What 1,686 owners told NHTSA about the 2016 Ford F-150 Supercab Diesel

Catalytic Converters have failed for second time. [XXX] original catalytic converters failed at 48060 mileage and Ford replaced under warranty including the assembly. [XXX] replacement catalytic converters failed again at 92830 mileage. Neither the original or replacement converters were working at 50,000 miles or reached the National emission warranty of 80,000 miles. Reduced fuel mileage by 30% has been identified. Karl Flammer Ford 41975 US 19 North Tarpon Springs FL 34689 indicates no Ford programs cover $4000 plus repair. Ford Customer Affairs POBox 6248 Dearborn MI 48126 [XXX] responded no programs cover this repair and they work with NHTSA on consumer concerns. The Catalytic Converters shouldn’t fail at low mileage in a Ford F150 especially twice with reduced fuel usage. As a senior, a $4000. plus repair is a hardship for an equipment failure that should be either identified for recall or identified as a lemon. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11571671

Check engine light just came on. Before that engine would shutter then stall. No steering and brakes could end up poorly. Think this is a safety hazard

NHTSA ODI 11571399

The driver door latch froze during cold outside temperatures and the door would not latch closed. I had to drive while holding my door closed with my hand. This is extremely dangerous. This is a known recall from Ford and the repair was already performed. This happened 2 days in a row. Tomorrow I will be contacting Ford for a solution.

NHTSA ODI 11570156

plastic oil pan leaking. had to replace it with a factory improved since many problems have been reported with this truck. Replacement cost was $1,343.87. The electrical problems deals with the radio sometimes it does not work until the next day. Has been that day since day 1 with the new truck. Dealership said nothing was wrong!!!!

NHTSA ODI 11569507

While traveling at high speed, 60mph plus, the vehicle unexpectedly shifts into fist gear causing rapid slow down and dangerous near miss condition.

NHTSA ODI 11568298

The contact owns a 2016 Ford F-150. The contact stated while driving 55-60 MPH, the vehicle went into LIMP Mode and lost motive power. There was no warning light illuminated. The contact was able to veer to the side of the road. The contact turned off the vehicle and restarted the vehicle after a while. The contact continued driving; however, the failure recurred several times while driving. The contact was able to drive to the residence. The vehicle was towed to the dealer, where unknown repairs were performed. Additionally, the contact stated while driving 20 MPH on a slight incline and depressing the accelerator pedal, the vehicle failed to respond. The message "Hill Assist Not Working" was displayed. The contact stated that she reversed at 3 MPH to her residence. The contact stated that the failure recurred several times while driving on a level road. The contact veered to the side of the road and shifted into Sport(S) mode, and was able to drive 30-35 MPH. The vehicle was taken to Rocky Mountain Yeti Pinedale Jeep RAM (153 S Entertainment Ln, Pinedale, WY 82941), where it was diagnosed that the throttle body had failed and needed to be replaced. The vehicle was repaired. Additionally, the contact stated that the windshield wipers failed to disengage and remained on slow intermittent mode. The dealer reset the windshield wipers setting; however, the failure persisted. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the VIN was not included in a recall. The failure mileage was approximately 90,000.

NHTSA ODI 11568079

Intermittent wiper operation stop working. Yes it is available for inspection. Had to operate wiper operation manually. No! Not confirmed. No inspection by others. Unknown. Just skip, then stoped intermittent operation.

NHTSA ODI 11567619

My truck continues to stall at stop signs, traffic lights and when just idling. This is unacceptable and a hazard to me and other traffic.

NHTSA ODI 11567306

When braking, the brake pedal goes to the floor and makes stopping the vehicle difficult. There is no sign of leaks from the lines, and is acting like the open recall on other VIN numbers on this model however Ford does not have an open recall on this VIN. The recall is the brake booster leaking into the master cylinder.

NHTSA ODI 11566996

My 2.7L echo-boost engine had to have 2 cylinder heads replaced at 62K miles, fortunately I had purchased the extended warranty. I have since learned this is an engine design that is prone to this problem. Unfortunately they are still allowed to put these engines in their trucks. I have since purchased additional warranty to protect myself from further expense related to the bad engine design. I'm upset that when I go to sell my truck the carfax report will include this engine issue and my truck will be devalued for it. Prior to my taking it to the dealer, my check oil light was coming on with no trace of an oil leak anywhere, they knew right away what the cause was because they had seen this problem many times before. It took them 6 weeks to get my truck repaired. The warranty company kept stalling on whether they were going to pay for the repair, which eventually they did.

NHTSA ODI 11566772

Galvanic corrosion forming on transfer case because of improper bolts used to connect steel bolts onto an aluminum case corrosion is bad will eventually lead to transfer case failure an safety concern

NHTSA ODI 11566779

The contact owns a 2016 Ford F-150. The contact stated that the sunroof failed to close properly causing rainwater to enter the vehicle while driving. The vehicle was taken to the local dealer who determined that the sunroof needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 90,000.

NHTSA ODI 11566428

The contact owns a 2016 Ford F-150. The contact stated that the driver’s side front door was unable to open due to being frozen shut. The contact had to aggressively pull at the door handle for an extensive amount of time for the door to open. The contact believed the failure was related to manufacturer communication with the NHTSA ID Number: 10149786 (Locks, Latches, Linkages). The dealer had been contacted but was unable to confirm if the vehicle was included in any recall campaigns. The vehicle had not been taken to the dealer. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The failure mileage was 75,000.

NHTSA ODI 11566527

Transmission display went blank and truck shifted from 6th gear (?) to 1st gear (?) by itself causing the vehicle to suddenly decelerate while on the highway This has been diagnosed to be a faulty lead frame issue

NHTSA ODI 11566470

Driver side door would not close after opening assuming due to frigid temperatures. Had to hold door closed in transit.

NHTSA ODI 11565407

When fueling the Ford F 150, it will not shut off almost all fuel handles and as a result gasoline spews out a couple feet past the fuel pump handle as well as spilling fuel all over the side of the truck. This poses a fire hazard as well as slipping and carcinogen issue. Also, the paint and tires are subjected to deterioration and the vehicle smells of fuel for some time afterwards. I can never completely fill the vehicle without putting my ear up to the truck fill tube. No matter how far back I jump, I always get fuel on my feet, shoes and clothing. I haven't had fuel get in my eyes yet, but it is just a matter of time. Maybe a fuel station has already blown up. I'm sure that won't bee long if it has not already happened.

NHTSA ODI 11565270

The contact owns a 2016 Ford F-150. The contact stated that the air bag warning light was illuminated. The contact learned of NHTSA Campaign Number: 16V110000 (Air Bags) and related the failure to the recall. The vehicle was taken to the dealer where it was diagnosed that the front passenger’s side air bag sensor had failed. The dealer confirmed that the failure was related to NHTSA Campaign Number: 16V110000 (Air Bags) however, the VIN was not included. The contact was also informed that the part needed for the repair, part number GL3Z6362A22A: CAD/SEAT, was no longer in production. The vehicle had not been repaired. The manufacturer was made aware of the failure, and it was confirmed that the VIN was not included in the recall. The manufacturer referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was 666,100.

NHTSA ODI 11565115

Merging onto interstate and truck begins to shutter and won't accelerate accordingly. Pull over and when the truck comes to a stop and idles the oil gauge begins to move erratically. Took truck in for an inspection on August 15, 2023. Mechanic stated intake manifold needed to be replaced due to malfunction (flaps not opening to allow airflow). Mechanic also stated that replacement part was on national backorder with no release date.

NHTSA ODI 11564685

The contact owns a 2016 Ford F-150. The contact stated that while the independent mechanic was rotating the tires, he was informed that the lug nuts on all four wheels were swollen. The vehicle was taken to the dealer; however, the dealer did not inspect the lug nuts and informed the contact that they were unaware of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 75,000.

NHTSA ODI 11563750

The contact owns a 2016 Ford F-150. The contact stated that the driver's front door did not close and lock securely. The contact stated that the door did not lock securely. The contact had to hold the door while driving to prevent the door from independently opening. The contact stated that the failure occurred at times when the outside temperature was below freezing. The contact also stated that the failure occurred two years ago on two occasions and the failure had reoccurred. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 60,000.

NHTSA ODI 11563789

The contact owns a 2016 Ford F-150. The contact stated while driving approximately 30 MPH, the vehicle began to misfire and shake. The contact stated that the vehicle lost motive power. Additionally, the contact stated that while starting the vehicle there was blue smoke coming from the exhaust. The contact stated no warning light was illuminated. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the spark plugs, and the coils needed to be replaced. The vehicle was not repaired. The contact researched online and related the failure to Technical Service Bulletin Number: 19-2384 Oil Consumption, Rough Idle, Misfire with Or Without Blue Exhaust Smoke (Engine and Engine Cooling). The contact relayed the information to the dealer who then determined that the engine needed to be replaced. The manufacturer was informed of the failure. The failure mileage was approximately 119,000.

NHTSA ODI 11563791

The contact’s grandson owns a 2016 Ford F-150. The contact stated that while driving approximately 76-77 MPH, the vehicle accelerated improperly and was jerking. There were no warning lights illuminated. The vehicle was driven to the dealer where it was diagnosed and determined that there was only 20% compression in cylinder #2. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and it was confirmed that there was no recall associated with the VIN or the failure. The contact was referred to the NHTSA Hotline. The approximate failure mileage was 100,000.

NHTSA ODI 11563254

The contact owns a 2016 Ford F-150. The contact stated that while approaching a stop, the brake pedal was depressed, but the vehicle accelerated to unknown speeds. The driver continuously depressed the brake pedal, but it failed to respond. The driver crashed into a mailbox, brick decorations, a stop sign, a golf cart, a gas line, and a tree. The driver pulled the emergency brake, and the vehicle stopped.  There were no warning lights illuminated. The vehicle was towed to a collision center. The contact sustained injuries to her hip, but medical attention was not provided. A police report was filed. There was no reported fire or air bag deployment. 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 30,000.

NHTSA ODI 11562985

The contact owns a 2016 Ford F-150. The contact stated that the vehicle abruptly downshifted to first gear while driving at high rates of speed with several unknown warning lights illuminated. Additionally, the contact stated that the lights on the gear shifter used to indicate the gear position had failed to illuminate as designed. The contact also stated that the vehicle failed to accelerate as needed while depressing the accelerator pedal while driving at various speeds. The contact called several dealers for assistance but due to high demand, the vehicle was not diagnosed or inspected. The manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was approximately 148,000.

NHTSA ODI 11563024

While driving my 2016 F-150 in heavy traffic, the vehicle suddenly loses all forward power as if the transmission were in neutral. The engine is running and the tachometer indicates the RPM's are approximately 1,200, but it will not respond to pushing the gas pedal. The RPM's remain the same, regardless of how hard the pedal is pushed. Shifting the transmission to other forward gears does nothing, it still acts as though it is in neutral. A wrench symbol appears on the main screen, as well as a message that says "Hill Start Not Available". The *ONLY* way to fix the problem is to bring the vehicle to a complete stop, turn it off, wait a few seconds, and then start it again. It starts very roughly at first. After one or two attempts at this, the engine will reengage with the transmission and respond properly. It then drives normally for several days or a week. After considerable research, I found a TSB from Ford that indicates this is a known problem with their Electronic Throttle Body. The TSB number is 16-0139. It is extremely dangerous because it often happens at high speeds. It once happened to me on a narrow causeway, blocking all traffic while I came to a complete stop and restarted the truck. It also happened on a very busy highway. I was able to pull off to a narrow shoulder and restart the vehicle, but it was terrifying in extremely heavy traffic.

NHTSA ODI 11562849