What 1,686 owners told NHTSA about the 2016 Ford F-150 Super Cab

I went for an oil change, tire rotation, etc at the dealer on 6/9/25 and was told that my frame had rust damage/holes and would not pass inspection this coming December. Went to Ziebart on 6/11/25 and they confirmed multiple hole/rust damage on frame which needed repair. They were perplexed as no problem was seen at my last yearly check of the rust protection in July of 2024. Also, no mention of a potential problem was found at my last vehicle inspection in December of 2024. How does this kind of damage occur in 6 months? I'm reading on-line that this is an issue with Ford F-150s, but no recall?

NHTSA ODI 11666530

The contact owns a 2016 Ford F-150. The contact stated that while driving at undisclosed highway speeds, the vehicle stalled after the transmission shifted to the sixth gear. The contact stated that upon restarting the vehicle, the vehicle operated as needed; however, the failure recurred while accelerating and shifting to the sixth gear. The vehicle was taken to the local dealer. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was 79,000.

NHTSA ODI 11666559

The contact owns a 2016 Ford F-150. The contact stated that upon opening the front passenger's side door, the contact noticed that water had leaked into the interior of the door panel through the rubber seal. There was no warning light illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 128,000.

NHTSA ODI 11666633

The contact owns a 2016 Ford F-150. The contact stated that while attempting to accelerate from a stop, the vehicle failed to accelerate as intended while the accelerator pedal was depressed. In addition, while accelerating the vehicle jolted forward. The contact stated that the check engine warning light was illuminated. The vehicle was taken to a local independent mechanic where it was diagnosed with an output shaft speed sensor fault related to Customer Satisfaction Program: 17E01 and 24E03; however, the VIN was not included. The contact stated that several local dealers were contacted however, the vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 168,000.

NHTSA ODI 11665733

The contact owns a 2016 Ford F-150. The contact stated while driving 55 MPH, the transmission unexpectedly downshifted, causing the vehicle to dramatically decelerate. The contact then pulled over to the shoulder of the roadway. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. The “Service Transmission” warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the powertrain control module. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 19V075000 (Power Train); however, the VIN was not included. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA hotline for assistance. The failure mileage was 145,000.

NHTSA ODI 11665767

The contact owns a 2016 Ford F-150. The contact stated that while the vehicle was parked, the vehicle failed to start. The contact’s husband went underneath the vehicle to maneuver the gear shifter cable and the vehicle was able to start. While driving approximately 45 MPH, the vehicle lost motive power and started to decelerate. The contact coasted to the side of the road where the vehicle was turned off. After waiting and after several attempts the vehicle was restarted, and the contact continued driving. The failure had occurred several times intermittently. The contact stated that the gear indicator lights on the instrument panel failed to illuminate. The vehicle was taken to the dealer who diagnosed that the transmission had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The manufacturer transferred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 150,000.

NHTSA ODI 11665860

After passing a car on a two lane highway 120 miles from home a wrench light came on and the transmission got stuck in 5th gear. We pulled over, stopped the truck and then it got stuck in 3rd gear and then the check engine light came on. The truck then proceeded to on into limp mode. At that point with the transmission clunking we and the truck shutting down we didn't feel safe driving the vehicle to our weekend destination nor did we feel safe driving it home as we had no idea if the transmission would completely fail. These were two lanes roads with not much shoulder and steep cliffs along the road in many areas and it was very unpopulated so any number of things could have happened to put us at risk. We had the truck towed 120 mileshome and taken to the nearest Ford Dealership, which was Larry H Miller Ford in Mesa, Arizona. The wrench and check engine light did go off but the service center was able to find the codes when they checked and it was determined to be lead frame failure. They removed and replaced the lead frame. There was no warning or codes prior to this happening - only on the day it happened.

NHTSA ODI 11664665

The contact owns a 2016 Ford F-150. The contact stated that while driving at an undisclosed speed, the transmission unexpectedly downshifted to first gear. The vehicle returned to normal functionality, but the failure became a regular occurrence. The contact stated that the check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to determine the cause of the failure. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 24V444000 (Power Train), but the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was 215,000.

NHTSA ODI 11664347

2016 Ford F-150 XLT panoramic sunroof rails damaged not adhered to truck properly and water leaking into Vehicle. excessive water damage from faulty Sunroof. Danger of separation from roof and breaking and flying off.

NHTSA ODI 11664405

Radio system

NHTSA ODI 11664153

Throttle body failure lead to loss of power right as I pulled out into traffic. Serious safety issue. No light appeared on the dash after turning truck off and back on and the same thing happened again.

NHTSA ODI 11663791

Transmission will unexpectedly downshift on its own while driving at highway speeds causing significant RPM increase and wheel slowdown.

NHTSA ODI 11663806

After vehicle warms up. There is a "shudder" in either the engine or the power train. It is random and makes the truck vibrate. RPM gauge also fluctuates.

NHTSA ODI 11663510

The contact owns a 2016 Ford F-150. The contact stated that while driving at slow speeds, the vehicle failed to accelerate as intended while depressing the accelerator pedal. The vehicle vibrated abnormally, and the vehicle stalled. There were no warning lights illuminated. The vehicle was taken to the dealer; however, no cause for the failure was found. The vehicle was not repaired. The contact stated that the failure persisted. The contact stated that occasionally, while the vehicle was stopped at a traffic light or stop sign, the failure reoccurred. The manufacturer was notified of the failure. The failure mileage was unknown.

NHTSA ODI 11663530

While at idle with a hot engine, the vehicle will intermittently shudder and stall. Once a check engine light appeared with the vault being cam shaft sensor. The check engine light has not reappeared to assist a mechanic as to the specific fault. The engine still has an idle issue which seems to be common with this engine and model year according to auto forums I have visited.

NHTSA ODI 11663005

Truck Shifts from 6th gear to 1st gear at freeway speeds. This only takes place for a matter of seconds and then shift back to 6th gear. During down shift all throttle response is gone and then regains throttle as if it was resetting. My fear is its going to happen and lock up the truck causing a major accident. I recently had the trucks transmission serviced (Fluid, filter and flushed) thinking old fluid may be causing the issue. But sadly the problem is still there with nothing looking broke or out of place according to FORD. Then today i find my trucks year is apart of a Investigation opened into nearly 1.3 million Ford F-150 trucks over unexpected gear shifts [XXX] . This is a major safe concern not to mention very expensive repair,. Looks like ford is back to old ways, this similar Problem was in the 2012-14 model I believe and eventually ford recalled the vehicles. Now i ask what about the rest of us???? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11662821

Engine failure at 90,000 miles Services all done at ford dealership yet the engine still didn’t work somehow. Wheel bearing at 100,000 failing causing rattling of wheels

NHTSA ODI 11662671

The contact owns a 2016 Ford F-150. The contact stated that upon starting the vehicle, there was an abnormal rattling sound coming from the engine. The contact stated that while driving at various speeds, the vehicle was sputtering while attempting to accelerate, and the check engine warning light was illuminated. The local dealer was contacted; however, the vehicle was not diagnosed, and the VIN was not included in a recall. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 90,000.

NHTSA ODI 11662213

Truck suddenly downshift into 5th gear and bucked for second starting out to get up to 60 mph Wrench light comes on transmission at 60 mph. holding back due to communications from the output sensor and the PCM. Took it to a ford dealer and had transmission flushed it was diagnosed with code PO722. Dealer said earlier years of these type of transmission on F150 had same problems.

NHTSA ODI 11662225

The contact owns a 2016 Ford F-150. The contact stated that the transmission warning light was intermittently flashing on the instrument panel. The contact stated that the transmission unexpectedly downshifted while driving at various speeds. In addition, the vehicle occasionally shut off while driving, with the "Transmission not in Park" message displayed on the instrument panel, while the gear shifter was in park(P). The vehicle was taken to an independent mechanic where it was discovered that the molded lead frame had caused the failure. The dealer and the manufacturer were notified of the failure and stated that the VIN was not under recall. The contact was then referred to the NHTSA Hotline to file a complaint. The vehicle was not repaired. The failure mileage was approximately 82,000.

NHTSA ODI 11661859

Transmission issue. Driving in 3rd or 4th gear at about 40 MPH when vehicle dropped down into 1st gear. Additionally, Multiple occasions of 1st and 2nd gear not being available while vehicle is at full stop, only 3rd gear and higher.

NHTSA ODI 11661127

The contact owns a 2016 Ford F-150. The contact stated that occasionally while driving at various speeds, the transmission unexpectedly downshifted from 6th gear to 1st gear, with the service vehicle's soon-to-be warning light illuminated. The local dealer was contacted; however, the vehicle was not diagnosed. The contact was informed that the VIN was not under recall. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 24V444000 (POWER TRAIN) as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 70,000.

NHTSA ODI 11661046

Driving on freeway at 70mph and suddenly the truck shifted to a lower gear causing my RPM's to shoot to over 6,000rpm. I was able to get to the shoulder and turn off vehicle. I waited about 10 minutes and restarted the truck. When it happened the wrench light came on and then went away before I got to the shoulder. I checked for stored codes and it was showing PO720 Out put speed sensor (lead frame in transmission).

NHTSA ODI 11660620

Sudden and without any warning, complete catastrophic brake failure while stopped attempting to pay at the pay station to exit a parking garage. My truck was fully stopped, in drive with my foot on the footbrake pedal, and started moving forward and suddenly lurched thru the parking exit gate and damaging it and the front end of my truck. Fortunately, no one was crossing on the sidewalk in front my truck or they would have been injured or worse, or we would have T-boned by oncoming traffic on the street. There was brake fluid in several areas where I parked the vehicle on the street after moving from the parking garage. There was a "low brake fluid warning light" after having the truck towed to Haley Ford in Chester, VA. There were warnings prior to the accident. The truck had had a "The Works" service done at Haley Ford the week prior. Haley Ford claims the front brake lines were leaking and need to be replaced after their "diagnostic" inspection.

NHTSA ODI 11660236

The contact owns a 2016 Ford F-150. The contact stated that while exiting a highway at an undisclosed speed, the transmission downshifted hard, and the vehicle jolted forward. The contact stated that simultaneously, the power train warning light illuminated. The vehicle was taken to a dealer where it was diagnosed that the molded lead frame needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was 114,476.

NHTSA ODI 11659436