Four weeks ago after driving for a slightly longer distance than usual the car starting having big lulls in power. When we went back in the car about 2-3 hours later, the same started to happen again, the car wouldn't pick up above 3000 revs and went into "safety mode". We called out green flag who suspected the problem may be DPF.
The car went straight into the same garage who diagnosed DPF, replaced and gave us the car back. The car had the same problems the following day, we took the car back to the garage and they advised that the DPF was completely blocked again. This time, faulty EGR valve was diagnosed and replaced. Again, we took the vehicle away.
The car had the same problems on the way home (approx. 2 miles), wouldn't pick up above 1500 revs, went into "safety mode" twice and this time the engine maintenance light also came on and we had to pull over. Returned the car immediately and were then told that the faulty EGR valve had caused a heat build up and had caused a plastic part in the manifold to melt shut. This was replaced. We have now been told by the garage that after extensive testing and putting the vehicle back on diagnostics again, the filter is still blocked and is blocking approx. every 30 miles. They have phoned Ford who have claimed they have never heard of this before and advised them to check for an air leak. They have checked for this and there is none. They have now advised that they don't know where to go with this. Any advice as this has cost a huge amount of money already? Thanks.