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Old 4th August 2021, 11:38   #1
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Default Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency

This is so awfully handled by Ford India! First off, hundreds of Ford owners are complaining about DPF warnings, noticeable power loss, drop in pickup / acceleration & other related issues. Worse still, the dealers are largely clueless (because Ford is too), there is a complete lack of transparency, zero communication from Ford and poor Ford owners are made to run from pillar to post .

There are people who have brand new Ford 1.5L diesel cars and are frustratingly trying to get someone to hear their problems! Authorised dealers aren't responsive, Ford is saying nothing, what the heck is an owner supposed to do then? Go wait at the service center endlessly with his / her brand new car? I heard of a surgeon who bought a new Ford and is fed up, as he simply doesn't have the time to follow up. Owners are complaining since months and HAVE STILL NOT RECEIVED A RESOLUTION.

One of those situations where silence isn't golden, Ford. Speak the hell up, own up to these issues, apologise, issue an official recall and tell your customers what to do. If you have any sense, throw in a freebie like a complimentary 1st service, a full tank of diesel or something. People are paying 10 – 15 lakh rupees to Ford, despite rumours of the company’s exit from India, only to be treated like 2nd-rate customers.

Someone who's suffering says:
Quote:
Ford really needs to do something about it! They can’t expect people living in cities to drive endlessly on highways for miles just to clear a damn filter! It’s literally like saying- my way or the highway .
Problem is, highway driving doesn't solve it either!

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage001.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage002.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage003.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage004.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage005.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage006.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage007.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage009.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage010.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage011.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage012.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage013.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage014.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage015.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage016.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage017.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage018.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage019.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage020.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage021.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage022.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage023.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage024.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage025.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage026.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage027.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage028.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage029.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage030.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-ford-dpf-issue-1st-aug-2021-finalpage031.jpg

Last edited by GTO : 5th August 2021 at 08:02.
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Old 4th August 2021, 11:47   #2
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Default re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency

Thanks to Ayush for sending this information in. Heartfelt gratitude for sharing it with other enthusiasts via this page! All the images in the post above were received this week, while the email below was shared with me in June:

Quote:
Hi Rush,

This email is around the DPF issues associated with Ford EcoSport (and other Ford vehicles using the same 1.5L TDCI engine). We don't know the full extent of the issue as a customer yet, but my efforts along with the help of other owners facing similar issues led Ford India to suspend deliveries of new Ford vehicles until July 15th. Below is a short version of the issue; detailed experience is in the shared attachment.

My newly purchased Ford EcoSport Diesel started facing DPF (exhaust filter; diesel particulate filter) issues and despite following all the steps as per the owner's manual, talking to Ford customer care and even spending more than a day at a Ford assigned service station (under the guidance of Ford Hotline tech team) - the issue did not go away. This led to a loss of power in the engine and poor pick-up in the lower gears. At this point, Ford did not have any other solution but to ask me to drive the car more, despite a heavily choked DPF. I was really concerned about safety as well as the long-term damage caused to the vehicle. At this stage, due to the negligence of Ford and the poor handling of our case, we started pouring through social media and forums.

We realized this is not a one-car issue and saw many Ford EcoSport Diesel BS6 owners (with newly purchased cars) having the same issue. This led us to the start of our data gathering process, which revealed nearly 30 other distressed owners facing similar concerns (from our limited reach). Post this, we had to even escalate the issue to the higher management of Ford. And after relentless follow-ups for days, and being the victim of no official communication (no emails despite multiple requests), we have finally seen some early signs. Today, I, along with a few other owners, have confirmed with multiple Ford dealerships that the deliveries for Ford diesel vehicles (EcoSport, Figo & Freestyle) have been halted until July 15th. My understanding is that Ford will push a software update to hopefully resolve the DPF issues on new vehicles. Additionally, we have heard reports of a recall of diesel vehicles manufactured by Ford between February to June 2021. Owners like me (who purchased the car in April 2021), are still waiting for a proper resolution so that we can enjoy the pleasure and safety associated with driving a new vehicle. The detailed experience is in the attachment. Also attached are some supporting images.

Hope this suffices.

Regards,
Ayush
Quote:
Issue became worse an hour ago and the car has an engine oil pressure warning at 2956 km on the odo. Ford assured me 'safety' via email at 2935 km odo level two days ago and told me to drive 500 kms today to get proper service as the nearby service station didn't help. Started our drive today, booked hotels and the warning popped up in 2 kms - now Ford finally asked me not to drive anymore. Let's see how they tackle things now, some hope.
Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-img20210611wa0010.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-img20210611wa0011.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-img20210611wa0013.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-img20210616wa0007.jpg

Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency-img20210616wa0009.jpg

Last edited by GTO : 4th August 2021 at 12:57.
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Old 4th August 2021, 11:51   #3
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Default re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparency

Ford keeps mum on the issue, but we confirmed it anyway, thanks to Preekshith A who shared an email with us - Software Update from Ford (Software update causes Ford EcoSport Diesel delivery delays).

Quote:
Originally Posted by Nikhil Beke View Post
More than anything else, Ford India's lack of transparency is intriguing. Why not clearly say that it's a software update that's being tested for fixing DPF issues? As if they didn't have enough uncertainties regarding their existence already! This suspiciously long timeline for unknown issues (and presently questionable efficacy of rectification measures) is bound to make their customers jittery- especially if they're expecting a new vehicle delivery. Adding to that, I had written an email to them a month back regarding these very issues (if they would be solved in the new batch of engines(as there was a talk of Ford providing update to older customers)) and they flat out denied existence of any such issues on Diesel engines.
Quote:
Originally Posted by fiat_tarun View Post
From comments on the Facebook owners forum this appears to be the update to fix the DPF clogging and regeneration issues that some BS6 owners are having. Even after driving the required distances at >2000 rpm the DPF warning remains.

From what I read, owners have been complaining for a while so good that Ford finally is taking some action to fix this issue.

It looks like the DPF only BS6 diesels are not meant for only slow speed city drives. They need the good old 'Italian Tune up' once in a while
Quote:
Originally Posted by witwat View Post
I just got my BS6 EcoSport Titanium S Diesel updated today. My car was delivered a couple of weeks back. Have just clocked 350kms on Odo! Apparently it is an April 2021 model which got delayed with the delivery due to the lockdown here in Bengaluru. Soon after the delivery I had visited the workshop to update my Sync 3.2 (factory version) to sync 3.4 since I couldn't update it manually from my end

With a successful update, I thought this was it until I got a call from the delivery executive to visit the workshop today for another update. He told me, he happen to get notified by the system and this needs to be updated by their end! Seems like they are being advised by Ford to update on the same! Apparently, this update is available only to BS6 diesel vehicles manufactured post March 2021 and as told by the professional at the authorised workshop.

On enquiring further, I got to know that this is a PCM (powertrain control module) update V.6.1 helping BS6 Diesel vehicles to address the DPF issues. However, upon driving back I could also sense a considerable upgrade in my throttle response and could easily reach 95+ kms on Bengaluru airport road, which didn't happen before while driving to the workshop! The whole power delivery seems like an uplift!

Yet to see the long term benefits and witness more changes. Not sure how much I can analyse since I have clocked only 350+ kms before the update.

Overall I was pleasantly surprised by the dealer and service staff to initiate and accomplish the task in jiffy

Last edited by GTO : 4th August 2021 at 12:58.
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Old 4th August 2021, 12:59   #4
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

Thread moved from the Assembly Line to the Indian Car Scene!
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Old 4th August 2021, 13:09   #5
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

This is really unlike Ford, who advertise "Family wali feeling".

This should have been tested properly and more rigorously before, and in case of a miss, a customer who's invested 10+ lakh in your company deserves a better response and resolution.
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Old 4th August 2021, 13:11   #6
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

Excessive smoke has been an issue with Ecosport diesel engines, our 2013 had this problem right up until it was sold sometime back. ASC said it is normal for that engine to smoke like that and did nothing to it. I have noticed this problem in other Ecosport vehicles as well. Those days there was no exhaust filter to be bothered about, so no harm done, now this can really cause problems.
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Old 4th August 2021, 13:24   #7
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

This really has the potential to be the final nail in the coffin for Ford (considering how many enthusiasts like their Diesel powertrains) if they don't get their act together and proactively reach out to all customers and fix this issue.

Also, I don't really get how these two statements go together:

Quote:
My understanding is that Ford will push a software update to hopefully resolve the DPF issues on new vehicles. Additionally, we have heard reports of a recall of diesel vehicles manufactured by Ford between February to June 2021.
Quote:
Seems like they are being advised by Ford to update on the same! Apparently, this update is available only to BS6 diesel vehicles manufactured post March 2021 and as told by the professional at the authorised workshop.
Why is there an update only for vehicles manufactured post March 2021? Should it not be for all BS6 diesel ones?

Regardless, I would like to know if this update has caused any other affects ..perhaps something like lower fuel efficiency figures.

NOTE: I really hope Saurav has escalated the scam from Ganges FORDs end by using their employees mobile number as the customers one. It's high time that manufacturers try to fool proof their feedback mechanisms. Something like take both email and mobile numbers from the new customers directly and only allow these details to be changed with 2FA. If a unscrupulous dealer then tries to update the mobile number then we would get a notification and OTP on our emails.
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Old 4th August 2021, 13:34   #8
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

If I remember correctly, Ford was the first to move their 1.5 Tdci to BS6 compliance and most of us were surprised as to what and how they did it.

It looks like they haven't tested this enough and now they are clueless as well. From the software update that one of the owners received for his Ecosport who felt that the throttle response has increased, it looks like Ford has tweaked the software to pump in more fuel even when driving gently, thereby reducing soot buildup. This will take a hit on the fuel efficiency now.

The thing is, on a diesel or those who are used to driving a diesel, because of the torque available from low down, the revs don't climb that often and not every owner is going to take the car out and drive pedal to metal, risking life to clean a filter.

Ford should have had an automatic regen process, if not already wherein the engine revs up when sensing the DPF is nearing full capacity.
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Old 4th August 2021, 14:44   #9
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

First, I don't see a reason why we have to drive cars to clear that warning. In today's age of technology this looks like latest cars with 19th century tech. Why can't there be a feature which takes care of such warnings? (without driving and keeping the engine on). I am sure technology can be developed to that extent. Coming to Ford, given all the rumors of exit from India, I am not very surprised. A simple email to dealers and customers would solve this otherwise complicated issue (lack of communication). Big companies need small ideas to gain customers. That is the big picture.
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Old 4th August 2021, 14:56   #10
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

I got a headache after seeing so many DPF clean pictures. This is not funny at all, nor acceptable.

What if I am using my BS-6 diesel SUV as an office on go and sometimes have to sit in it with AC running in idle for 30 to 60 mins? [I do that with my BS-4].
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Old 4th August 2021, 15:39   #11
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I am not sure why Ford is struggling with a relatively simple bug to fix.

I was part of the Ford R&D team in Europe 21 years ago, when they were working with PSA to bring the market's first DPF-equipped car. The problem mentioned in this thread is a relatively simple one to fix.

There are broadly 2 ways a DPF can be regenerated.
1. Post Injection - This is most commonly used method. In this is a method, fuel is injected so late, that it doesnt burn in the combustion chamber. Instead, it travels all the way down the exhaust and ignites on the clogged DPF burning the soot / particulates along with it. Post injection is usually triggered when the delta pressure betwen 2 pressure sensors [one upstream of the DPF and another downstream] exceeds a certain preset value, indicating clogging.
2. Catalyst coating - This method is also used where the DPF is coated with a catalyst to bring down the spontaneous soot combustion temperature. In this method, the regeneration is bit more frequent as high temperatures dont need to be reached for regeneration.

So, in both the cases, it is a relatively simple hardware+software solution. I am quite surprised that Ford, of all companies is struggling to fix this, considering they were the first ones to work on this technology.

Can any new Ford owners confirm if there are 2 pressure sensors installed upstream and downstream of the DPF? This will answer many questions!

Sorry, forgot to mention - in both cases explained in my post above, the regeneration happens automatically with no perceptible impact on vehicle performance and / or driving behaviour!! A driver would not even know the regeneration process has been triggered / completed!

Last edited by GTO : 4th August 2021 at 17:52. Reason: Merging back to back posts
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Old 4th August 2021, 15:51   #12
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

Quote:
Originally Posted by Sheel View Post
What if I am using my BS-6 diesel SUV as an office on go and sometimes have to sit in it with AC running in idle for 30 to 60 mins? [I do that with my BS-4].
My BS6 diesel sees a good mix of city driving (500+ kms) in between highway trips. And I do have to idle it for extended periods during these city rides. Haven't faced any issue so far.

However honestly, this fear keeps playing on my mind
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Old 4th August 2021, 16:20   #13
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

This issue would be more prominent in the ecosport than figo twins.

8v motor with 'just adequate power' for the heavy chassis ecosport would mean urban driving cycles would cause more soot formation, particularly those who floor the pedal.
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Old 4th August 2021, 16:27   #14
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

I don't think it is practically possible for any DPF filter, to get choked within minutes of leaving Service center after having done a DFP Regen.

This could be either a poor software issue, OR poor sensor integration.
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Old 4th August 2021, 19:09   #15
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Default Re: Ford India struggles with DPF problems in 1.5L TDCI | Poorly handled & utter lack of transparenc

This problem has been there from the launch of BS6 Diesel engine. The 1.5 TDCi used currently is 8v and is almost a 3 decade old engine. Ford had mentioned that an update will solve the issue through select dealers and it's been a hit or miss. Some have the problem resolved while a few others are still stuck with thr problem.

The worst part is on the highway, the car suddenly looses power while overtaking. This is a dangerous issue with thr BS6 TDCi.

Some cars like XUV300 diesel have automatic DPF regen whereas in EcoSport it's manual DPF regeneration which is why most of the BS6 TDCi owners are facing this issue.

Either Ford India must give a complete resolution to this issue ASAP or bring the EcoBlue 1.5 engine from Europe. It's BS6 compliant too and not much development cost. Already the rumours of Ford leaving India have done enough damage + their penny wise pound foolish attitude by skimping on features every quarter have customers disgruntled.

Since the Facebook groups already have a lot of traction regarding this issue, if all the group admins can collate an excel of the affected oweners details and send an email to Ford India and Consumer complaints, we'll get a resolution. Nowadays consumer complaints take complaints seriously and act swiftly.
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