2.5 Duratec I4 Common Problems

The 3 Most Common Ford 2.5L Duratec I4 Engine Problems

Jake Mayock

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Jake is a founder of 8020 Media and TuningPro. He has over a decade of experience in the automotive industry including parts sales, writing, DIY modifications & repairs, and more. Jake is currently converting his N54 to a single turbo and building a Miata track car. He’s an experienced, hands-on automotive enthusiast who delivers in-depth, well-researched content.

With a max output of 175hp, the 2.5 Duratec often gets overlooked due its minimal power. While it may not be an engine for a true auto enthusiast, it’s an excellent choice for those looking for a reliable and fuel efficient engine to get from point A to point B. Despite its good reliable the engine is still subject to a few flaws and issues. Some of the most common Ford 2.5 Duratec problems include the transmission, coolant consumption, and power steering system.

2.5 Duratec I4 Common Problems

Ford 2.5 Duratec I4 Common Problems

  • Coolant consumption
  • Transmission hard shifting
  • Power steering failure

I had an extremely difficult time finding any common problems on these engines. I have heard the term over-engineered used for the Duratec I4. While I won’t disagree, it’s extremely difficult to break a piston or run into issues with the engine internals, block, etc. when you have 2.5L only putting out 175hp. This is great news for reliability and my inability to find major problems with this engine is a testament to its longevity.

1. Coolant Consumption Problems

The most common “problem” with the Duratec I4 is its propensity to guzzle engine coolant. Most owners claim having to refill on coolant once to twice per year whereas most cars typically only need a coolant top off every few years, if at all.

There hasn’t really be any conclusive reason for why the Fusion and Escape’s consume so much coolant. However, it isn’t typically caused by any sort of noticeable coolant leak which has led some to believe that the cause is engine block porosity.

While there isn’t a solution we know of to this problem, it’s important to be aware of the issue. If you run low on coolant the engine can overheat. When an engine overheats it can warp the engine block, heads, and internals and lead to catastrophic engine damage. We recommend keeping an extra bottle of coolant in your trunk in case you see the low coolant warning light in the middle of a trip.

Outside of the mysterious coolant loss, there are a number of other potential causes of coolant loss. A cracked radiator, leaking water pump or hoses, blown head gasket, or cracked heads can all cause significant coolant loss.

Symptoms of Coolant Loss

  • Low coolant warning light
  • Engine overheating
  • Possible coolant leaks

Coolant loss symptoms are generally straight-forward. All engines consume some degree of coolant however excess coolant loss isn’t normal. Symptoms include a low coolant warning light and possibly overheating if the coolant level falls too low.

It’s possible the cause of the coolant loss is a physical leak. Check for coolant puddles or leaks after your 2.5L Duratec has been parked for a while. Any visible leaks are a dead giveaway that the engine is experiencing coolant leak problems.

Potential Causes of Coolant Loss / Leaks

  • Cracked / leaking radiator
  • Bad radiator cap
  • Blown water pump
  • Leaking hoses
  • Blown head gasket
  • Expansion tank failure

Start with the basics and look for any visible leaks. The coolant system is pressurized so any major leaks should be evident while the engine is running. You can also pressure test the coolant system with the engine off and look for any leaks or listen for air escaping.

2. Transmission Shifting Problems

The transmissions in the Fusion, Escape, and Milan use a traditional 6-speed automatic. Unfortunately, the transmissions have leaking issues which causes the trans fluid to run low and lead to numerous issues like hard shifting, erratic shifting, slippage, etc. On the 2012-2014 Fusion’s and Escape’s the issues are likely to start arising around the 70,000 mile mark.

While these problems are most prone on 2012-2014 cars, we have seen issues reported with all years. The common cause of the issue is a leaking shaft seal, located on the left side of the transmission. The output shaft seal is located on the front of the transfer case and is responsible for sealing the output shaft to the transfer case. As is common with seals overtime, they wear out and deteriorate which causes transmission fluid to leak out at the output shaft.

A second common cause of transmission problems in these cars is caused by the powertrain and transmission control modules. The software calibration can fall out of sync and need to be upgraded. When the TCM/PCM is the issue you will typically notice rough or delayed shifting between gears 1 and 2 and between 4 and 5.

The most telltale sign is tranny fluid leaking from the transfer case. However, a lot of 2.5 Duratec owners don’t notice the leaks until it is too late. Once enough fluid leaks out, the transmission becomes highly problematic experience issues from rough shifting to gear slippage.

First, check your transmission fluid and transfer case for any leaks. If there are no leaks and fluid looks good, then the likely issue is with the PCM/TCM.However, read on below as a TCM or PCM upgrade can lead to further transmission problems.

Leaking Transmission Fluid Symptoms

  • Fluid leaking from transfer case
  • Hard shifting
  • Gear slippage
  • Delayed shifts

3. Power Steering Failure

While this problem again isn’t necessarily engine focused, it is a potentially dangerous issue for Ford Fusion and Escape drivers. Ford replaced the hydraulic power steering units with new electronic power assister steering (EPAS) units. The new system simplified power steering in the sense that it removed all the pump, pulleys, and fluids needed for hydraulic systems. However, it complicated it in the sense that the whole system is now controlled by computers.

The new EPAS system has a motor, ECU, torque sensor, and steering wheel position sensor controlling the system. The issue with the EPAS system in the 2.5 Duratec is that the torque sensor is prone to sudden failure. The torque sensor monitors how hard and how far you have turned. This sensor is the primary failure point and usually fails instantaneously without any warning lights or heads-up.

When the sensor fails it no longer sends a signal to the ECU and the ECU then disables the power steering unit. Ultimately, you will lose power steering and have a really difficult time turning the wheel, especially at slow speeds.

Torque Sensor Replacement

Unfortunately the repair isn’t as simple as just replacing the torque sensor. The torque sensor is built directly into the steering column and therefore cannot be replaced without pulling the steering column. Fortunately, this issue became a recall item for the majority of models with the 2.5 Duratec.

2.5 Duratec I4 Reliability

As I mentioned above, finding common problems for the Duratec 25 was rather difficult. While these engines lack power, the tradeoff is fantastic reliability. It is hard to bust a lot of systems when you are pushing 175hp in a 2.5L engine making this engine extremely reliable.

There are virtually no common problems associated with this engine by itself. The Fusion and Escape’s using it have had some transmission and power steering issues but overall nothing in particular has plagued the engine. They are known to guzzle coolant so just make sure you frequently top off on coolant as needed.

There aren’t many performance modifications available for the Ford 2.5 so it is hard to say how reliable these are with added power. However, we can say for certain that these engines are extremely reliable when kept stock and used simply for getting from point A to B.

Yes, they are extremely reliable but maintenance is to be expected with age. Once you surpass the 100k mile mark and make your way towards 150k, you can expect some basic repairs to pop up eventually like water pumps, spark plugs and ignition coils, fuel injectors, gaskets and seals, suspension components, etc. A well maintained 2.5 Duratec can last 250,000+ miles.

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  1. Have 250,000 miles on my 2010 Fusion 2.5L and it runs like new! It has plenty enough power. I will NOT buy anything with an ecoboost engine! I wish Ford kept the 2.5L as an option.

    1. I own a 2014 Tourneo (Transit connect) LWB wagon, aka dork mobile… with the 2.5L with 80k miles on it and luv it… want a new one, but, they come with a 2.0L engine now… 2.5L is a strong work horse and bullet proof… this little van is like a Nat on steroids…

  2. My 2011 fusion had spark tip burn off in cylinder 4 has 190,000 miles and running like new connot belive it

  3. 205,000 miles on my 2010 Ford Fusion Hybrid when I sold it. Engine showed no signs of weakness. I used Mobil 1 0W20.

  4. I have a 2012 Fusion and at 150K miles she still runs as strong and smooth as the day I drove her off the lot with only 30K miles of course I’m an auto shop tech and manager so I meticulously maintain my Fusion with only the best. I’ve replaced minor things at higher mileage like the engine mounts and the water outlet but otherwise I always replace parts as maintenance by mileage with only OEM Motorcraft parts I never wait for parts to fail and my fusion looks and runs better than the day I got her. Best car I’ve ever owned by far!

  5. I have a 2016 fusion with the 2.5 and I absolutely love this car . Bought it new and have had zero issues with it . Still has the original front brakes on it . Still gets 30 mpg at 136000. Gets driven about 100 miles a day . Best car I have ever owned by far

  6. I very much agree with you about ecoboost motor. I have a 2008 Mariner and a 2010 Escape, both with Duratec 3.0L engines that work flawlessly. I was considering purchasing a new Escape, but they all have EcoBoost engines, which are unreliable, as I’ve discovered.

  7. I have a 2016 fusion and am having the transmission slippage issue mainly when shifting from park into reverse/drive or from reverse to drive (which tells me that it’s the TCM) but every ford tech I take it to says “oh there’s nothing wrong with it!” Okay… sure.
    I’m coming from a camry 2.5l (2ar-fe) with almost 50 more HP and a lighter car. Comparatively, the fusion’s ~175 hp feels anemic. The fusion is way more comfortable but the trans issue bothers me to no end. Ford refuses to admit that my car has a computer problem. I am currently looking to do some mods to squeeze an extra 40-50 hp out and fix/replace the TCM and/or trans.

  8. I have a 2018 ford fusion 2.5 and having harsh shift. It has almost 80k. Took it to the dealer and they wanted to replace everything total price 10k. Lack of power and getting bad MPGs any advice on what to check. Not a car guy tbh

    1. Yeah certainly wouldn’t listen to them. If you don’t know what you’re looking at on a car best bet is to take it to an independent service shop and get a better quote/diagnostic.

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