Ford Transit Custom Problems: Buyer's Guide to Known Issues

Ford Transit Custom Common Problems: What to Check Before You Buy

The Ford Transit Custom is, without question, one of the finest medium panel vans ever built in Britain. It's won What Van? Van of the Year so many times the trophy probably has a permanent indent in the shape of that blue oval badge. Plumbers love them. Electricians swear by them. Courier drivers rack up hundreds of thousands of miles in them. And there's a very good reason for all of that. When they're good, they're absolutely brilliant.

But here's the thing. No van is perfect. And the Transit Custom, for all its talents, has a few gremlins lurking under that handsome bonnet that every buyer needs to know about. Especially if you're shopping for a used example with a few years and a fair few miles on the clock.

This isn't about scaring you off. Far from it. This is about making sure you know exactly what to look for, which model years deserve a bit of extra scrutiny, and how to avoid buying someone else's expensive headache. Because nothing ruins your week quite like a dead turbo two months after you've handed over your hard earned cash.

The Early Years: 2012 to 2016

The Transit Custom launched in 2012 and it was a genuine game changer. Ford took everything people loved about the old Transit and wrapped it in a much more car like package. Better to drive, more economical, and with an interior that didn't feel like it belonged in an agricultural vehicle.

But those early models, particularly anything built between 2012 and 2016, came with a few teething troubles that Ford took a while to sort out.

Gearbox Synchroniser Woes

The six speed manual gearbox fitted to early Transit Customs developed a bit of a reputation. Specifically, the synchronisers on second and third gear had a tendency to wear prematurely. You'd notice it as a crunchy, reluctant gear change, particularly when the box was cold. Some owners reported it happening as early as 40,000 miles, which is frankly not good enough for a commercial vehicle.

Ford eventually revised the synchroniser design, and vans built from late 2016 onwards are generally much better. But if you're looking at an early example, get that gearbox warmed up during your test drive and really pay attention to how it shifts. Any notchiness or resistance going into second or third is a red flag. A gearbox rebuild isn't cheap, and you're looking at four figures easily if it needs sorting.

The 2.2 TDCi Engine

The 2.2 litre Duratorq diesel that powered early Transit Customs is fundamentally a solid engine. Ford had been using variants of it for years and it's proven to be pretty reliable in the grand scheme of things. But it's not without its quirks.

Turbocharger failures cropped up on some examples, particularly those that had been thrashed from cold or run on cheap oil. The symptoms are pretty obvious. Excessive smoke, lack of power, and sometimes a rather alarming whistle from under the bonnet. Replacement turbos aren't hideously expensive in the aftermarket, but labour costs add up quickly when you're pulling half the engine apart.

The EGR valve is another known weak point on the 2.2. These can clog up with carbon deposits, especially on vans that spend most of their life doing short urban journeys. A sticky EGR causes rough running, poor fuel economy, and sometimes puts the van into limp mode at the worst possible moment. Cleaning or replacing the EGR is a common job on higher mileage examples.

The EcoBlue Era: 2016 Onwards

In 2016, Ford introduced the new 2.0 litre EcoBlue diesel engine to replace the ageing 2.2. On paper, it was better in every way. More power, better economy, cleaner emissions. And for the most part, it delivered on those promises.

But the EcoBlue brought its own set of challenges, and some of them have proven to be rather expensive.

Turbocharger Issues

The twin turbo setup on higher powered EcoBlue models is a clever piece of engineering. A smaller turbo spools up quickly for low end response, while a larger one takes over higher in the rev range. Sounds great in theory. In practice, some owners have experienced premature turbo failures, particularly on the 170PS and 185PS variants.

The culprit is often oil starvation or contamination. These turbos are incredibly sensitive to oil quality and service intervals. Miss a service or use the wrong oil, and you're basically playing Russian roulette with components that cost well over a thousand pounds to replace. If you're looking at a high powered EcoBlue model, service history isn't just important. It's absolutely essential.

DPF Blockages

Diesel Particulate Filter problems plague pretty much every modern diesel van, and the Transit Custom is no exception. The DPF traps soot particles and periodically burns them off during a regeneration cycle. But if the van spends most of its life doing stop start urban work and never gets a decent motorway run, that regeneration can't complete properly.

The result is a blocked DPF, warning lights on the dash, and potentially a van stuck in limp mode doing 30mph maximum. Some owners have reported needing DPF replacements at surprisingly low mileages when the regen cycle has been repeatedly interrupted.

The fix is fairly simple in theory. Give the van a good Italian tune up on the motorway regularly, let it get properly hot, and allow the regen to complete. But if you're buying a van that's clearly done nothing but city work, check the DPF status carefully before you commit.

Injector Seal Failures

This one's a bit of a horror story that's affected various EcoBlue engines across the Ford range. The copper injector seals can fail, allowing combustion gases to escape past the injector. You'll notice it as a ticking noise from the engine, often accompanied by a diesel smell and sometimes visible soot marks around the injectors.

Left untreated, this causes all sorts of problems including damaged injectors and contaminated oil. The seals themselves are cheap, but accessing the injectors is labour intensive. And if the problem has been ignored, you might be looking at new injectors too, which gets properly expensive.

Electrical Gremlins

Modern vans are packed with electronics, and the Transit Custom has its fair share of electrical oddities. The central locking system has been known to play up, with doors refusing to lock or unlock properly. Sometimes it's a faulty door latch motor, sometimes it's the body control module getting confused.

Parking sensors going haywire is another common complaint. They'll either beep constantly for no reason or stop working altogether. Usually it's a failed sensor rather than anything more sinister, but tracking down which one can be tedious.

The stop start system, while great for fuel economy in theory, causes some owners no end of frustration. Batteries that aren't quite up to the task can cause the system to behave erratically, and replacement AGM batteries are significantly more expensive than conventional ones.

What Model Years Should You Approach With Caution?

If we're being brutally honest, the 2015 and 2016 model years are the ones that deserve the most scrutiny. These vans were built right at the end of the 2.2 era and the very start of the EcoBlue transition. Some of the 2.2 engines from this period had lingering EGR and turbo issues, while early EcoBlue models were essentially real world test beds for the new engine.

That doesn't mean you should avoid them entirely. Plenty of 2015 and 2016 Transit Customs are still going strong with astronomical mileages. But you need to be extra careful with your pre purchase inspection and absolutely insist on full service history.

Vans from 2018 onwards, particularly post facelift models, tend to be much more sorted. Ford had ironed out most of the early EcoBlue issues by then, and build quality improved noticeably.

Your Pre Purchase Inspection Checklist

Before you hand over any money for a used Transit Custom, you need to check a few things properly. And ideally, get an independent inspection done by someone who knows these vans inside out.

Start with a thorough test drive. Get the engine up to temperature and pay attention to how it runs. Any hesitation, rough idle, or excessive smoke needs investigating. Check that gearbox carefully. Every gear, up and down, multiple times. Listen for any turbo whistle or whine that sounds out of the ordinary.

Look at the service history like your wallet depends on it. Because it does. These vans need servicing on time, every time, with the correct oil. Any gaps or sketchy looking stamps should make you very nervous indeed.

Check the DPF status if you can. Many diagnostic tools can show you the soot loading percentage and regeneration history. A DPF that's showing 80 percent plus loading is a problem waiting to happen.

Inspect the injector area for any signs of soot or diesel leakage. Pop the bonnet and have a good look around the top of the engine. Black marks around the injectors are a telltale sign of seal failure.

And obviously, check all the electrical systems. Every door, every window, every sensor. Central locking should be crisp and immediate. Parking sensors should work without throwing random phantom alerts.

Running Costs and Service Intervals

A well maintained Transit Custom shouldn't break the bank to run. Ford recommends servicing every 25,000 miles or two years, whichever comes first. For a hard working van, you might want to halve that interval, particularly on higher mileage examples.

A basic service at an independent garage will run you around £150 to £250 depending on where you are in the country. Main dealer prices are predictably higher. Budget for a major service every other time, which includes filters, brake fluid, and various other bits that adds another hundred or so.

If you're browsing Ford Transit Custom for sale listings, factor these costs into your budget. A van that's been serviced religiously will almost always be worth paying a bit more for upfront.

Timing belts on the 2.0 EcoBlue need doing at 125,000 miles or ten years. That's a £400 to £600 job depending on who does it. The older 2.2 uses a chain, which is theoretically lifetime but can stretch on very high mileage examples.

The Verdict

The Ford Transit Custom remains one of the best medium vans you can buy. Its driving dynamics embarrass most of the competition, residual values are strong, and parts availability is excellent. But like any popular vehicle, there are known issues you need to be aware of.

Do your homework. Insist on service history. Get a proper inspection done. And don't be afraid to walk away from a van that doesn't feel right. There are plenty of good Transit Customs out there. You just need to find one that's been looked after properly.

For more detailed specifications and official technical information, the Ford Transit Custom page has comprehensive details on current and recent models.