Problems with the Ford Tourneo Custom
Reliability Ford Tourneo Custom: common problems, issues symptoms and faults
- Automatic transmission problems: The automatic transmission can develop shifting problems in models from 2018 onwards, especially in the 2.0 TDCi variant. These symptoms are often characterised by jerky gear changes and can occur after just 40,000-60,000 km.
- Turbocharger wear: The turbocharger in 2.2 TDCi engines often shows signs of wear after 80,000-120,000 km. Particularly affected are 2019 models, where the turbocharger can be damaged by a lack of oil or clogged filters.
- AdBlue system faults: The adblue system does not function correctly in many vehicles after 60,000-80,000 km mileage. The faults manifest themselves through warning messages and can lead to an emergency stop.
- Air conditioning defects: The air conditioning system shows cooling performance losses in models from 2024 onwards with mild-hybrid technology. These breakdowns occur particularly in the summer months and can be caused by defective compressors.
Ford Tourneo Custom: Problems with the automatic transmission
The automatic transmission of the Ford Tourneo Custom shows characteristic weak points in various model variants, which manifest themselves in irregular gear changes, jerking when starting off and delayed gear changes. The 2.0 TDCi models from 2018 are particularly affected by these common faults, with the symptoms often starting gradually and worsening progressively. The reliability of the transmission is affected by various factors, including irregular oil changes, aggressive driving or overloading the vehicle. Initial complaints often manifest themselves in the form of "sticking" between gears, while more serious cases can result in the vehicle no longer starting properly or failing to shift into certain gears.
A systematic check is essential for the early detection of transmission problems. The complex Ford Tourneo Custom automatic transmissions require regular flushing of the transmission oil every 60,000 km and professional diagnosis at the first sign of shifting problems. The service life can be considerably extended by preventive maintenance, paying particular attention to the correct operating temperature and oil level. In the case of serious defects, a complete transmission overhaul or replacement is often necessary, whereby the costs can vary considerably.
Ford Tourneo Custom: Turbocharger wear and defects
The turbocharger of the Ford Tourneo Custom, especially in the 2019 2.2 TDCi variant, develops characteristic wear problems that manifest themselves through whistling noises, loss of power and bluish smoke from the exhaust. These common faults are often caused by insufficient oil supply, clogged air filters or aggressive driving without adequate warm-up phases. The reliability of the turbocharger is significantly influenced by the quality of the engine oil and adherence to the maintenance intervals. Typical symptoms often start with a subtle whistle under acceleration and can develop into complete failures where the vehicle no longer functions at full power.
Regular maintenance is critical to the longevity of the turbocharger. The sensitive Ford Tourneo Custom turbocharger components require high quality engine oil with the correct specifications and regular checks of the air supply and exhaust system. Preventative measures include avoiding short journeys without warming up, regular checks of the air filters and the use of high quality fuel. At the first sign of turbocharger problems, a diagnosis should be made immediately, as consequential damage to the engine can be considerably more expensive.
Ford Tourneo Custom: AdBlue system faults and malfunctions
The adblue system of the Ford Tourneo Custom shows characteristic malfunctions in diesel variants, which are manifested by error messages in the on-board computer, warning lights and, in severe cases, power limitations. These problems occur particularly frequently in vehicles that are mainly used in urban traffic, as the system requires regular regeneration at higher temperatures. The weak points often lie in clogged injection nozzles, defective sensors or crystallised AdBlue residues in the system. Typical complaints include messages such as "AdBlue refill required" despite a full tank or "Engine start no longer possible in X km", which can lead to considerable interruptions in operation.
A professional inspection is required to properly diagnose AdBlue problems. The sensitive Ford Tourneo Custom AdBlue components require regular cleaning of the injectors and checking of the lines for crystal formation, especially after long periods of inactivity. Preventive measures include the use of high-quality AdBlue, regular long-distance journeys to regenerate the system and avoiding running the AdBlue tank empty. In the event of system faults, a professional flushing of the entire system or the replacement of defective sensors is often necessary.
Ford Tourneo Custom: Air conditioning problems and loss of cooling capacity
The air conditioning system of the Ford Tourneo Custom, especially in the newer models from 2024 with mild-hybrid technology, shows various problems that manifest themselves through insufficient cooling, unusual noises or complete failure of the air conditioning function. These common faults are often caused by defective compressors, leaking refrigerant lines or dirty condensers, with the additional load of the hybrid system adding to the complexity. The reliability of the air conditioning system is influenced by factors such as vehicle age, intensity of use and maintenance quality. Typical symptoms start with reduced cooling capacity and can develop into complete failures where the system stops working and unpleasant odours develop.
Professional maintenance is essential for the optimum functioning of the air conditioning system. The complex Ford Tourneo Custom air conditioning systems require regular refrigerant checks, filter cleaning and electrical component checks, especially every 24 months for hybrid variants. Preventive measures include regular use, even in winter, replacement of the cabin filter and professional system cleaning. Defects should be diagnosed immediately, as refrigerant leaks can lead to compressor damage, which is significantly more cost-intensive than preventive maintenance measures.
Ford Tourneo Custom: Engine starting problems and electrical faults
The starting problems in the Ford Tourneo Custom manifest themselves through various symptoms, from delayed starting to complete starting failures, with the 2.0 TDCi engines from 2018 being particularly affected. These problems are often caused by defective glow plugs, weak batteries, corroded contacts or faults in the fuel system, whereby cold temperatures can exacerbate the symptoms. The electrical system shows additional weaknesses in the form of sporadic failures of various systems, whereby the vehicle does not start or various consumers do not function properly. Particularly problematic are intermittent faults, which are difficult to diagnose and can lead to unpredictable breakdowns, significantly affecting the reliability of the vehicle.
A systematic check is crucial for identifying starting and electrical problems. The sensitive Ford Tourneo Custom starting systems require regular battery voltage checks, glow plug checks on diesel engines and inspection of all electrical connections for corrosion or looseness. The life of the electrical components can be significantly extended by preventive maintenance, including regular battery tests and cleaning of the contacts. If starting problems persist, computerised diagnostics should be carried out to identify hidden faults in the control unit or sensors.
Additional common Ford Tourneo Custom faults
Based on the experiences of Ford Tourneo Custom drivers, the following problems also occur:
- Brake squeal and premature wear: often occurs after 25,000-40,000 km, especially in heavily loaded vehicles due to intensive use.
- Tailgate problems: Electric tailgate does not function correctly from 50,000-70,000 km, often caused by defective motors or sensors.
- Fuel pump defects: Can occur as early as 60,000-80,000 km, manifested by starting problems or loss of power.
- Lane departure warning system faults: On 2024 models with mild-hybrid system after 15,000-30,000 km, often due to sensor calibration problems.
- Particulate filter clogging: Especially in 2.2 TDCi engines after 70,000-100,000 km of city driving without sufficient motorway driving.
- Headlight condensation: Occurs in various model years after 40,000-60,000 km, caused by leaking housings.
- Glove compartment mechanism: Defective locking mechanism after 20,000-35,000 km, especially with intensive use.
Ford Tourneo Custom: weaknesses and strengths
| Strengths |
Weak points |
| Spacious interior and load capacity |
Automatic transmission problems |
| Modern safety equipment |
Turbocharger wear with high mileage |
| Versatile configuration options |
AdBlue system faults |
| Good road holding and ride comfort |
Air conditioning defects |
| Solid workmanship of the body |
Electrical problems and starting failures |
| Efficient diesel engines |
Brake wear |
| Extensive equipment options |
Particulate filter blockage |
The Ford Tourneo Custom proves to be a versatile and fundamentally robust van, but it has specific weak points that require regular attention. Most problems can be avoided or at least their effects minimised through consistent preventive maintenance and timely intervention. The more complex systems in particular, such as the automatic transmission, turbocharger and AdBlue system, require professional care to ensure the longevity of the vehicle and avoid costly repairs.
19 December 2025 (updated) 
