Some 2013-2016 Super Duty vehicles equipped with a 6.7L diesel engine and 2015-2019 Transit vehicles equipped with a 3.2L diesel engine may not pass a state smog test due to the exhaust gas system (EGS) monitor that will not run after completing the Exhaust Gas Sensor drive cycle located within Section 2 of the Powertrain Control/Emissions Diagnostics (PC/ED) Manual > Drive Cycles. This may be due to the vehicles diesel oxidation catalyst (DOC) age counter being under the 120-minute requirement. Engineering is investigating this issue and working on a solution.
full bulletin at NHTSA ↗2016 Ford Transit engine problems
severe 14 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Complaints
14
Recalls
0
Avg fix
$3,100
1fire
When does it fail?
Of the 14 engine complaints filed for the 2016 Ford Transit, here's the actual mileage breakdown — failures cluster heaviest at 150,000+ mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
For 2015-2024 Ford and Lincoln vehicles equipped with turbocharged engines and customer concern of an engine oil leak, refer to Workshop Manual (WSM), Section 303-00 for oil leak inspection and testing methods. Ford has evaluated turbochargers replaced for oil leak symptoms and although oil may collect on the external surface of a turbocharger, it is extremely rare for a turbocharger assembly to be the root cause of the oil leak. Careful inspection of the turbocharger oil feed and drain tubes should be performed along with the recommended WSM procedures as needed. Warranty claims for turbocharger replacement going forward will be assessed.
full bulletin at NHTSA ↗Certain 2015-2019 Model Year Transit Vehicles Equipped With 3.2L Diesel Engine - Exhaust Gas Temperature (EGT) Sensor Replacement
full bulletin at NHTSA ↗Certain 2015-2019 Model Year Transit Vehicles with 3.2L Diesel Engine - Crankcase Ventilation Hose Assembly Replacement and Powertrain Control Module Software Update
full bulletin at NHTSA ↗Some 2017-2022 F-Super Duty and 2016-2022 F-650/F-750 with 6.7L diesel engines, 2015-2019 Transit with 3.2L diesel engines and 2018-2021 F-150 with 3.0L diesel engines may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P206C in the powertrain control module (PCM). Review of repair data supports that P206C is often the result of incorrect diesel exhaust fluid (DEF) concentration. Per Powertrain Control/Emissions Diagnosis (PC/ED) Pinpoint Test (PPT) RJ, a DEF concentration reading below 28% will set P206C and cause vehicle derate. If low concentration is suspected, drain fluid and replace with known good DEF before replacing any parts. Low concentra
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report distinct failure patterns across 2016 Ford Transit engines. The most common complaint involves sudden stalling and loss of power—often without warning—at varying mileage points (74,000 to 165,000 miles). Some stalls occur at highway speeds, forcing vehicles to the shoulder; others happen in parking lots or during normal driving. Several owners describe fuel system problems: metal shavings discovered in fuel lines, fuel pump failures, and high-pressure fuel pump (HPFP) breakdown. One owner experienced complete engine seizure at 79,000 miles after the engine made a loud bang; a replacement engine subsequently failed, and a third unit had to be installed.
Owners also report exhaust system issues—leaking exhaust manifolds around 75,000 miles causing loud chirping noises, and an exhaust pipe design flaw allowing noxious fumes into the cabin. Air intake problems occur after highway driving in rain, with water-saturated air filters reducing fuel economy from 17–19 mpg to 14 mpg. Throttle body failure caused sudden loss of acceleration on a freeway, and catalyst system failures occur repeatedly across multiple vans in one owner's fleet, with repair costs reaching $2,500 per unit. Owners also report EGR fracture and a brake issue paired with engine revving during braking, though the exact mechanism remains unclear. No warning lights appeared in some cases; others show "Reduced Power," "High Temperature," "Engine Fault Service Now," or check engine warnings.
Same Ford Transit engine reports on nearby years: 2015
Failure modes owners describe
Fuel pump failure and fuel system contamination
High-pressure fuel pump (HPFP) failure and/or low-pressure fuel pump detachment, causing sudden loss of engine power and stalling. Metal shavings found in fuel system requiring complete fuel system replacement (pump, valves, injectors).
When: 74,000–165,000 miles
Symptoms owners cite: Sudden engine stall without warning; Loss of power while driving; Vehicle coasted to shoulder or stopped; Metal shavings in fuel system; Recurring stalls after repair attempts
Codes mentioned: NHTSA Campaign 16V618000 (fuel system, diesel, engine), P0XXX (generic fuel-related codes inferred from dealer diagnosis)
Repairs/costs cited: Complete fuel system replacement including fuel pump, fuel valves, and fuel injector; high-pressure fuel pump replacement; low-pressure fuel pump replacement and reattachment
Recalls/TSBs owners mention: NHTSA Campaign 16V618000 (recall); some vehicles excluded based on production date cutoffs; dealer diagnosis cited but manufacturer referred some owners to NHTSA Hotline; some vehicles not included in recall despite identical failures
Complete engine failure
Catastrophic engine seizure with loud bang and total loss of function, requiring complete engine replacement. Replacement engines also failed, necessitating multiple engine swaps.
When: 79,000 miles
Symptoms owners cite: Loud bang from engine; Engine ceased function completely; No warning lights illuminated; Replacement engine exhibited problems immediately
Repairs/costs cited: Complete engine replacement; second replacement engine also failed; third engine replacement ordered; three months repair timeline
Recalls/TSBs owners mention: Ford acknowledged second engine was defective and covered rental car and subsequent replacement engine installation
Exhaust manifold leaking
Exhaust manifold develops leak due to warping, described by dealership as a design flaw in bolt pattern. Allows noxious gases to accumulate in engine compartment and possibly enter cabin.
When: 75,000 miles
Symptoms owners cite: Loud chirping or ringing sound; No warning lights; Noxious gas buildup in engine compartment
Repairs/costs cited: Dealership diagnosis of leaking exhaust manifold noted as common issue with 3.5 EcoBoost engines; repair not specified in narrative
Exhaust system design flaw
Exhaust pipe designed not to extend fully to rear bumper, causing noxious fumes to accumulate and potentially enter passenger compartment.
When: 16 miles (very early failure)
Symptoms owners cite: Burning odor inside cabin; Difficult breathing; Odor present whenever vehicle driven
Repairs/costs cited: Dealer diagnosed design issue; vehicle not repaired as of complaint date
Recalls/TSBs owners mention: Manufacturer notified; no resolution provided
Water intrusion into air intake system
Air intake design allows rain and moisture to be sucked into air filter during highway driving in wet conditions, saturating filter and reducing engine performance.
When: During extended highway driving in rain
Symptoms owners cite: Water-saturated air filter; Reduced fuel economy (dropped from 17–19 mpg to 14 mpg); Potential for engine stall and loss of power
Repairs/costs cited: Air filter replacement; air intake design criticized as needing revision
EGR (Exhaust Gas Recirculation) fracture
EGR component fractured, causing temperature gauge fluctuations and high-temperature warning.
When: 150,000 miles
Symptoms owners cite: Message: 'High Temperature - Pull Over Safely'; Temperature gauge fluctuating from normal to high; Check engine warning light illuminated
Codes mentioned: Ford Campaign Number 18M06
Repairs/costs cited: EGR replacement needed; vehicle not repaired as of complaint
Recalls/TSBs owners mention: Ford Campaign 18M06; manufacturer informed contact campaign had expired and referred to NHTSA Hotline
Throttle body failure
Throttle body failure caused sudden and complete loss of acceleration while driving on freeway during rush hour.
When: Unknown mileage
Symptoms owners cite: Dash message: 'ENGINE FAULT SERVICE NOW'; Sudden loss of acceleration; Vehicle had to coast to shoulder
Codes mentioned: ENGINE FAULT code
Repairs/costs cited: Throttle body replacement required
Recalls/TSBs owners mention: Ford stated this is a safety feature to prevent engine damage when parts fail
Catalyst system failure
Repeated catalyst (catalytic converter) failures across multiple 2016 Ford Transit vans in the same fleet, indicating potential systemic issue.
When: Unknown specific mileage
Symptoms owners cite: Check engine light and catalyst fault codes (inferred)
Repairs/costs cited: At least two catalyst replacements on one 3.5L Transit 350 van; second replacement cost $2,500; owner reports all five vans in fleet exhibiting same symptoms
Engine fault with loss of power and throttle shaking
Engine fault warning displayed, vehicle lost power while crossing intersection, then exhibited shaking upon acceleration after restart.
When: Unknown mileage
Symptoms owners cite: Message: 'ENGINE FAULT SERVICE NOW'; Loss of power at 25 mph; Vehicle shaking when accelerating after restart
Codes mentioned: ENGINE FAULT code
Repairs/costs cited: Not specified; issue resolved after second restart without issues
Brake-related engine revving issue
Engine revved unexpectedly during braking, causing acceleration and making vehicle difficult to stop. Brakes inspected and deemed normal by multiple shops.
When: Unknown mileage; occurred on road trip with 6 children
Symptoms owners cite: Engine revved when brakes applied at 55 mph; Difficult to stop vehicle; Issue recurred multiple times over two days; No warning lights illuminated
Repairs/costs cited: Sensors cleaned without resolution; no mechanical issue found by Ford dealerships or independent shop
Recalls/TSBs owners mention: Two Ford dealerships and independent shop (Les Schwab) found no problem; brake booster leak ruled out
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The contact owns a 2016 Ford Transit. The contact stated that while driving at various speeds, the vehicle stalled. During the failure, the warning message "Reduced Power" was displayed. The contact stated that after restarting the engine, the vehicle operated as intended; however, the failure reoccurred later. The vehicle was taken to the local mechanic who replaced the fuel injector, but the…
Had engine trouble with your 2016 Ford Transit?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2016 Ford Transit?
It's a meaningful issue. 14 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Based on the 14 complaints filed, engine issues most often appear around 84,121 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2016/Ford/Transit.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.