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

Lug nuts swelled to the point they had to be replaced

NHTSA ODI 11467520

Swollen lug nuts could break off causing extremely unsafe hazardous driving conditions.

NHTSA ODI 11466510

The contact owns a 2016 Ford F-150. The contact stated that while the vehicle was at the dealer for an unknown repair, the dealer informed the contact that the lug nuts were corroded on all four wheels. The lug nuts were all replaced. The vehicle was repaired and remained at the dealer. The manufacturer was made aware of the failure and referred the contact to file a complaint with NHTSA. The failure mileage was approximately 78,000. The VIN was unavailable.

NHTSA ODI 11447881

Re: [XXX]. On 10/11/21, I brought my 2016,Ford, F-150 into Hollingsworth Richardson, Baton Rouge, LA for an oil change, and tire rotation. I was informed by the Intake Clerk that the technician could not rotate the tires because he could not remove the lug nuts. Later, I discovered that from. About 2010 to 2015, Ford Manufacturing used composite materials over the lug nuts that would swell, thus rendering the lug nuts immovable. I contacted Ford Manufacturing, and made a complaint. They were to respond within 24 hours. Two days later, after not receiving a response, I contacted Ford via chat, and was told that my case had been summarily closed. This potentially dangerous defect required me to purchase 24 replacement lug nuts at a cost of $73.00, then take my vehicle to a local mechanic, who used a compression air wrench to remove the defected lug nuts, and replace them with those that I purchased. The mechanic who did the replacement work did not charge me for his work, having had the same problem with Ford. Regarding the on-line chat FMC, and their dismissal of my complaint, I took screen shots with my cell phone, Nd saved it to my picture file. If there is a Class Action Suit Log pending, I would like my name to be added to the list. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI 11446740

Wheel lug nuts outer layer has deformed making it impossible to tighten lug nuts correctly. Dealer stated this is a common occurrence, but usually happens after 100,000 miles. My vehicle is at 60,996 miles. Dealer stated only option is to change lug nuts at a cost of 129.00 dollars or tires could not be rotated until new lug nuts were purchased. What happens if you have a flat tire on the side of the road? With distorted lug nuts, a person could not get proper torque and wheel could separate from vehicle while driving.

NHTSA ODI 11445081

Mushroomed Lug Nuts needs replacements04

NHTSA ODI 11444918

Vehicle has less than 30,000 miles and lug nuts were so swollen that when I did a tire rotation they ended up having to replace the lug nuts. This is inexcusable and a significant safety hazard.

NHTSA ODI 11438902

Chrome lugnuts swell and become damaged if removed

NHTSA ODI 11434175

Most lug nuts were stripped and the shop had a difficult time removing them. I had to replace all with solid lug nuts to ensure I had no other issues. This was an additional cost of $239.28.

NHTSA ODI 11433789

The contact owns a 2016 Ford F-150. The contact stated that while her son was driving 55 MPH, the driver’s side rear tire experienced a blowout. The driver pulled over to the side of the roadway and attempted to place the spare tire on the vehicle however, the driver was unable to remove the lug nuts. The driver had the vehicle towed to a local dealer, where the dealer inspected the vehicle and stated that the lug nuts were swollen. The dealer replaced the lug nuts with aftermarket lug nuts and mounted the spare tire on the vehicle. The vehicle was repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 42,000.

NHTSA ODI 11431393

THE LUG NUTS ARE IN TWO PARTS AND THE DIFFERENT PARTS TEND TO SEPARATE FROM EACH OTHER, NOT ALLOWING YOU TO REMOVE THE LUG NUTS TO CHANGE A FLAT TIRE. I WAS CHANGING THE BRAKES ON THE TRUCK SO I WAS STATIONARY BUT COULD NOT REMOVE THE TIRE DUE THE LUG NUT.

NHTSA ODI 11373934

DIVER'S SIDE FRONT TIRE WHEN FLAT. I WAS UNABLE TO REMOVE THE LUG NUT WITH THE SUPPLIED LUG WRENCH. THE 2-PART LUGS HAD SWELLED MAKING THE LUG WRENCH UNUSABLE. WAS ABLE TO REMOVE THE LUGS WITH A PERSONAL TOOL SET IN THE REAR OF THE TRUCK. WENT TO A FORD DEALER AND WAS ADVISED TO CHANGE MY LUG NUTS TO A SOLID AFTERMARKET LUG. DEALER SAID THIS IS A COMMON PROBLEM THAT CAN LEAVE PEOPLE STRANDED.

NHTSA ODI 11321361

TL* THE CONTACT OWNS A 2016 FORD F-150. THE CONTACT STATED THAT WHILE ATTEMPTING TO CHANGE THE PASSENGER SIDE REAR TIRE THE COVER ON THE LUG NUT EXPANDED AND THE FACTORY SUPPLIED WRENCH SOCKET WOULD NOT FIT OVER THE LUG NUT. THE CONTACT WAS UNABLE TO REMOVE THE TIRE DUE TO THE FAILURE LEAVING THE CONTACT STRANDED WITH A FLAT TIRE. THE CONTACT INDICATED THAT THE FAILURE WAS CAUSED DUE MOISTURE INSIDE THE LUG NUT COVER. THE LOCAL DEALER FRONT ROYAL FORD LOCATED AT (1935 WINCHESTER RD, FRONT ROYAL VA) AND THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 50,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI 11317057

LUCKILY I WAS NOT STRANDED ON THE SIDE OF THE ROAD BUT HAVING WORKED FOR FORD THIS IS A KNOWN ISSUE AND HAS NOW HAPPENED TO BOTH OF MY FORD TRUCKS. FORD MAKES LUG NUTS WITH ALUMINUM CASINGS THAT AFTER 1-5 USES BECOME SWOLLEN AND MAKING IT IMPOSSIBLE TO REMOVE LUG NUTS FROM VEHICLE ESPECIALLY IN AN EMERGENCY SITUATION WHICH COULD RESULT IN SOMEONE TAKING MORE TIME THAN NEEDED ON THE SIDE OF THE ROAD STRUGGLING TO BREAK SAID LUG NUTS LOOSE AND WILL RESULT IN SOMEONE BEING STRUCK BY ANOTHER VEHICLE.. THIS HAS BEEN AN ONGOING ISSUE FOR 10 + YEARS. I HAVE SPENT HUNDREDS OF DOLLARS REPLACING THESE LUG NUTS. MULTIPLE OF WHICH HAD TO BE CUT OFF BY MECHANICS. PLEASE DO SOMETHING!!

NHTSA ODI 11310184

THE LUG NUTS ON MY TRUCK NEEDED TO BE REPLACED DUE TO SWELLING OF THE METALS. SO IF YOU NEEDED TO CHANGE YOUR TIRE YOU LUG WRENCH WOULD NOT FIT AND WOULD LEAVE YOU STRANDED.

NHTSA ODI 11307962

TL* THE CONTACT OWNS A 2016 FORD F-150. WHILE THE VEHICLE WAS BEING SERVICED AND THE TIRES WERE ROTATED BY AN INDEPENDENT MECHANIC, THE CONTACT WAS INFORMED THAT THE LUG NUTS COULD NOT BE REMOVED. THE CONTACT STATED THAT THE LUG NUTS WERE REPLACED IN AUGUST OF 2019. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 102,020.*JB

NHTSA ODI 11265597

LUG NUTS SWELLED AND COULD NOT USE FACTORY PROVIDED WRENCH TO REMOVE THEM AFTER HAVING A FLAT. LEFT ME ON THE SIDE OF A BUSY HIGHWAY FOR AN EXTENDED TIME PERIOD

NHTSA ODI 11258140

TL* THE CONTACT OWNS A 2016 FORD F-150. WHEN THE VEHICLE WAS TAKEN TO SUNSET FORD (314-843-4431, LOCATED AT 11700 GRAVOIS RD, ST. LOUIS, MO 63127) FOR AN OIL CHANGE AND TIRE ROTATION, IT WAS DIAGNOSED THAT WATER SLIPPED THROUGH THE CHROME SEAL ON THE LUG NUTS, WHICH CAUSED THE LUG NUTS TO SWELL. THE DEALER INFORMED THE CONTACT THAT IF THE TIRES NEEDED TO BE CHANGED IN AN EMERGENCY SITUATION, THE LUG NUTS COULD NOT BE REMOVED. THE DEALER STATED THAT THE FAILURE WAS A KNOWN ISSUE AND THERE WAS NO RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THAT THE FAILURE WAS A KNOWN ISSUE AND THAT ACTION WAS ALREADY TAKEN AGAINST THE SUPPLIER. THE CONTACT WAS NOT COMPENSATED. THE CONTACT WAS INFORMED THAT THE FAILURE WAS REPORTED TO NHTSA AND THERE WOULD BE NO REIMBURSEMENT. THE VEHICLE WAS REPAIRED AT THE CONTACT'S EXPENSE. THE FAILURE MILEAGE WAS 49,658.

NHTSA ODI 11222193

TL* THE CONTACT OWNS A 2016 FORD F-150. WHILE ATTEMPTING TO HAVE A TIRE ROTATION, THE CONTACT WAS INFORMED THAT THE LUG NUTS WERE SWOLLEN. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO CRAIN FORD OF LITTLE ROCK (4601 COLONEL GLENN PLAZA DR, LITTLE ROCK, AR 72210, (501) 436-0341) WHERE IT WAS DIAGNOSED THAT THE LUG NUTS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND PROVIDED A CASE NUMBER [XXX]. THE LUG NUTS WERE REPLACED BY APPROVAL FROM FORD CUSTOMER RELATIONS. HOWEVER, NO FURTHER ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 59,489. *AS 'PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).'*AS

NHTSA ODI 11218015

THE FRONT DRIVERS SIDE STEEL WHEEL FRACTURED AND SEPARATED WHILE DRIVING ON A BLACK TOP ROADWAY. THE PART THAT SEPARATED AND CAME OFF WAS LOCATED. THERE APPEARED TO BE NO DAMAGE THAT WOULD HAVE CAUSED THE FRACTURE. THIS IS A LAW ENFORCEMENT VEHICLE.

NHTSA ODI 11207806

TOOK TRUCK FOR REGULAR SERVICE AND ADVISED THAT THEY COULD NOT ROTATE TIRES. LUG NUTS ARE OF A FLAWED DESIGN THAT SWELL DUE TO HEAT, MOISTURE ETC. DEALER MENTIONED THAT I SHOULD BUY REPLACEMENTS FROM AN AUTO STORE AS FORD IS STILL SELLING THE SAME DEFECTIVE LUG NUTS. ISSUE IS SO COMMON THAT SERVICE DEPT SAID FORD ACTUALLY ENGINEERED AND SENT A SPECIALIZED TOOL TO DEALERS TO REMOVE THESE DEFECTIVE PARTS. ADVISED THAT IN THE EVENT OF A FLAT TIRE, I WOULD NOT BE ABLE TO CHANGE DUE TO LUG NUTS SWELLING AND TOOL NOT FITTING. NOT ONLY ARE CUSTOMERS ON THE HOOK FOR $200+, BUT ALSO POSSIBLE TOWING FEES FOR A NON-MECHANICAL, ROUTINE ISSUE.

NHTSA ODI 11205088

AN UNSAFE, ROAD HAZARD, A BOOBY TRAP F150 TRUCK. THIS IS WHAT I GOT FROM A FORD DEALER IN COVINGTON. AN UNSAFE TRUCK.WHOSE FAULT THAT THE TRUCK IS ON THE ROADS? WOULD LIKE TO FIND OUT. FORD COMP. OR THE DEALER? WE ARE AN OLDER, SENIORS, MINORITY COUPLE JUST TRYING TO BUY OUR FIRST F150 TRUCK. ON DEC. 31ST 2018, BOUGHT A 2016 F150 FORD TRUCK FROM THIS DEALER. I WAS TOLD THAT THIS TRUCK IS COVERED BY A SPECIAL FORD COMP. TAKE BACK THE TRUCK. I HAVE HIS MESSAGE ON MY VOICE MAIL. THEY WILL TRY TO FIX IT FULL WARRANTY BEING A BUY BACK TRUCK,INCLUDING EVEN THE LIGHT BULBS, ON TOP OF THE REGULAR WARRANTY. . SAID THAT VIBRATION CAME FROM THE WHEELS NO, CALLED THEM AGAIN, SENT THEM FEW EMAILS. I TOLD THEM THAT I WILL GO ON A HUNGER STRIKE IN FRONT OF THEIR DEALER. FINALLY, THE OWNER,MATH, CALLED ME TO OR THEY WILL GIVE ME ANOTHER TRUCK. THEY KNEW THAT THE TRUCK IS NOT SAFE TO DRIVE ON THE STREETS. IT'S ROAD HAZARD. AND NOT TALKING ABOUT THE SMOKE INSIDE THE CABIN. YOU CAN DIE OF SUFFOCATION. DROVE ANOTHER OUR OR SO TO THEIR DEALER. HAD ERDDYN, THE SELLER GUY TO DRIVE TEST THE TRUCK. AFTER FEW MINUTES OF DRIVE, WE NOTICED THE VIBRATION. HE SAID IS NORMAL. THEN IT STARTED TO VIBRATE EVEN WORST. I ASKED HIM ABOUT THE STRONG SMOKE SMELL. DID NOT SAY ANYTHING. GOT BACK TO THE DEALER, INSPECTED THE TRUCK.THE TRUCK WAS IN GOOD SHAPE. AFTER 2 HOURS OF TALK WITH THE OWNER, THEY OFFER ME GET ME ANOTHER TRUCK. OLDER YEAR MODEL, INFERIOR CLASS. DID NOT ACCEPTED, SO, THEY SAID HIT THE ROAD. AND LEFT AFTER WASTING OVER 3 HOURS. SO, HERE I AM WITH A VERY UNSAFE TRUCK DRIVING ON THE ROADS. SOONER OR LATER AN ACCIDENT IS GONNA HAPPEN, OR ME DYING OF SUFFOCATION IN THE CABIN. NO. I'M GONNA PROTEST IN FRONT OF THEIR DEALER , AND THEN I'M GONNA DO THE SAME IN FRONT FORD MOTOR COMPANY HEADQUARTER. IS THEIR FAULT TOO. PUTTING BACK ON THE ROADS A UNSAFE CAR? AND COVINGTON FORD TO SELL IT.

NHTSA ODI 11181464

FAILURE OF INTEGRATED WHEEL ENDS (IWE) ON BOTH FRONT WHEELS DUE TO SEAL FAILURES AND LOSS OF VACUUM. SYMPTOMS: GRINDING OR GROANING AT LOW SPEEDS WITH OR WITHOUT BRAKES APPLIED. VIBRATION IN STEERING WHEEL AND BRAKE PEDAL. DEALERSHIPS WILL INITIALLY DENY PROBLEM AND BLMAE THE BRAKES (I.E. DRAGGING CALIPER). MY TRUCK WAS INSPECTED BY 3 SHOPS TO RULE OUT THE BRAKES AND I STILL RECEIVED A SIMILAR COMMENT AT THE DEALERSHIP. 1/30/19: DEALERSHIP FINALLY CONFIRMED ISSUE AND REPLACED BOTH IWES AT 35090 MILES. THIS PROBLEM HAS BEEN AN ONGOING ISSUE WITH FORD FOR MANY YEARS BASED UPON THE VAST NUMBER OF COMPLAINTS ON TRUCK FORUMS. NUMEROUS COMPLAINTS OF IWE FAILURES. THE PROBLEM IS SO FREQUENT THAT THE FIRST RECOMMENDATION FROM MOST DEALERSHIPS IS TO REPLACE THE VACUUM SOLENOID OR INLINE CHECK VALVE. IN MY CASE, THE REPLACEMNT PARTS DID NOT FIX THE PROBLEM

NHTSA ODI 11175927

LUG NUTS SWELL MAKING IT UNABLE TO REPAIR ON ROAD.

NHTSA ODI 11165245

TL* THE CONTACT OWNS A 2016 FORD F-150. THE CONTACT STATED THAT THE OEM LUG NUTS WERE SWOLLEN TO THE POINT THAT THEY WERE UNABLE TO BE MANUALLY REMOVED FROM THE WHEELS. THE DEALER (BOB SIGHT FORD, 610 NW BLUE PKWY, LEE'S SUMMIT, MO 64063, (816) 524-6550) WAS NOTIFIED OF THE FAILURE AND INDICATED THAT THE VEHICLE WOULD NEED TO BE DIAGNOSED AND THAT THEY WOULD HAVE TO ORDER THE PARTS FOR THE OEM LUG NUTS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 38,250.

NHTSA ODI 11165252