The Three Most Regular 2.5L Duratec I4 Ford Engine Issues

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The Three Most Regular 2.5L Duratec I4 Ford Engine Issues. Ford’s 2.5L Duratec engine, often known as the Duratec 25, is an inline four-cylinder engine with naturally aspirated combustion that was utilized from 2009 to 2019. The Mazda L5 engine served as the foundation for the I4 Duratec, which was developed in collaboration with Mazda. The 2.5 Duratec produced 136-172 lb-ft of torque and 156-175 horsepower. Finally, Ford’s new EcoBoost engine family replaced the 2.5 Duratec in 2019 and replaced it. The base engine for the Fusion and Escape was the 2.5 Duratec. Upgrades with greater power were available, including the 1.6 EcoBoost and 2.0 EcoBoost.

Early in the 1990s, Ford and Mazda collaborated to create the 2.5L Duratec V6 engine. The I4 and V6 versions of the Duratec 25 engine, which were utilized in different vehicles, are fundamentally distinct even though they have the same name.


The 2.5 Duratec, with a maximum output of 175 horsepower, is frequently disregarded because of its low power. It might not be the engine for a true car enthusiast, but it’s a great option for anyone searching for a dependable and fuel-efficient engine to get them from point A to point B. We go over the reliability and issues with the Ford 2.5 Duratec in this manual.

The Three Most Regular 2.5L Duratec I4 Ford Engine Issues

Uses for 2.5L Duratec I4 vehicles

The following years and models are equipped with the Ford 2.5L Duratec engine:

  • Ford Escape, 2009–2019
  • Ford Fusion 2010–2019
  • Ford Fusion Hybrid, 2010-2013
  • Ford Transit Connect 2014–2018
  • Hybrid 2011 Lincoln MKZ
  • Mercury Milan, 2010–2013
  • Mercury Milan Hybrid, 2010-2011
  • Ford 2.5 Duratec I4 Typical Issues

It was really challenging for me to identify any typical issues with these engines. For the Duratec I4, I’ve heard the phrase “over-engineered” used. While I won’t argue with you, when you have a 2.5L engine making only 175hp, it’s very tough to break a piston or experience problems with the engine’s internals, block, etc. This is fantastic news for dependability, and the fact that I haven’t discovered any significant issues with this engine is evidence of its durability.

  • Use of Coolant in Excess
  • Hard Shifts in the Transmission
  • faulty power steering
  • Issues with 2.5 Duratec Coolant Usage

The Duratec I4’s propensity to suck engine coolant is its most prevalent “problem”. Yet, most cars only require a coolant top up every few years, if at all, according to most owners, who claim to have to replenish it once to twice per year.

The reason why the Fusion and Escape consume so much coolant hasn’t truly been proven. But there usually isn’t any kind of obvious coolant leak, which has prompted others to speculate that engine block porosity is to blame.

Although we are unaware of a remedy to this issue, it is critical to be aware of it. The engine may overheat if your coolant level is too low. An engine can suffer catastrophic damage from overheating by having the block, heads, and internals warped. In case you encounter the low coolant warning light in the middle of a journey, we advise carrying an extra bottle of coolant in your trunk.

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There are numerous more possible reasons of coolant loss besides the mystery coolant loss. A damaged radiator, leaking water pump or hoses, blown head gasket, or cracked heads can all cause severe coolant loss.

Consequences of Coolant Loss

Problems with coolant loss on the Ford 2.5 Duratec include the following symptoms:

  • warning sign for low coolant
  • heating of the engine
  • potentially leaking coolant

The signs of coolant loss are typically obvious. All engines need some coolant, but excessive coolant loss is abnormal. A low coolant warning light and potential overheating are symptoms. If the coolant level is too low, overheating may occur.

It’s possible that a physical leak is what’s causing the coolant loss. Once your 2.5L Duratec has been parked for a time, look for coolant leaks or puddles. Any obvious leaks are a sure sign that the 2.5 Duratec has coolant leak issues.

Possible Root Causes of Coolant Leaks and Loss

The following is a list of potential reasons for coolant leaks or loss:

  • leaky or cracked radiator
  • improper radiator cap
  • damaged water pump
  • unreliable hoses
  • Head gasket blown
  • ket
  • Tank expansion failing

Start with the fundamentals and search for any obvious leaks. Any significant leaks in the coolant system should be visible while the engine is running since it is pressured. With the engine off, you can pressure test the cooling system and check for leaks or listen for air leaving.

Issues with the 2.5 Duratec Transmission Shifting

The Fusion, Escape, and Milan all have conventional 6-speed automatic transmissions. Sadly, the transmissions have leaky problems that result in low levels of trans fluid and a variety of problems like hard shifting, erratic shifting, slippage, etc. On the 2012-2014 Fusion’s and Escape’s the concerns are anticipated to start occurring around the 70,000 mile mark.

Although 2012–2014 vehicles are the ones most likely to experience these faults, all years have also had problems reported. The issue is frequently caused by a leaky shaft seal, which is found on the transmission’s left side. The output shaft seal is in charge of sealing the output shaft to the transfer case and is found on the front of the transfer case. Transmission fluid leaks out at the output shaft as a result of seals degrading and wearing down with time, as is typical.

The powertrain and gearbox control modules in these vehicles are a second frequent source of transmission issues. The software calibration may need to be updated if it becomes out of sync. You will generally experience jerky or delayed shifting between gears 1 and 2, as well as between 4 and 5, when the TCM/PCM is the problem.

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Tranmission fluid pouring from the transfer case is the most obvious symptom. Many 2.5 Duratec owners, however, don’t become aware of the leaks until it is too late. Once enough fluid has leaked out, the transmission can face problems like gear slippage and jerky shifting.

Check for leaks in your transfer case and transmission fluid first. If there are no leaks and the fluid appears to be in good condition, the PCM/TCM is probably the problem. Nonetheless, keep reading because a TCM or PCM upgrade may result in additional transmission issues.

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Signs of a Leaking Transmission Fluid

Some signs of transmission fluid leakage include:

  • leakage from the transfer case
  • tough switching
  • Shift slippage
  • sluggish shifts

Alternatives for Replacement or Prevention

Reprogramming or updating the software on the powertrain control module and gearbox control module is Ford’s fix for these problems. Other professionals, however, contend that the software update is really a temporary fix that results in bigger fluid leaks, which can eventually cause clutch and transmission failure.

The transmission software upgrade raises pressure within the transmission to prevent leaking. Unfortunately, the higher pressure causes the output shaft seal to experience more wear and tear, which eventually results in bigger fluid leaks. While it is a realistic remedy in a handful of vehicles, check sure you are not leaking fluid already. Instead of only reconfiguring the control modules, you need replace the output shaft seal if you are leaking fluid.

Maintaining proper trans fluid levels in the transmission is the simplest approach to avoid problems and guarantee transmission longevity.

The Three Most Regular 2.5L Duratec I4 Ford Engine Issues

3. Fusion and escape due to power steering failure

Even though this issue, once more, isn’t technically engine-related, it could be harmful for Ford Fusion and Escape drivers. Ford installed new electronic power assister steering (EPAS) units to replace the hydraulic power steering units. With regard to power steering, the new system was more straightforward because it did away with every pump, pulley, and fluid required for hydraulic systems. Yet, the fact that computers now run the entire system complicated matters.

The new EPAS system is controlled by a motor, ECU, torque sensor, and steering wheel position sensor. The torque sensor in the 2.5 Duratec’s EPAS system is problematic because it can fail suddenly. The torque sensor keeps track of how far and how quickly you’ve rotated. The main point of failure is this sensor, which typically malfunctions instantly and silently.

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When a sensor malfunctions, the ECU no longer receives a signal from it and turns off the power steering system. Eventually, you will lose power steering and find it quite challenging to turn the wheel, particularly at low speeds.

Torque Sensor Replacement

Unfortunately, the fix requires more than just swapping out the torque sensor. Since the torque sensor is integrated into the steering column, the steering column must be removed in order to replace it. For most cars with the 2.5 Duratec, this problem fortunately became a recall item.

Reliability of the Duratec I4 2.5

Finding common issues with the Duratec 25 was challenging, as I previously said. These engines don’t have much power, but they are incredibly reliable. When you are pushing 175hp in a 2.5L engine, it is difficult to blow many systems, making this engine quite dependable.

Hardly no typical issues are connected to this engine by itself. It has been used in the Fusion and Escape, which have experienced occasional transmission and power steering troubles, but overall the engine has not been very troubled. They have a reputation for guzzling coolant, so make sure you top them out as often as necessary.

For the Ford 2.5, there aren’t many performance upgrades available, so it’s difficult to say how dependable these are with more power. Yet, we can affirm that these engines are incredibly dependable when utilized solely to move from point A to point B and kept stock.

Indeed, they are incredibly dependable, but with age, upkeep is to be expected. You may anticipate that some basic repairs, such as water pumps, spark plugs and ignition coils, fuel injectors, gaskets and seals, suspension components, etc., will eventually need to be made once you cross the 100k mile mark and go towards the 150k mile mark.

A 2.5 Duratec with proper care may travel more than 250,000 miles.