2012 Ford Flex Recalls, Issues & Maintenance

The 2012 Ford Flex carries 2 open NHTSA recalls — most recently covering frontal and electric power assist system. Owners report 8 recurring issue clusters, led by “Power steering assist failure.” 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

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.

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.

Recall data refreshed Sep 13, 2026.

Known issues for this vehicle

What drivers and federal regulators have officially reported about the 2012 Ford Flex.

Reported to NHTSA

Power steering assist failure

STEERING

23 NHTSA complaints · 2014-08 → 2025-12

The contact owns a 2012 Ford Flex. The contact stated while the vehicle was parked, the vehicle intermittently became difficult to maneuver. The failure occurred on several occasions, including while the contact was driving
Owner report, NHTSA ODI #11645654
Vehicle power steering will stop working while driving and notification of (power steering assist failure) will appear. Vehicle becomes extremely unsafe to operate as the steering wheel is very difficult to move
Owner report, NHTSA ODI #11524479
POWER STEERING ASSIST FAILS; DRIVING AND THE POWER STEERING STOPS WORKING, SOMETIMES UNEXPECTEDLY. VERY DANGEROUS! IT IS SPORADIC--SOMETIMES IT WORKS AND OTHER TIMES IT DOES NOT WORK
Owner report, NHTSA ODI #11022692

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Power transfer unit fluid leak

POWER TRAIN

3 NHTSA complaints · 2017-02 → 2020-02

2012 FORD FLEX LI HAS 70K THOUSAND MILES. WHILE DRIVING, VEHICLE STARTED TO HUM. SUDDENLY CAR STARTS TO SHAKE AND GRINDING NOISES COMING FROM CENTER OF VEHICLE AND VEHICLE BECOMES DISABLED IN MID-STREAM DRIVING. VEHICLE SMELLS OF BURNT TRANSMISSION OIL
Owner report, NHTSA ODI #11311999
HAVE A 2012 FORD FLEX WITH 72XXX MILES THATS LEAKING FLUID FROM THE PTU (POWERTAKE OFF UNIT). LEARNED THAT FORD HAS THIS PROBLEM IN MANY VEHICLES FLEX,EDGE, MTX
Owner report, NHTSA ODI #10954357
THE FRONT AWD MECHANISM (BETWEEN THE FRONT WHEELS - PTU????) IS LEAKING AND THE OIL HAS SHAVINGS AND "DIFFERENT COLORS" IN THE FLUID
Owner report, NHTSA ODI #11112726

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Water pump failure

UNKNOWN OR OTHER

2 NHTSA complaints · 2021-10 → 2022-04

Bad design of water pump , under parts would fail one day , but the water pump is a bad design. It failed too soon and hurt the engine
Owner report, NHTSA ODI #11462538
The water pump has faliure and is causing expensive repair. It seems to be a know defect. We some pending law suits
Owner report, NHTSA ODI #11435176

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Rear suspension toe link failure

SUSPENSION

3 NHTSA complaints · 2021-04 → 2024-05

I was driving around 55 and suddenly lost control and fish tailed to the right, then to the left over the center line, then back to the right. Luckily no other vehicles on the road. The rear driver side toe link broke
Owner report, NHTSA ODI #11588893
I own a 2012 Ford Flex. It was not included in this recall. The recall included Ford Flex years 2013 through 2018
Owner report, NHTSA ODI #11443458
MY VEHICLE WAS MANUFACTURED JUST A FEW MONTHS SHY OF A RECALL FOR BAD TOE LINKS IN THIS MAKE AND MODEL. I HAVE HAD MY CAR DIAGNOSED WITH HAVING BAD TOE LINKS AND WOULD LIKE TO SEE ABOUT GETTING MY VEHICLE INCLUDED IN THE RECALL SINCE IT WAS MANUFACTURED AROUND THE SAME TIME AS
Owner report, NHTSA ODI #11407044

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Brake caliper seizing and rotor damage

SERVICE BRAKES

4 NHTSA complaints · 2013-06 → 2016-09

BOTH RIGHT AND LEFT FRONT BRAKE CALIPERS STUCK SIMULTANEOUSLY. THE VEHICLE WAS IN MOTION, GOING DOWN A RESIDENTIAL ROAD, WHEN THERE WAS A THUMP FROM THE DRIVERS SIDE (FRONT) WHEEL. IT SOUNDED LIKE THE BRAKE PADS WANTED TO FALL OUT
Owner report, NHTSA ODI #10904271
MY FORD FLEX HAS A TOTAL OF 82000 MILES ON IT. I LIVE IN UPSTATE NEW YORK. I HAVE HAD THREE INSTANCES WHERE THE REAR BRAKE CALIPERS STICK AND SEVERELY REQUIRE BOTH PAD AND ROTOR REPLACEMENT
Owner report, NHTSA ODI #10850521
WHILE DRIVING AT HIGHWAY SPEED THERE WAS A SUDDEN METAL ON METAL SOUND. SHORTLY AFTER THIS NOISE STARTED THERE WAS A BURNING SMELL AND THEN VISIBLE SMOKE FROM THE WHEEL
Owner report, NHTSA ODI #10744806

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Throttle body failure causing engine stall

ENGINE

7 NHTSA complaints · 2012-10 → 2020-09

BAD THROTTLE BODY. STALL WHEN DRIVING AND JERKY MOTION, BOTH WHEN GOING SLOW AND WHEN GOING HIGHWAY SPEEDS. RED WRENCH LIGHT COMES ON, PULL TO SIDE OF ROAD SHUT OFF AND TURN BACK ON AND DRIVES FINE UNTIL THE NEXT TIME
Owner report, NHTSA ODI #11277966
MY 2012 NEW FORD FLEX HAD COMPLETE ENGINE FAILURE 3 TIMES 1-27 DRIVING..COMPLETE SHUT DOWN. I CRUISED TO CURB. RESTARTED QUICKLY 2-01 SAME INCIDENT 2-02 REPEAT ON MAJOR STREET DEALERS HAVE SAID THAT THEY HAVE NO IDEA WHAT TO DO
Owner report, NHTSA ODI #10500705
VEHICLE WAS UNABLE TO MAINTAIN OR INCREASE ENGINE POWER: PRESSING DOWN THE THROTTLE HAD NO EFFECT. FIRST I THOUGHT THE ENGINE HAD STALLED. AFTER A FEW MOMENTS THE ENGINE DID FUNCTION AGAIN
Owner report, NHTSA ODI #10566570

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Electrical system malfunctions (dash, lights, sensors)

ELECTRICAL SYSTEM

7 NHTSA complaints · 2014-07 → 2017-06

TRAVELING ON INTERSTATE HIGHWAY IN RAIN STORM, MID MORNING, WINDSHIELD WIPERS ON, INSTRUMENT PANEL LIGHTS AND HEADLIGHTS SHUT OFF. PULLED OFF HIGHWAY AND SET HEADLIGHT CONTROL TO ALL FOUR POSITIONS AND ALL LIGHTS REMAINED OFF REGARDLESS OF CONTROL POSITION
Owner report, NHTSA ODI #10758660
DRIVING UP AN ON RAMP TO AN INTERSTATE, SUDDENLY ALL THE LIGHTS STARTED FLASHING ON THE DASHBOARD DISPLAY. I COULD NOT SEE ANY SPEED OR DRIVING INFORMATION. I PULLED OVER TO THE SIDE OF THE ROAD TURNED OFF THE VEHICLE AND IT WOULD NOT RESTART
Owner report, NHTSA ODI #10993774
THE RIGHT REAR DOOR SENSOR SAYS THAT THE DOOR IS OPEN WHEN IT IS NOT. TRIED TO CLOSE IT A FEW TIMES BUT THAT DIDN'T WORK. NOW I CAN'T LOCK MY CAR AT NIGHT BECAUSE MY CAR ALARM WILL GO OFF THINKING THAT SOMEONE IS TRYING TO BREAK IN
Owner report, NHTSA ODI #10823506

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Unintended acceleration and vehicle rollaway

SERVICE BRAKES

4 NHTSA complaints · 2012-08 → 2018-01

TL* THE CONTACT OWNED A 2012 FORD FLEX. WHILE DRIVING 1 MPH, THE VEHICLE ACCELERATED BACKWARDS RAPIDLY AND CRASHED INTO A TREE. THE AIR BAGS DID NOT DEPLOY
Owner report, NHTSA ODI #11057995
TL* THE CONTACT OWNS A 2012 FORD FLEX. THE CONTACT STATED THAT WHILE ATTEMPTING TO PARK, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE ACCELERATED FORWARD. THE CONTACT STATED THAT THE VEHICLE JUMPED A CURB AND CRASHED INTO A POST
Owner report, NHTSA ODI #10468831
WHILE STOPPED AND IN PARK THE VEHICLE STARTED ROLLING, I ATTEMPTED TO JUMP IN THE VEHICLE BUT COULD NOT PULL MYSELF ALL THE WAY IN. I WAS ABLE TO YANK THE KEYS FROM THE IGNITION AND THEN I COULD NO LONGER RUN ALONG SIDE THE VEHICLE AND I FELL ON THE ASPHALT
Owner report, NHTSA ODI #10903897

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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)

5 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.

4

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 2012 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.