Ford P2002

DPF efficiency below threshold on Ford — substrate damage or ash overload after repeated failed regens.

Ford P2002 — DPF efficiency below threshold on Ford — substrate damage or ash overload after repeated failed regens. Typical UK independent garage cost: £180–£1900.

What actually causes P2002 on a Ford

P2002 means the DPF physically can't trap soot effectively — substrate is cracked, melted from an uncontrolled regen, or so loaded with ash that there's no capacity left. Unlike P2463 (soot overload, often clearable), P2002 usually means a DPF replacement or off-vehicle clean. Ford TDCi DPFs typically last 120–150k if regens are kept healthy, far less on short-trip use.

Ford engines that log P2002

• 1.6 TDCi DV6 (Focus, C-Max, Fiesta)
• 2.0 TDCi (Mondeo, S-Max, Galaxy, Transit Connect)
• 2.2 TDCi (Transit)

How we diagnose P2002 on a Ford

1. Scan tool: read DPF differential pressure, soot mass, ash mass, regen attempt history
2. Inspect DPF visually for substrate damage via endoscope through the DPF temp sensor port
3. Back-pressure test cold vs hot to assess flow capacity
4. Quote off-vehicle clean before replacement
5. If replacing, sort the root cause (EGR, injectors, short trips) or the new DPF will follow

The common misdiagnosis to avoid

Don't pay for a new DPF until an off-vehicle clean has been attempted (£200–£300) — many P2002 cases clear with professional cleaning if the substrate is intact.

Ford P2002 repair cost in the UK

Expect £180–£1900 including parts and labour at an independent garage. Main-dealer quotes on Ford are usually higher for the same job, and the spread exists because the cheap cause and the expensive cause throw the same code — pay for the diagnosis before you pay for parts.

Bob's workshop tip

If the customer's been mostly short trips for years, recommend a 30-minute motorway run weekly AFTER any DPF work — same DPF, same engine, different driver habits, hugely different lifespan.

Codes usually seen alongside P2002 on Ford

• P244A
• P244B
• P2463

Symptoms drivers report with P2002

• The 'Engine Service Now' message on the dash, often without a limp mode initially.
• Thick black soot deposits around the inside of the tailpipe (it should be clean enough to eat off).
• A heavy smell of diesel fumes inside the cabin when sitting at traffic lights.
• The car seems to perform fine but the 'DPF Full' warning keeps popping up every 50 miles.
• Excessive cooling fan noise because the car is constantly trying (and failing) to start a regeneration.

Repairs that clear P2002

• Static regen on scan tool
• Replace pressure sensor
• Injector leak-off test
• Chemical DPF clean, replace if blocked >80%

For the generic, all-makes explanation of this code — meaning, every known cause and UK cost bands — see our P2002 guide.