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2011 Ford Flex Recalls, Issues & Maintenance

The 2011 Ford Flex carries 2 open NHTSA recalls — most recently covering electric power assist system and frontal. Owners report 6 recurring issue clusters, led by “Water pump failure causing engine damage.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

2 Open Recalls

Source: NHTSA

STEERING:ELECTRIC POWER ASSIST SYSTEM

Campaign #15V340000 · Feb 6, 2015

Issue: Ford Motor Company (Ford) is recalling certain model year 2011-2012 Ford Fusion vehicles without a 3.5L engine and Lincoln MKZ hybrid electric vehicles, 2011 Mercury Milan vehicles, 2011-2012 Ford Taurus, Ford Flex, Lincoln MKS, and Lincoln MKT vehicles equipped with a 3.5L GTDI engine and 2013 Ford Taurus, Ford Flex, Lincoln MKS, and Lincoln MKT vehicles equipped with any available engine. The affected vehicles have electric power steering assist systems that may shut down as a result of a steering motor sensor fault.

Risk: If the vehicle experiences a loss of power steering assist, extra steering effort will be required at lower speeds, increasing the risk of a vehicle crash.

Fix: Ford will notify owners, and dealers will check the Power Steering Control Module (PSCM) for Diagnostic Trouble Codes (DTC). If dealers find any loss of steering assist DTCs, the steering gear will be replaced, free of charge. If, no codes are found during the PSCM inspection, the PSCM software will be updated, free of charge. The recall began on July 21, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S18.

AIR BAGS:FRONTAL

Campaign #16V247000 · Apr 26, 2016

Issue: Ford Motor Company (Ford) is recalling certain model year 2009-2012 Ford Flex, 2008 and 2010-2012 Ford Taurus, 2008-2009 Ford Taurus X, 2008 Mercury Sable, 2009 and 2011 Lincoln MKS vehicles. The driver frontal air bag may improperly inflate during second-stage deployment in the event of a high speed crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection."

Risk: An improperly inflated air bag increases the risk of injury in the event of a crash.

Fix: Ford will notify owners, and dealers will inspect and replace the driver's frontal air bag module, as necessary, free of charge. The recall is expected to begin on June 13, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16C06.

Recall data refreshed Sep 13, 2026.

Known issues for this vehicle

What drivers and federal regulators have officially reported about the 2011 Ford Flex.

Reported to NHTSA

Water pump failure causing engine damage

ENGINE

12 NHTSA complaints · 2016-06 → 2023-01

“WATER PUMP FAILURE LED TO TOTAL ENGINE LOSS. REPORTED ON MULTIPLE FORD VEHICLES”
— Owner report, NHTSA ODI #11256632
“TL* THE CONTACT OWNS A 2011 FORD FLEX. THE CONTACT CALLED ON BEHALF OF HER SON. THE CONTACT STATED THAT THE WATER PUMP ON THE VEHICLE FAILED. THE CONTACT STATED THAT HER SON CALLED AN UNKNOWN FORD DEALER AND INFORMED THEM OF THE FAILURE”
— Owner report, NHTSA ODI #11365168
“MY 2011 FORD FLEX 3.5L ENGINE HAS HAD CADASTROFIC FAILED DUE TO PREMATURE FAILURE OF THE INTERNAL CHAIN DRIVEN WATERPUMP”
— Owner report, NHTSA ODI #11203371

Read all complaints on NHTSA →

Second-row power-fold seat entrapment hazard

SEATS

7 NHTSA complaints · 2011-01 → 2020-06

“TL* THE CONTACT OWNS A 2011 FORD FLEX. THE CONTACT STATED THAT THE VEHICLE WAS PARKED WHEN ONE OF HER CHILDREN ACCIDENTALLY PRESSED THE BUTTON TO AUTOMATICALLY FOLD DOWN THE THIRD ROW PASSENGER SEAT”
— Owner report, NHTSA ODI #10427606
“MIDDLE ROW SEATING. SEAT IS DESIGNED TO FLIP FORWARD TO LET 3RD ROW PASSENGERS EXIT. HOWEVER, SEAT MALFUNCTIONS AND LOCKS IN THE FULL UPRIGHT POSITION THUS TRAPPING POTENTIAL 3RD ROW OCCUPANTS”
— Owner report, NHTSA ODI #10872048
“TL* THE CONTACT OWNS A 2011 FORD FLEX. THE CONTACT STATED THAT THE SECOND-ROW DRIVER'S SIDE SEAT RELEASE HANDLE WAS INOPERABLE. THE CONTACT STATED THAT THE SECOND-ROW SEAT FAILED TO MOVE FORWARD WHICH MADE THIRD-ROW PASSENGER'S UNABLE TO EXIT THE VEHICLE”
— Owner report, NHTSA ODI #11328286

Read all complaints on NHTSA →

Premature tire wear and sidewall failure

TIRES

5 NHTSA complaints · 2011-05 → 2018-08

“VEHICLE CONTINUES TO WEAR OUT BRAND NEW TIRES EVERY 5 TO 10K MILES. I HAVE KEPT UP ON ALIGNMENT, TIRE ROTATING AND TERMS THIS PROBLEM CONTINUE”
— Owner report, NHTSA ODI #10806611
“TL* THE CONTACT OWNS A 2011 FORD FLEX EQUIPPED WITH HANKOOK OPTIMO H426 TIRES, SIZE: 255/45R20. WHILE DRIVING 65 MPH, THE CONTACT HEARD A HUMMING NOISE COMING FROM THE FRONT DRIVER AND PASSENGER TIRES. THE CONTACT NOTICED THAT BOTH TIRES BEGAN TO SHRED”
— Owner report, NHTSA ODI #11122733
“HANKOOK OPTIMA 19" TIRE SIDEWALL FOR FORD FLEX. I PURCHASE A BRAND NEW 2011 FORD FLEX ON 5/5/11 WITH 19" HANKOOK OPTIMA TIRES”
— Owner report, NHTSA ODI #10402075

Read all complaints on NHTSA →

Electric power steering assist failure

STEERING

55 NHTSA complaints · 2010-10 → 2025-08

“The contact owns a 2011 Ford Flex. The contact stated that on several occasions while attempting to start the vehicle, the power steering assist warning light illuminated, and the steering wheel became firm”
— Owner report, NHTSA ODI #11681381
“POWER STEERING FAILURE MESSAGE APPEARED IN MESSAGE CENTER WHILE DRIVING ON A CITY STREET, POWER STEERING IMMEDIATELY FAILED. THIS MADE STEERING NEARLY IMPOSSIBLE. MADE IT TO A PARKING LOT, WAITED A FEW MINUTES AND STARTED THE VEHICLE”
— Owner report, NHTSA ODI #11074172
“WHILE DRIVING MY POWER STEERING LOSES POWER. TOOK IT TO MECHANIC WHO TOLD ME IT HAD TO DO WITH ELECTRIC POWER STEERING. I LOOKED IT UP AND MY CAR ISNT COVERED IN THE RECALL”
— Owner report, NHTSA ODI #11209800

Read all complaints on NHTSA →

Transmission hesitation, lurch and PTU failure

POWER TRAIN

13 NHTSA complaints · 2011-03 → 2026-04

“MY VEHICLE WILL ACT AS IF IT IS IN NEUTRAL WHEN I PULL AWAY FROM A STOP. THE ENGINE REVS WITH NO FORWARD MOVEMENT THEN THE TRANSMISSION "BANGS" INTO GEAR AND THE VEHICLE PROCEEDS. THE HESITATION COULD CAUSE AN ACCIDENT”
— Owner report, NHTSA ODI #10395999
“AFTER SEVERAL VISITS TO THE DEALER, BEGINNING AT 52K IN APRIL 2014 COMPLAINING OF A BURNING OIL SMELL AFTER HIGHWAY DRIVING, THE DEALER DIAGNOSED THE PROBLEM TO BE A FAILED PTU/PTO AND NEEDING REPLACEMENT FOR $1800 AFTER I EXCEEDED 75K MILES”
— Owner report, NHTSA ODI #10819879
“Went to put car in reverse and it kept driving forward- no weird sound or anything. Proceeded to put the car in park and it was still moving forward. Transmission was stuck on drive”
— Owner report, NHTSA ODI #11734241

Read all complaints on NHTSA →

Brake caliper and rotor failure

SERVICE BRAKES

4 NHTSA complaints · 2013-08 → 2014-11

“PERSISTENT BRAKE SQUEALING EVEN THOUGH BRAKES WERE REGULARLY SERVICED. ON FURTHER INSPECTION, IT WAS DISCOVERED THAT A FRONT BRAKE CALIPER WAS CRACKED AND LEAKING. HAD TO BE REPLACED”
— Owner report, NHTSA ODI #10572908
“ON MY WAY HOME FROM WORK 7-14-2014, ENTERED THE EXIT RAMP TO GRATIOT NORTH BOUND AND HAD TO STOP FOR A LIGHT. WHEN THE LIGHT CHANGED GREEN I EASED OFF OF MY REAR BRAKES AND HEARD A LOUD NOISE COMING FROM THEM AND COULD TELL THAT THE BRAKES WERE SEIZING UP A LITTLE”
— Owner report, NHTSA ODI #10616380
“CPSC: I1380138A. 2011 FORD FLEX. CONSUMER STATED THAT THE CHEMICALS USED TO MELT ICE AND SNOW CAUSES BRAKES ROTORS TO ROT. STATED AT 23,000 MILES HIS REAR BRAKES HAD TO BE REPLACED”
— Owner report, NHTSA ODI #10537648

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 13, 2026. Investigation data refreshed Sep 13, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

F-150 4x4 and Bronco 4x4: replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

23 crashes 2010–2024

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

5

complaints mentioning a crash

1

complaints mentioning a fire

Reviewed known issues for this vehicle·Open recalls for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2011 Ford Flex reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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