Ford Transit Custom Problems: Common Issues and Repair Costs
The Ford Transit Custom is the UK’s most popular van, used by builders, electricians, couriers and mobile trades every day. It’s reliable, practical and tough. But even the best vans have known faults. This guide explains the most common Ford Transit Custom problems and the typical repair costs you can expect in the UK.
1. AdBlue and Emissions System Faults
Problem:
On Euro 6 models, drivers often see warnings like “AdBlue System Fault” or “Engine Start Inhibited.” The van may even refuse to start if the issue isn’t sorted.
Causes:
- Crystallised AdBlue
- Faulty NOx sensor
- AdBlue injector or tank heater failure
- Blocked pump or pipe
Repair costs:
- NOx sensor: £180 to £250
- AdBlue injector: £150 to £250
- Tank heater or pump: £400 to £600
- Full SCR system repair: £600 to £1,000
Tip: Always refill with clean, quality AdBlue and top it up early. Avoid running it dry.
2. EGR Valve and DPF Blockage
Problem:
Frequent short journeys cause soot to build up, blocking the Diesel Particulate Filter and causing EGR valves to stick.
Symptoms:
- Loss of power
- Warning lights on the dash
- High fuel use
- Regeneration issues
Repair costs:
- Forced DPF regeneration: £120 to £200
- EGR valve replacement: £300 to £450
- DPF sensor: £100 to £150
- New DPF: £800 to £1,200
Tip: Take the van for a 15 to 20 minute drive on a dual carriageway every week to help clear the system.
3. Clutch and Gearbox Problems
Problem:
Clutch slip and poor gear engagement are common on hard-worked vans. Automatics can hesitate or jerk when pulling off.
Causes:
- Worn clutch plate
- Damaged dual-mass flywheel
- Gear linkage wear
- Mechatronic unit failure (autos)
Repair costs:
- Clutch kit and labour: £600 to £900
- Flywheel: £400 to £600
- Manual gearbox repair: £700 to £1,200
- Auto gearbox fault: £1,500 to £2,800
Tip: Don’t overload the van and avoid riding the clutch, especially in traffic.
4. Electrical and Locking Faults
Problem:
Transit Customs often develop electrical issues. Common faults include central locking failures, battery drain and random warning lights.
Causes:
- Broken wiring in door looms
- Faulty actuator
- Water in connectors
- Battery voltage issues
Repair costs:
- Door lock actuator: £120 to £200
- Battery: £100 to £150
- Wiring loom repair: £150 to £400
- Software reset or update: £60 to £100
5. Suspension Wear and Knocking
Problem:
Suspension knocking is common after 50,000 miles, especially if the van carries tools or materials daily.
Causes:
- Anti-roll bar links worn
- Coil springs cracked
- Lower arm bushes perished
Repair costs:
- Anti-roll bar link: £60 to £120
- Coil spring: £120 to £180
- Lower control arm: £150 to £250
- Wheel alignment: £60 to £90
Tip: Check for uneven tyre wear and rattling over speed bumps.
6. Turbo and Boost Problems
Problem:
Lack of power, black smoke or a hissing noise can point to turbo faults or boost leaks.
Causes:
- Split boost pipe
- Sticking actuator
- Worn turbo bearings or vanes
Repair costs:
- Boost pipe replacement: £100 to £200
- Turbo actuator: £250 to £400
- Full turbo replacement: £900 to £1,400
Tip: Let the engine idle for 30 seconds after a long drive to protect the turbo.
Summary of Common Repairs and Costs
| Fault Area | Typical UK Repair Cost |
|---|---|
| AdBlue and emissions system | £150 to £1,000 |
| EGR and DPF problems | £120 to £1,200 |
| Clutch and gearbox issues | £600 to £2,800 |
| Electrical and locking faults | £60 to £400 |
| Suspension and handling | £60 to £250 per corner |
| Turbo and boost system | £100 to £1,400 |
Average Yearly Maintenance Costs
| Service Type | Estimated UK Cost |
|---|---|
| Oil and filter service | £140 to £180 |
| Full service | £250 to £350 |
| Brake pads and discs | £200 to £300 |
| MOT with minor repairs | £60 to £200 |
| Tyres (commercial set of 4) | £350 to £500 |
Tips to Avoid Major Repairs
- Keep AdBlue topped up before the warning shows
- Avoid short trips – give the van a proper run weekly
- Don’t overload the van or tow beyond its limit
- Use trusted garages for gearbox and turbo servicing
- Get electrical faults diagnosed early before they spread
Final Thoughts
The Ford Transit Custom is built to work and can easily go beyond 200,000 miles with care. Most of its issues come from high mileage, heavy use and missed servicing. The key is catching problems early. Emissions systems, clutch wear and electrical faults are the top issues owners face, but with regular maintenance, this van will keep earning its keep.
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