a different position. The revised housing together with a splash shield has been fitted since 12/2001.

Ford Transit 2000 build code YG

Problem: Front brake metallic noises.

Solution: The probable cause is the vanes interacting with the brake pad and creating a low frequency matallic noise. The solution is to fit revised front brake pads.

Ford Transit 2000

Problem: Knocking noises from the power steering at low speeds.

Solution: The probable cause is a filter spigot in the power steering fluid reservoir that has broken off. The solution is to fit a revised power steering reservoir. A revised power steering pressure line may also need to be fitted. A revised reservoir has been fitted since 05/2000.

Ford Transit 2000 - 2001 with double rear doors

Problem: Central locking and rear heated window no longer work.

Solution: A common problem is a lack of flexibility in the protective sleeve of the rear door wiring harness. The solution is to fit a revised wiring harness with additional reinforced protective sleeving. The revised wiring harness has been fitted since 04/2001.

Ford Transit 2000 on 2.4 Di

Problem: Indicator signal lamps do not work or flash too quickly.

Solution: A common problem is an incorrect bulb is fitted. Another common failure is an incorrectly programmed turn signal relay. These problems should be addressed in order. Revised turn siganl relays have been fitted since 2001.

Ford Transit Bus 2000

Problem: Odd smell in vehicle.

Solution: The problem could be rear axle ventilation gases entering the vehicle. The solution is to replace and re-route the rear axle ventilation hose into a side member. A revised vent hose has been fitted since 02/2000.

Ford Transit 2.5 Di 1991 on

Problem: Oil leaks around the turbocharger.

Solution: Two of the most common oil leaks will occur at the charge air clamps and hose leaks. The first problem requires installing new clamps and torquing to 2.5 - 3.5 Nm. Leaking hoses need to be replaced with new revised viton lined hoses.

Ford Transit 2000 to 2001

The tightening torques for steel and alloy wheels have been increased from 185 to 200 Nm.

Ford Transit

Problem: When accelerating or changing gear, excessive black smoke is produced.

Solution: The causes could be any number of engine components. Follow these procedures to cure the problem:

1. Check the engine for any concerns, paying particular attention to the air intake and exhaust systems.

2. Road test the vehicle for smoke, re-creating the conditions under which smoking occurs.

3. To confirm the severity of the problem, do a smoke/emissions test and retain the printout.

4. Black smoke indicates a lack of air, high fuelling or excessive EGR.

5. Assess the engine hot idle quality. Idle should be regular with no misfire and no hesitation on blipping the accelerator.

6. Use a diagnostic scanner to check for fault codes and record any shown.

7. Inspect the air cleaner element and replace it if it's contaminated with oil, dirt or water.

8. Check the components of the EGR system in the following sequence:

9. Throttle body camplate/roller mechanism.

- Replace the roller if it is worn or sticking.
- Clean the camplate and roller with an approved degreasing agent.

10. Vacuum hoses.

- Vacuum hoses should be checked for their general condition. Ensure that they are all secure and that they are correctly routed. Clean/replace as necessary.

11. Throttle body link rod.

- Using a 20mm spacer and peg, check the adjustment of the camplate link rod.

12. Throttle body operation.

- Using a hand operated vacuum pump, check the operation of the throttle body. The vacuum should not decay within 30secs.
- The throttle plate should move freely.
- Remove the throttle body and clean the internal throttle plate with an approved degreasing agent if a leaking vacuum or any sticking/binding are evident. Remove all residues before assembly.

13.Breather oil separator.

- Remove the engine breather oil separator and inspect it for oil emulsification. If some is present, clean with an approved cleaning agent.
- This could indicate head gasket failure, if the vehicle is not predominantly used on short journies, or frequently started from cold.

14. Remove the EGR valve.

- Operate the EGR valve with a hand operated vacuum pump to check it. The vacuum pump should not decay within 30secs.
- Replace the EGR valve if it fails to: Open / Retain vacuum / Close once vacuum is released.

15. Check the fuel pump timing.

16. Fuel filter element should be checked.

- If it is contaminated with water or dirt replace it.

17. Fuel line connectors should be checked.

- Check for air leaks at lift pump.

18.Check fuel pressure.

- With the pressure gauge, measure the fuel pressure between the filter and the fuel injection pump. The pressure should be between 0.1 and 0.3 bar.

19. Remove fuel injectors.

- Once removed, check the function of the injectors using appropriate testing equipment and replace any injector which is not performing correctly.

20. Engine compression.

- Do an engine compression check. If the compression is less than 33.8 bars, or if the variation between cylinders exceeds 2.07 bars, rectify as necessary.

21. Inlet manifold.

- Should be checked for excessive carbon build up. If the carbon build up is less than 3 mm, omit step 22.

22. Remove the cylinder head and de-coke the inlet ports if carbon build up exceeds 3mm.

23. Valve gaps.

- Check the valve gaps and reset if not to specification. Also check for corrosion.

24. Rocker cover.

- Check for the presence of water or excess oil.
- Check rocker pedestal bolts.

25. When rebuilding the engine, correct any faults from the initial checks.

26. To confirm whether the problem has improved, repeat the road and smoke tests. If the performance is at an acceptable level no further action is needed.

27. If the vehicle is still showing signs of excessive black smoke emissions, remove the fuel injection pump, check the fuel settings and timings and rectify as required.

Ford Transit 1997

Problem: Misfiring and intermittent reduction in performance.

Solution: Probably caused by air ingress to the high pressure fuel lines, from the leak off rail. Re-route the leak-off return tube to make sure that a puddle of fuel is maintained in the leak-off tubes, so that any air present is purged from the No. 1 injector to the fuel tank.

Ford Transit 1997

Problem: The correct combination of injectors and fuel injection pump must be fitted.

Solution: As a result of the need to install later level fuel injection pumps and injectors, the correct combination of these parts must be installed when repairing or renewing them to prevent lack of power or excessive exhaust smoke.

Ford Transit 1995

Problem: Indicators inoperative

Solution: May be caused by a damaged indicator switch multiplug. To rectify this, repair the indicator switch multiplug using solder/crimp connectors.

Ford Transit 1993 to 1998

Problem: Poor driveability while cornering after severe rear wheel spin on slippery surfaces.

Solution: High differential forces may have caused the surface lubrication film to breakdown at the differential pinion shaft. Install a revised differential assembly to solve this problem.

Ford Transit 1995

Problem: Water trap warning light coming on and/or Fuse 7 blowing.

Solution: The water trap wiring loom may be chafing on the starter motor brush connection terminal. Repair any damaged wiring and secure the water trap cable to the main loom to solve this problem.

Ford Transit 1997

Problem: No diagnostic scanner communication.

Solution: On this vehicle there is no sinal ground available on the Data Link Connector (DLC II) at pin 5 but this can be rectified by attaching a ground cable between the connector and the earth.