2009 Ford Flex Problems

What owners report

Owners of the 2009 Ford Flex describe two broad themes: electrical and cooling-fan faults that can leave the engine stalling or overheating while driving, and a fuel gauge that drops from about a quarter tank to empty, sometimes causing the engine to quit. Brake and power-steering complaints are also common and tend to appear at relatively low mileage, while transmission and driveline reports come in at higher mileage.

1. 1
   Engine

   Engine stalls or shuts off while driving

   • 28 complaints (15%)
   • median 24,500 mi at 3.2 yrs old (26 state mileage)
   • filed 2009–2021

   Complaints describe the engine quitting without warning at low speeds in parking lots, at stop signs, and occasionally at highway speed, with all dash lights coming on and the loss of power steering and power brakes. Owners often say the vehicle restarts after being shut off and restarted, and that dealers could not duplicate the problem; in some cases the dealer replaced a throttle body, a relay, or traced it to wiring harness and PCM work. Reported from very low mileage up to around 170,000 miles, with many occurring between roughly 20,000 and 75,000 miles and often at low speed or during idling.

   2 related service bulletins

   What to check: Ask for service records on throttle body, relay and PCM/wiring work, and take an extended test drive that includes idling in traffic and low-speed turns. Ask the seller whether the vehicle has ever stalled and how it was addressed.

   2 excerpts from owner complaints in NHTSA records

   “Part of my power in my car shut off on the freeway, at 1:39 pm at 67 degrees outside . I had been driving for 40 minutes. My dashboard went dark, and only my clock time was on. I glided to the side of the road, and was able to pull the car very hard to the right (as the power steering was off). Then turned the key to off, waited 3 minutes turned the key and it went back on. It has not happened again.”

   NHTSA complaint #11093939, filed 2018-05, 112,000 miles

   “I purchased my FLEX new on oct 2009 and it has shut off while driving three times since I bought it. The first time it happened I was driving through my neighborhood (with my children in the car with me) at 20mph all the warning lights came on my engine shut off, loss of power steering, loss of brakes. Luckily I was able coast to the side of the street. I waited a few minutes and it wouldn't start. I tried to start it again and it started up. …”

   NHTSA complaint #10441503, filed 2011-12, 25,000 miles
2. 2
   Fuel system

   Fuel gauge drops to empty near a quarter tank

   • 13 complaints (7%)
   • median 93,330 mi at 7.0 yrs old (12 state mileage)
   • filed 2014–2019

   Owners describe the fuel gauge and distance-to-empty display suddenly dropping to zero when roughly a quarter tank remains, after which the engine dies as if out of fuel. Complaints note that refueling only takes about three-quarters of a tank, suggesting fuel remains but cannot be drawn, and that dealers had no fix or advised keeping the tank above a quarter full. Some reports point to a sending unit and jet pump as the part involved. Mostly reported between roughly 40,000 and 160,000 miles, often at highway speed or while driving on a quarter tank or less.

   What to check: Check whether the fuel gauge reads steadily through the last quarter tank, and ask whether the sending unit or jet pump has been replaced. Plan to refuel well before a quarter tank until the behavior is confirmed.

   2 excerpts from owner complaints in NHTSA records

   “The issue that has recently cropped up on our FLEX is the fuel meter will read sufficient fuel for approximately 50 miles and then, in a matter of miles, the tank seems to run dry/indicate no miles left. On this particular date I was driving the car it indicated 49 miles to empty. After 3 miles it ran out of gas. Fortunately I was on a side street and not the highway. This behavior could have been fatal if I was operating on a highway. I am not the only one having this issue. …”

   NHTSA complaint #10671242, filed 2015-01, 68,000 miles

   “As has been reported many time on here and in the FLEX forums, the vehicle will suddenly stall at a 1/4 tank of gas for no reason. I was traveling down the interstate at high way speed when the fuel gauge dropped to e and the miles to empty read 0. This has happened three times. I called one of my local dealers who insisted they have never heard of this problem and nothing was done. There advice was to not let the car get to a 1/4 of a tank. They have no fix for this dangerous problem.”

   NHTSA complaint #11102854, filed 2018-06, 60,800 miles
3. 3
   Engine cooling

   Radiator cooling fans stop and engine overheats

   • 13 complaints (7%)
   • median 68,770 mi at 4.8 yrs old (12 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2011–2020

   Complaints describe the cooling fans failing to run, causing overheating and hot air from the A/C when the vehicle is idling or moving slowly in warm weather. Owners report that replacing the fan relay or the fan assembly helped for a time, and some say the fans failed again afterward; a few mention the engine going into reduced-power mode or the A/C blowing warm at stoplights. Typically reported between roughly 45,000 and 100,000 miles, with symptoms most apparent while idling or in slow traffic, especially in hot weather.

   3 related service bulletins

   What to check: Let the vehicle idle with the A/C on for several minutes and confirm the cooling fans cycle on and that the A/C stays cold. Ask whether the fan relay or fan assembly has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “This vehicle experienced failure of both radiator cooling fans. The engine entered reduced power mode due to high temperature while my wife was entering a busy street. Just prior to this the vehicle had been idling for approximately 10 or 15 minutes. Temperature light did not illuminate until engine entered reduced power mode. Check engine light did not illuminate. Loss of power without warning could be very dangerous under certain conditions. After some research I have found that this is not an isolated incident. …”

   NHTSA complaint #10493676, filed 2013-01, 70,000 miles

   “2009 Ford FLEX limited overheats while idling for the past 3 years. Ran multiple vacuum tests and there is no leak or shortage of coolant. A/c blows hot while idling. Replaced relays, thermostat, and fuses to no avail. Replaced cooling fans recently with oem parts. Car is no longer overheating, but now has a strong electrical or melting smell after driving. Fans potentially failing again.”

   NHTSA complaint #11089105, filed 2018-04, 100,000 miles
4. 4
   Brakes

   Premature brake wear, noise and soft pedal

   • 22 complaints (12%)
   • median 29,000 mi at 3.1 yrs old (20 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2009–2021

   Complaints describe grinding brakes and repeated replacement of pads and rotors, including rear rotors replaced more than once at low mileage, with some owners saying the dealer called it common for the model. Others report a brake pedal that travels to the floor or feels spongy, and two owners mention a brake light or auxiliary relay issue. Reported from as low as a few thousand miles up to about 70,000 miles, with rear and pad/rotor work often noted well under 50,000 miles.

   2 related service bulletins

   What to check: Have a mechanic measure pad and rotor thickness at all four corners and check the pedal for firmness. Ask for receipts showing how often brakes were serviced and whether the brake light and relay function normally.

   2 excerpts from owner complaints in NHTSA records

   “2009 Ford FLEX-complete brake failure after sitting for a period of time at high-altitude. Brakes had felt spongy other times but we thought it was due to icy parking lot-as after driving a bit brakes felt ok. This time brakes failed completely resulting in property damage. Car towed to local Ford dealership -- they told us the brakes were fine and there have been no issues with brakes on the Ford FLEX--which after researching we know to be false. …”

   NHTSA complaint #10455941, filed 2012-04, 67,000 miles

   “My 2009 Ford FLEX limited fwd has less than 50k miles and the rear rotors has been replaced twice. They rusted away, corrosive brake fluid causes rust. My dealer keeps saying that all FLEX vehicles have this problem.”

   NHTSA complaint #10604401, filed 2014-06, 24,590 miles
5. 5
   Steering

   Hard steering or power steering loss

   • 12 complaints (7%)
   • median 77,000 mi at 6.6 yrs old (11 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2013–2023

   Owners report the steering becoming extremely difficult to turn, sometimes suddenly at speed and sometimes only at low speed or when parking, with no warning light and no leak found. Dealers were often unable to identify a cause, and in some cases the complaint followed a stall that removed power assist. Reported from about 20,000 to 170,000 miles, with several complaints between roughly 30,000 and 80,000 miles.

   What to check: During the test drive, try low-speed turns and parking maneuvers and check that steering effort stays consistent. Ask about any prior steering pump, cooler or assist repairs.

   2 excerpts from owner complaints in NHTSA records

   “This is the third time the power steering has failed in this vehicle. I was driving 60 MPH and without warning the steering seized. Luckily I was driving in right lane and was able to get vehicle safely to a lot. There was no warning, no noises, no dashboard lights came on. The steering became very tight and was extremely difficult to turn the wheel.”

   NHTSA complaint #11328645, filed 2020-06, 170,000 miles

   “June 10, 2015 - everything was fine, parked the car. Got back in car, backed up put it in drive and couldn't turn the steering wheel. Ever since when turning right or left at slow speeds it is very very very hard to turn the wheel. If I am tuning like a curve on the highway, there is no problem. But stop lights and stop signs and the what not are about impossible anymore. So it seems when not going fast enough the steering is in manual mode.”

   NHTSA complaint #10726226, filed 2015-06, 110,000 miles

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.