Ford Kuga Problems: The Most Common Diesel and Hybrid Defects (2025 Guide)

A complete guide to problems and faults with the Ford Kuga Diesel and Hybrid. Expert analysis of DPFs, AdBlue, automatic transmissions, and official recalls. Read for proper maintenance and a safe purchase.

The Ford Kuga has established itself as one of the best-selling and most popular SUVs in Europe, a true pillar of the Ford range thanks to its balance of comfort, technology, and driving pleasure. However, like any modern and complex vehicle, the Kuga also has some known issues that a discerning owner or potential buyer should be aware of.

Drawing on my daily experience as General Manager of Autoricambi Tritella and ongoing dialogue with a network of specialized workshops, I've prepared this comprehensive and transparent guide. The goal is to analyze the real drawbacks of the most common diesel and hybrid engines to help you make informed choices and manage your Kuga's maintenance most effectively.

Common Problems with Diesel Engines (EcoBlue)

Ford EcoBlue diesel engines are known for their robustness and generous torque. However, their modern complexity, especially with regard to pollution control systems, exposes them to specific issues that require careful management.

Clogged Diesel Particulate Filter (DPF)

It's the Achilles heel of almost all modern diesel engines, and the Kuga is no exception. DPF clogging is a common problem, especially for those who use their car primarily in urban environments and for short trips.

• Typical symptoms: DPF warning light coming on, drop in performance, increased fuel consumption and, in the worst cases, engine failure messages.
• Expert Tip: The advice I always give to my Kuga diesel customers is simple: at least once every 2-3 weeks, plan a 15-20 minute long drive outside the city at a steady speed, above 2,000 rpm. This allows the DPF to reach the temperature needed to complete an effective regeneration cycle. Furthermore, the regular use of high-quality DPF additives can make a big difference in preventing particulate matter buildup.

Read Also: BEST DPF CLEANING ADDITIVE: 2025 GUIDE TO CLEANER DIESEL ENGINES

AdBlue System Problems

The SCR system (with AdBlue) is essential for reducing NOx emissions, but it can be a source of headaches.

• Typical symptoms: Warning messages such as "Anti-pollution system fault" or the dreaded "Starting impossible in X km".
• Solution and Prevention: Often, the fault isn't with the AdBlue itself, but with a system component, such as the NOx sensor or urea injector. I strongly advise against DIY solutions or the use of emulators. The best option is a professional diagnosis to identify the faulty component. Always use ISO 22241-certified AdBlue, which is the first step towards prevention.

Read Also: COMMON ADBLUE SYSTEM PROBLEMS: CAUSES, SYMPTOMS, AND SOLUTIONS 2025

Reported Issues on Hybrid Versions (Full and Plug-in Hybrid)

The Kuga's hybrid powertrains are technologically sophisticated and offer excellent efficiency, but their complexity introduces specific issues, often related to the electronic management of the battery pack.

Official Battery Pack Recall (Plug-in Hybrid Versions)

This is a crucial point, especially for those approaching the used market.

• The Problem: Ford has launched a massive recall campaign due to a potential risk of overheating in the high-voltage battery pack on plug-in hybrid models produced through 2020.
• Expert Tip: If you're considering purchasing a used Kuga Plug-in Hybrid, the first and most important thing to check is whether the vehicle was eligible for this campaign. An authorized Ford repairer can verify this in seconds using the vehicle identification number (VIN). This check is a non-negotiable step for a safe and worry-free purchase.

Read Also: Ford Kuga Plug-in Hybrid Battery Recall: Risks, Checks, and Recommendations for 2025

Hybrid Management Software Malfunctions

The perfect synergy between the internal combustion engine and the electric motor is entrusted to complex software, which is not always free from bugs.

• Typical symptoms: Switching between the two drive modes is not always smooth, generic error messages from the hybrid system or abnormal shutdowns of the internal combustion engine.
• Solution: As with other electronic systems, most of these anomalies are identified and corrected by Ford through software updates. Before assuming mechanical failures, it's always a good idea to check for available updates for the control units.

Common Gearbox and Electronics Problems

Some issues are transversal between the different engines and concern components such as the transmission and infotainment.

8-Speed ​​Automatic Transmission Wear

The 8-speed automatic transmission fitted to the Kuga is a generally reliable torque converter, but it isn't everlasting.

• Typical symptoms: After high mileage (usually over 150,000 km), some users report rougher gear changes, slipping or delays in shifting gears.
• Solution and Prevention: The key to the longevity of this transmission is simple maintenance. Flushing and completely changing the transmission fluid, often overlooked by owners, is vital and should be performed according to the manufacturer's instructions. It's the best investment to avoid costly overhauls in the future.

SYNC Infotainment System Bug

Infotainment system problems are among the most common problems in modern cars.

• Typical symptoms: Screen freezing or going black, Android Auto or Apple CarPlay disconnecting, slow and unresponsive system.
• Solution: The first thing to try is a soft reset (hold down the power button and the "next track" button for about 10 seconds). If the problem persists, check for software updates, which can also be downloaded from the Ford website and installed via USB.

Read Also: HOW TO CHECK IF YOUR FORD CAR HAS AN OFFICIAL RECALL – 2025 GUIDE

The Final Verdict: Is the Ford Kuga a Reliable Car?

Absolutely. Aside from the critical issues analyzed, the Ford Kuga remains an overall reliable and well-built vehicle. Known issues are almost always manageable and, more importantly, preventable with meticulous maintenance and the use of quality components.

My final piece of advice for buyers: if you opt for a diesel, make sure your driving style isn't exclusively urban. If you're opting for a used plug-in hybrid, carefully check its service history and battery health, as well as any recalls. A well-maintained car is one that won't cause any surprises.

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