Ford Van Parts UK - Quality Used & Genuine Parts

How to Replace Ford Van Headlights

Ford van headlight replacement is straightforward on Transit, Transit Custom, and Transit Connect models. Whether replacing standard halogen units or upgrading to LED headlights, this guide covers the complete Ford Professional van range including electric E-Transit models.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely with the prop rod or gas struts. Locate the rear of the headlight assembly from within the engine bay. On Transit models, the large bonnet opening provides excellent access to headlight mountings with clear visibility despite the van's size. On Transit Custom models, access is good with well-designed engine bay layout allowing straightforward reach to all mounting points. On Transit Connect models based on VW Caddy platform, access follows VW's practical design with accessible mounting points. Electric E-Transit and E-Transit Custom models offer even better access due to simplified electric motor layout with no traditional diesel engine components obstructing your working area.
2. Disconnect all electrical connectors from the headlight assembly carefully. Ford van headlights typically have 2-4 electrical connectors depending on specification and trim level. These include the main beam bulb connector, dipped beam bulb connector, side light connector, and on models equipped with daytime running lights an additional DRL connector to disconnect. Press the release tabs on each connector carefully without forcing and pull straight out to disconnect cleanly. Handle the plastic connectors gently as they can become brittle with age, heat exposure from the engine bay, and UV degradation, especially on high-mileage commercial vehicles that have worked hard in all weather conditions.
3. Remove the headlight mounting bolts and securing screws systematically. Most Ford van models use T20 or T25 Torx screws to secure the headlight assembly to the front panel and wing. On Transit models, there are typically 3-5 bolts along the top edge of the headlight that are easily accessible once the bonnet is fully open and secured. On Transit Custom models, expect 3-4 mounting bolts with clear access from above the engine bay without removing other components. On Transit Connect models following VW design, there are usually 2-3 mounting points with straightforward access. Remove all mounting bolts completely and keep them safely organized in a container for refitting to ensure you don't lose any during the job.
4. Release any additional clips or retaining tabs if fitted to your model. Some Ford van headlights use supplementary plastic clips at various points around the headlight perimeter for additional security and precise alignment during assembly. On Transit models, check for clips at the inner corner near the grille assembly and at the bottom edge near the bumper. On Transit Custom models, look for clips at the bottom edge of the headlight housing. On Transit Connect models, check VW-style clips which may differ from traditional Ford designs. Work the clips carefully using a plastic trim removal tool as they can become brittle and snap with age, heat exposure, and UV degradation from sunlight.
5. Carefully remove the headlight assembly from the van supporting its weight. With all bolts, screws, and clips released, gently pull the headlight straight forward out of its mounting position in the front panel. Ford van headlights slide forward on plastic locating pins or metal tabs that ensure correct alignment when refitting and prevent the headlight from sitting incorrectly or at wrong angles. Support the weight of the headlight unit as you pull to prevent dropping it and causing damage to the housing, lens, or reflector. If you feel any resistance when pulling the headlight forward, stop immediately and check thoroughly for missed fixings, clips, or electrical connections rather than forcing the headlight which could damage mounting points, break tabs, crack the headlight housing, or damage the wing panel.
6. Transfer components to new headlight if required for your application. If your replacement headlight doesn't include bulbs, leveling motors, or additional components, carefully transfer these from the old unit to the new headlight ensuring correct orientation and secure fitting. When handling halogen or LED bulbs, always wear clean gloves to avoid touching glass surfaces with bare hands as skin oils and fingerprints cause premature bulb failure, hot spots during operation, and reduced bulb lifespan. Different Ford van models, generations, and trim levels use various bulb types (H7, H4, H1, etc.), so ensure correct bulbs are fitted for your specific model year and specification.
7. Install the new headlight assembly into the van reversing removal steps. Reverse the removal process by aligning the new headlight with the locating pins or tabs on the front panel and push firmly but gently into place ensuring all mounting points engage correctly in their designated positions without forcing. Refit all mounting bolts, screws, and clips in the reverse order of removal and tighten securely without overtightening which could crack plastic mounting points or strip threads. Reconnect all electrical connections ensuring each one clicks firmly into place and is fully seated to prevent warning lights or intermittent operation. Test all lighting functions before final assembly including dipped beam, main beam, side lights, indicators, and daytime running lights to confirm everything operates correctly and there are no warning lights illuminated on the dashboard indicating electrical faults.

Important Notes: Ford van headlight replacement is a straightforward DIY job that can save significant money versus garage labour costs which can add £50-£100 to the bill. When handling new headlights, never touch lens or reflector surfaces as fingerprints, dust, and oils affect light output, create hot spots, and can cause permanent marks or damage. After fitting new headlights, check beam alignment using the adjustment screws on the rear of the headlight assembly accessible from the engine bay. Proper headlight alignment is crucial for optimal visibility during night driving, preventing dazzling of oncoming drivers which is illegal and dangerous, and ensuring MOT compliance as incorrectly aligned headlights will fail the MOT test.

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How to Replace Ford Van Front Bumper

Replacing a Ford van front bumper is achievable in 45-90 minutes depending on model, body size, and experience level. This process covers Transit, Transit Custom, and Transit Connect models, though specific screw locations, fixing methods, and number of fixings vary between generations, body sizes, facelifts, and model years.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely with the prop rod or gas struts on applicable models. Locate the upper bumper mounting fixings along the top edge just below the grille assembly and radiator support. Most Ford van models have 4-10 Torx screws or bolts securing the top edge of the front bumper to the body panel depending on model and width. On Transit models, these are typically T20 or T25 Torx screws clearly visible once the bonnet is fully open, with 8-12 fixings across the wide front depending on generation, facelift, and length variant. On Transit Custom models, expect 6-10 fixings across the front end width. On Transit Connect models following VW Caddy platform design, expect 4-6 fixings using VW-style mounting methods. Remove all upper fixings systematically working from one side to the other to maintain even tension and prevent bumper from dropping unexpectedly.
2. Access the wheel arch areas on both sides of the van carefully. Turn the steering wheel fully to one side (left for driver side, right for passenger side) to maximize access to the wheel arch liner behind each front wheel. Behind each front wheel, locate the plastic arch liner that protects the inner wing from road spray, stones, and debris. Remove or release 2-5 plastic clips or screws securing the front section of the arch liner to expose the side bumper mounting points hidden behind the liner. Ford vans typically use plastic push-in clips that release by pressing the center pin first before pulling the entire clip out, though some models use Torx screws instead. On Transit models the large arch liner may require removing more clips for adequate access. Repeat the process on both driver and passenger sides ensuring you don't lose any clips or screws.
3. Remove the side mounting screws from both wheel arches on each side. Behind each wheel arch liner section that you've pulled back or removed, you'll find 2-4 screws or bolts securing each side of the front bumper to the wing panel and chassis rail for structural support. These are usually T20 or T25 Torx screws on most Ford van models though some years and variants use Phillips head screws or 10mm bolts. Remove all side fixings on both driver and passenger sides completely taking care not to drop them. Keep track of which fixings came from which location if they differ in size, length, thread type, or design as this makes refitting easier, ensures correct reassembly without confusion, and prevents using wrong fixings in wrong locations which could cause damage or insecure mounting.
4. Remove undertray screws and lower bumper fixings safely and systematically. Get underneath the van safely using vehicle ramps rated for the van's weight, professional axle stands with appropriate capacity, or a vehicle lift in a professional workshop environment. Never work under a van supported only by a jack as this is extremely dangerous and could result in serious injury or death if the van falls. Locate and remove all screws and clips securing the engine undertray and the lower edge of the front bumper to the chassis. Ford vans typically use 8-15 fixings along the bottom edge of the bumper depending on model, size, and generation. These may be Torx screws, Phillips screws, plastic push-in clips, or a combination of different fixing types. On Transit models the large undertray requires removing more fixings due to greater width. You don't always need to remove the entire undertray, just the front section that secures the bumper lower edge and prevents bumper removal.
5. Disconnect fog lights, sensors, and all electrical connections carefully without damage. Reach behind the bumper from underneath or from the sides and disconnect all electrical connectors taking care with the plastic clips. This includes fog light connections if your van is fitted with front fog lights (common on higher specification models and Limited trim), parking sensor connections if equipped with front parking assist sensors (increasingly common on newer Ford vans with advanced driver assistance systems), and any additional connections for cameras, radar units for adaptive cruise control, automatic emergency braking systems, or other driver assistance systems on newer high-spec vans. Press the release tabs on each connector carefully without forcing as they can break easily and pull straight out cleanly. Count how many electrical connections you disconnect to ensure you reconnect them all during refitting and don't leave any disconnected which would cause warning lights, system malfunctions, and potential MOT failure.
6. Release the bumper side clips and mounting tabs on both sides without forcing. Ford van bumpers are secured by plastic clips, metal brackets, or a combination of both on each side that slot into recesses in the wing panels and chassis rails for precise alignment and structural support. With all screws, bolts, and clips removed from top, bottom, and wheel arches, firmly but gently pull the bumper forward from one corner while a helper supports the opposite side to prevent the bumper dropping and causing damage. You may need to wiggle the bumper slightly side to side or up and down to release the clips from their mounting points as they can bind. Listen and feel for clicks as the clips disengage from their positions. Work carefully and patiently to avoid breaking clips which are often expensive to replace individually, damaging mounting tabs which may require wing replacement, or cracking the bumper plastic which would ruin your replacement part.
7. Remove the bumper completely from the van supporting its weight throughout. With all fixings removed and all clips released, carefully pull the front bumper straight forward away from the van supporting its weight throughout the removal process. Ford Transit Connect bumpers are relatively lightweight allowing one person to manage removal comfortably without assistance. Transit Custom bumpers are larger and heavier due to increased van width and may benefit from a second person to support the weight, control the bumper during removal, and prevent dropping which could crack the bumper, damage the paintwork, or cause personal injury. Transit bumpers are large, wide, and heavy due to the van's size and definitely require two people to handle safely without risk of damage or injury. Place the removed bumper on a protected surface such as cardboard sheets, old blankets, or foam padding to avoid scratching the painted surface, cracking the plastic, or causing any damage during storage or inspection.
8. Prepare and fit the replacement bumper assembly correctly ensuring all components transfer. Before installation, transfer any brackets, mounting plates, trim pieces, number plate mounting brackets, towing eye covers, fog light surrounds, or components from the old bumper to your replacement if they're not already fitted to ensure complete functionality and correct appearance. Align the new bumper with the van's mounting points taking care to locate the side clips correctly in their recesses and push firmly into place ensuring all side clips engage properly into the wing panels and chassis mounting points without forcing. Reconnect all electrical connections including fog lights and parking sensors ensuring each clicks firmly and is fully seated to prevent warning lights or system malfunctions. Systematically secure the bumper with all screws and clips in reverse order of removal, starting with side fixings to hold position and alignment, then top fixings along the grille area for structural support, and finally undertray and lower fixings to complete the installation. Test all electrical functions including fog lights and parking sensors before final assembly to confirm everything works correctly and there are no warning lights on the dashboard. Check all panel gaps between bumper and wings are even on both sides and symmetrical before final tightening to ensure professional appearance and correct alignment that won't cause rattles or wind noise.

Top Tips: Ford van bumpers are designed for practical replacement to minimize downtime for commercial operators who rely on their vans for daily business operations and income. When refitting parking sensors if equipped, ensure each sensor clicks firmly into its mounting hole in the bumper and is correctly aligned flush with the bumper surface to prevent false warnings, incorrect distance readings, and system malfunctions that could affect safety. On Transit Custom models with the new 2024 generation, be aware of updated mounting methods and clip designs that may differ from previous generations. On Transit Connect models based on VW Caddy platform, some fixings follow VW design rather than traditional Ford methods. On electric E-Transit and E-Transit Custom models, some bumpers may house charging port covers, additional cooling vents for battery thermal management systems, or radar units for advanced driver assistance systems, so check these components transfer correctly to replacement bumpers and reconnect properly with secure electrical connections. Check all panel gaps between the bumper and wings are even on both sides and symmetrical before final tightening of all fixings to ensure professional appearance and correct alignment. Ford's manufacturing tolerances mean genuine replacement parts typically fit well without extensive adjustment, though minor tweaking of clip positions or mounting points may be needed for perfect alignment on older vans with worn mounting points or accident-damaged wings.

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Common Ford Van Parts Problems & Solutions

Ford vans are the UK's most reliable van manufacturer according to the FN50 2023 survey, demonstrating consistent excellence across their commercial vehicle range. The Transit ranked 3rd place moving up the reliability table, Transit Connect entered at 7th place after not ranking previously, and Transit Custom moved up to 9th place. The Transit Custom won Parkers Medium Van of the Year 2025 as the UK's best-selling van, while the Transit won Large Van of the Year 2023 and 2024. However, certain components can experience specific issues based on verified data from UK owners, mechanics, commercial fleet operators, and industry specialists. Here are the most commonly reported Ford van parts problems with realistic UK repair costs and practical solutions.

Injector Failures (MK7 and MK8 Transit - Common Issue):

• Diesel Fuel Injector Problems Causing Performance Loss: The MK7 Transit and to a lesser extent MK8 Transit are particularly prone to injector failures, especially in the diesel models which represent the vast majority of Transit vans sold in the UK. Faulty or leaking fuel injectors are a well-known issue affecting these generations. Leaking injectors cause carbon buildup on the cylinder head which creates a cascade of problems. Symptoms include rough running and uneven engine operation, significant loss of power especially noticeable when fully loaded or going uphill, excessive black smoke from the exhaust particularly during acceleration indicating incomplete combustion, poor fuel economy as fuel isn't burned efficiently, and difficulty starting especially when cold. Injectors can fail completely causing the engine to run on fewer cylinders or refuse to start.
• Diagnosis and Repair Costs: Diagnosis requires fault code reading using diagnostic equipment to identify which injectors are faulty and may include leak-off tests to check injector sealing. Ford Transit fuel injectors manufactured between 8 June 2021 and 28 June 2021 were subject to a recall concerning injector faults. Injector replacement costs vary but typically £150-£300 per injector for the part plus £100-£200 labour depending on how many cylinders need replacing. If multiple injectors have failed, costs escalate quickly with four injectors costing £800-£1,400 total. Some specialists offer injector cleaning services for £200-£400 which can restore function if caught early before mechanical damage occurs. Prevention involves using quality diesel fuel, regular servicing, and addressing any running issues promptly before they escalate.

Turbocharger Failure (Transit and Transit Custom - Relatively Common):

• Turbo Issues Affecting Power and Performance: Turbo issues are relatively common on Ford Transit vans, often manifested by a lack of power and black smoke from the exhaust. The culprit is often a failed turbo actuator, particularly in certain 2.0 TDCi models where this is a known weak point. Symptoms of turbo failure include intermittent or complete loss of power making the van unusable for commercial work, illuminated engine warning light on the dashboard indicating fault codes, poor acceleration or excessive acceleration indicating low boost or over boost conditions which the ECU tries to compensate for, strange whining, whistling, or grinding noises coming from the engine bay indicating bearing failure or turbine damage, and the vehicle going into limp mode with severely restricted power for safety. The fault code P2599 specifically indicates a faulty turbocharger actuator when read with diagnostic scanner.
• Prevention and Repair Options: Turbocharger failure can occur due to oil contamination, restricted oil supply to the turbo bearings causing oil starvation, or excessive carbon buildup from short journeys and stop-start driving. Turbocharger replacement costs £600-£1,200 for remanufactured units or £1,200-£2,000 for genuine new turbos plus £200-£400 labour depending on accessibility. Actuator replacement alone costs £200-£400 if caught early before complete turbo failure. Prevention involves regular oil changes using correct specification oil, allowing the engine to idle for 30 seconds after hard driving to cool the turbo before switching off, and avoiding excessive short journeys that don't allow the turbo to reach operating temperature. When buying used Transits, check for any turbo-related fault codes and verify service history shows regular oil changes.

DPF and EGR Problems (All Diesel Models - Very Common):

• Diesel Particulate Filter and EGR Valve Issues: Frequent short journeys cause soot to build up, blocking the Diesel Particulate Filter and causing EGR valves to stick, which is one of the most common problems affecting all Ford diesel vans including Transit, Transit Custom, and Transit Connect. The DPF is designed to trap soot particles to meet emissions regulations, but it requires regular regeneration at high temperatures achieved during sustained motorway driving. Short urban journeys prevent proper regeneration causing progressive blockage. The EGR (Exhaust Gas Recirculation) valve recirculates exhaust gases but carbon deposits cause it to stick. Symptoms include illuminated DPF warning light on dashboard, loss of power and sluggish acceleration, rough idling and uneven running, excessive black smoke during acceleration, increased fuel consumption, and in severe cases the engine going into limp mode or refusing to start.
• Cleaning and Prevention Tips: DPF cleaning costs £150-£300 professionally if caught before severe damage, or DPF replacement costs £600-£1,500 for the part plus £200-£400 labour making it an expensive repair. EGR valve cleaning costs £100-£200 or replacement costs £200-£400. The simple solution is taking the van for a 15-20 minute drive on a dual carriageway or motorway every week at sustained speeds allowing the DPF to regenerate naturally by burning off accumulated soot. Use quality diesel fuel and fuel system cleaners to reduce carbon buildup. Avoid excessive idling and short journeys where possible. When the DPF warning light appears, take immediate action with a motorway run rather than ignoring it as continued driving causes severe blockage requiring expensive professional intervention or replacement.

AdBlue System Faults (Euro 6 Models - Transit Custom):

• AdBlue DEF System Problems on Modern Diesels: On Euro 6 compliant Transit Custom models equipped with AdBlue (Diesel Exhaust Fluid) emissions systems, drivers often see warning messages like "AdBlue System Fault" or "Engine Start Inhibited" which can be extremely concerning. The van may even refuse to start if the issue isn't sorted promptly, leaving drivers stranded and businesses unable to operate. AdBlue is required for SCR (Selective Catalytic Reduction) systems to meet Euro 6 emissions standards, and the system is designed to prevent engine starting if AdBlue levels are too low or if system faults are detected to ensure compliance with emissions regulations.
• Solutions and Prevention: AdBlue tank refilling costs £10-£30 depending on capacity and is a simple DIY job. AdBlue quality sensor replacement costs £150-£300. AdBlue pump replacement costs £300-£600. AdBlue injector replacement costs £200-£500. Always refill with clean, quality AdBlue from reputable suppliers avoiding contaminated or cheap alternatives which damage the system. Top up AdBlue early when the warning appears rather than running it completely dry which can cause air locks requiring professional purging. Never put diesel in the AdBlue tank or vice versa as this causes catastrophic system damage requiring complete replacement costing thousands. If you see AdBlue warnings, address them immediately rather than continuing to drive as the system will eventually prevent starting for emissions compliance.

Clutch and Gearbox Problems (Transit Custom - Hard-Worked Vans):

• Premature Clutch Wear and Transmission Issues: Clutch slip and poor gear engagement are common on hard-worked Transit Custom vans especially those used for heavy loads, frequent stop-start urban delivery work, or operated by multiple drivers with varying driving styles. Some Transit Custom owners have experienced premature wear of the clutch leading to concerns about longevity and replacement costs. Additionally, issues with the gearbox such as difficulty shifting gears or transmission noise have been cited by owners and mechanics. Symptoms include clutch slipping especially when fully loaded or pulling away on hills, difficulty engaging gears with resistance or grinding noises, juddering when pulling away from standstill, burning smell from clutch area indicating overheating friction material, and complete clutch failure preventing gear engagement.
• Repair Costs and Solutions: Clutch replacement costs £500-£900 including parts and labour depending on van specification and whether single or dual-mass flywheel. Gearbox repairs cost £600-£1,200 for minor issues or £1,500-£2,500 for major rebuilds or replacement. The 7-speed DSG automatic gearbox on Transit Connect (which is the VW unit from the Caddy platform) can develop issues costing £1,000-£2,000 to repair professionally. Regular clutch inspections during services can identify wear before complete failure. Driver training to avoid riding the clutch and proper gear selection extends clutch life significantly. When buying used Transit Customs, test the clutch bite point and all gear selections thoroughly during test drive to identify potential problems before purchase.

Electrical Problems (Transit Custom - Frustrating Issues):

• Various Electrical System Malfunctions: Electrical problems can be a source of frustration for any vehicle owner and the Transit Custom is no exception to this common modern van issue. Reports have included troubles with the central locking system failing or operating intermittently, malfunctioning dashboard displays or digital instrument clusters, battery drain issues where the battery goes flat overnight, and various sensor issues causing warning lights. As vans become more reliant on advanced electronic systems for everything from engine management to driver assistance features, addressing electrical problems promptly is essential to prevent potential breakdowns and ensure the safety and functionality of the vehicle.
• Common Causes and Repairs: Common electrical faults include water ingress in the fuse box causing multiple random issues (£100-£300 to repair), damaged wiring particularly in areas subject to flexing like door looms (£150-£500 depending on extent), faulty relays causing intermittent operation (£50-£150 to replace), and battery drain from components drawing power when they shouldn't (diagnosis £50-£150). Central locking faults cost £100-£400 to repair depending on whether it's wiring, actuators, or control modules. Dashboard display issues cost £200-£600 for replacement units. Many electrical faults can be diagnosed using fault code readers helping identify specific issues rather than expensive trial and error. When experiencing electrical gremlins, check battery connections and earth points first as loose or corroded connections cause many seemingly unrelated faults.

Suspension Knocking (Transit Custom - High Mileage):

• Worn Suspension Components After Heavy Use: Suspension knocking is common on Transit Custom vans after 50,000 miles, especially if the van carries tools, equipment, or materials daily subjecting the suspension to constant loading and harsh road conditions. Commercial vans work hard and suspension components wear faster than on passenger cars due to higher loads and rougher usage patterns. Symptoms include knocking, clunking, or rattling noises from the suspension when driving over bumps or speed bumps, uneven tire wear indicating alignment or suspension geometry issues, and the van feeling less stable or wallowing more than when new indicating worn dampers.
• Inspection and Repair: Common suspension repairs include shock absorber replacement £150-£300 per pair fitted, suspension bushes £100-£250 per corner, drop links £80-£150 per pair, and ball joints £150-£300 each side. Check for uneven tire wear patterns and listen for rattling over speed bumps as early warning signs. Regular suspension inspections during services can identify worn components before they fail completely or cause secondary damage. When buying used Transit Customs, thoroughly inspect suspension condition and listen for knocks during test drive especially over rough roads. The independent rear suspension on the latest generation Transit Custom (2024+) provides better ride comfort but adds complexity to repairs.

Head Gasket Failure (Transit Connect 1.5 TDCI - Expensive):

• Serious Engine Problem on 1.5 Diesel: One expensive repair which has caught out many Transit Connect owners is head gasket failure, a weak area of the 1.5 TDCI engine particularly on MK2 models from 2013 onwards. This is a known issue that can result in catastrophic engine damage if not addressed promptly. Symptoms include van losing coolant with no visible external leaks indicating internal consumption, creamy sludge around the oil filler cap indicating coolant mixing with oil, small bubbles entering the coolant expansion tank from the return pipe indicating combustion gases entering cooling system, overheating especially under load, and white smoke from exhaust indicating coolant burning in cylinders.
• Repair Costs and Prevention: Head gasket replacement on the 1.5 TDCI Transit Connect costs £800-£1,500 including parts and labour as it's a time-consuming job requiring cylinder head removal and skimming. If left too long, cylinder head warping or cracking can occur requiring cylinder head replacement adding £500-£1,000 to costs. In severe cases where coolant has contaminated the oil for extended periods, complete engine damage can occur requiring full engine replacement costing £2,000-£4,000. Regular coolant level checks and immediate investigation of any unexplained coolant loss can catch head gasket problems early before catastrophic damage occurs. When buying used Transit Connect 1.5 TDCI models, specifically ask about head gasket replacement history and check thoroughly for any symptoms during inspection and test drive.

Timing Belt Issues (Transit Connect 1.5 TDCI - Critical):

• Cambelt Replacement Critical for Engine Longevity: The timing belt (cambelt) on Ford Transit Connect 1.5 TDCI engines is a critical maintenance item that requires replacement at specified intervals. Ford recommends replacement every 10 years or 125,000 miles, whichever comes first. Timing belt failure is catastrophic on these interference engines where the valves and pistons occupy the same space at different times, meaning belt failure causes valves to hit pistons resulting in bent valves, damaged pistons, and potential complete engine destruction requiring replacement.
• Prevention and Inspection: Timing belt replacement costs £400-£700 including water pump which should always be replaced simultaneously as labour costs are the same. Complete engine rebuild or replacement after timing belt failure costs £2,000-£5,000 making preventative replacement essential and cost-effective. When buying used Transit Connect vans, verify timing belt replacement history with documentation or receipts. Check for stickers in the engine bay that some garages apply when replacing the belt. Inspect the timing belt cover area for fresh-looking sealant indicating recent work. Check for oil leaks around the timing cover as this indicates seals are perishing suggesting the belt is overdue. If there's no evidence of replacement and mileage or age is approaching limits, factor replacement cost into purchase price or insist on replacement before buying.

Power Steering Failures (Transit and Transit Custom - Safety Issue):

• Electric Power Steering System Problems: There are reports of problems with the power steering pump or rack making it harder for drivers to turn the steering wheel due to reduced assistance which is a serious safety concern. This can be the result of insufficient levels of power steering fluid on hydraulic systems or complete failure of electric power steering motors on newer models. Ford Transit vans manufactured between 30 June 2019 and 26 April 2021 were recalled because some vehicles may have been built with an additional bolt that may be loose within the electric power steering system causing failures.
• Repair Solutions: Power steering pump replacement costs £300-£600. Power steering rack replacement costs £400-£800. Electric power steering motor replacement costs £500-£900. Power steering fluid is inexpensive at £10-£20 but neglecting levels causes expensive pump damage. Regular power steering fluid checks and topping up prevents many failures on hydraulic systems. Address any power steering warning lights immediately as complete failure makes the

  2.0 EcoBlue Engine Issues (2016+ Transit - Teething Troubles):

  • Problems with Newer Diesel Engines: The 2.0 EcoBlue diesel engines introduced in 2016 to meet latest Euro 6 emissions regulations offer greater performance at every power level compared to previous engines. Unfortunately, they also seem to be suffering with some teething troubles which it's unclear Ford has successfully resolved according to owner reports and specialist feedback. Highlighted problems center around early oil change service requests where the onboard computer requests servicing much earlier than the scheduled interval, an issue which has been put down to software problems, faulty injectors causing oil contamination, and even incorrectly calibrated dipstick lengths causing false low oil readings.
  • Understanding and Addressing the Issue: The onboard computer decides when a service is due based on multiple parameters, and if you drive unsympathetically with lots of cold starts or mostly do short journeys you can expect the van to request an oil change early which is actually appropriate for those harsh operating conditions. Faulty injectors can contaminate oil requiring early changes. Software updates from Ford dealers can recalibrate service intervals. Using correct specification oil and maintaining proper service intervals prevents most issues. While frustrating, these teething troubles haven't prevented the Transit from ranking 3rd in the FN50 2023 reliability survey showing overall the engines are proving dependable in fleet service once properly maintained.

  Ford Van Reliability Assessment:

  UK's Most Reliable Van Manufacturer: Ford vans are the UK's most reliable van manufacturer according to the FN50 2023 survey based on real-world fleet data from leasing companies measuring average days off the road with unplanned mechanical problems. The Transit ranked 3rd place moving up the reliability table, Transit Connect entered at 7th place after not ranking previously, and Transit Custom moved up to 9th place. The Transit Custom won Parkers Medium Van of the Year 2025 as the UK's best-selling van demonstrating commercial confidence. The Transit won Large Van of the Year 2023 and 2024 particularly due to the impressive E-Transit electric version. Despite known issues like injector failures on MK7/MK8, DPF/EGR carbon buildup, and clutch wear on hard-worked vans, Ford's overall reliability is excellent with proper maintenance.

  Best Years and Model Selection: The best years of reliability for the Ford Transit Custom are 2017 and beyond according to specialist mechanics. The 2015 and 2016 model years were known for engine compression issues and rear differential problems that gave Ford a bad name temporarily, but these were resolved in later models. When buying used Ford vans, prioritize post-2017 Transit Customs for better reliability, Transit Connect models based on the proven VW Caddy platform introduced 2021 onwards, and any Transit generation as they consistently rank highly for reliability. The Transit Connect benefits from VW Group's proven TDI diesel and TSI petrol engines which are generally reliable. Electric E-Transit and E-Transit Custom models eliminate diesel-related issues entirely while offering impressive performance for urban operations.

  Maintenance and Prevention Recommendations: To maximize Ford van reliability, adhere strictly to service schedules especially oil changes critical for turbo and injector longevity. Take regular 15-20 minute motorway runs weekly to regenerate the DPF and prevent EGR carbon buildup. Always use quality AdBlue and top up early before running dry. Check coolant levels regularly on Transit Connect 1.5 TDCI models to catch head gasket issues early. Verify timing belt replacement history and replace at correct intervals. Address any warning lights promptly rather than ignoring them. When buying used Ford vans, prioritize examples with full service history from Ford dealers or Ford specialists, verify recalls have been completed, check for common issues specific to the model during inspection, and have pre-purchase inspections performed to identify potential problems. Despite known issues, Ford vans remain the UK's most popular and reliable commercial vehicles offering excellent value, practical features, strong dealer support, and exceptional resale values backed by decades of Transit heritage and engineering excellence.

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