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

Lug nut were swollen so they couldn’t be taken off without cutting. Ford technician stated it is a know issue that Ford knows about. Aluminum caps over steel bolts. According to the tech at the dealership, they could also break while driving due to the swelling.

NHTSA ODI 11519649

2016 Ford F150 XLT 5.0 violently downshifted traveling at highway speeds. wrench and check engine light appeared. got off exit, turned off vehicle and unable to restart. waited several minutes and was able to restart vehicle. appears that there is an issue with the transmission range sensor and leadframe.

NHTSA ODI 11519717

Coolant intrusion into cylinders. 109,054 miles. Well-maintained vehicle. Internet research suggests that this is a common problem with the EcoBoost engine.

NHTSA ODI 11518783

The contact owns a 2016 Ford F-150. The contact stated while driving 20-25 MPH, he heard water sounds coming from the body of the vehicle. The vehicle was taken to the dealer, where the door drains were inspected and drained; however, the failure persisted. The vehicle was taken to a second dealer, Ford Service (1401 S Beacon Blvd, Grand Haven, MI 49417), where it was diagnosed that the sunroof rivets were installed incorrectly, causing water intrusion into the sunroof and curtain air bags. The dealer diagnosed that the sunroof, the sunroof frame and the curtain air bags needed to be replaced. The dealer forwarded the diagnostic report to the manufacturer, and the manufacturer agreed to partially cover the repair cost. However, the contact stated that the failure was due to a Manufacturer’s defect; therefore, the manufacturer should completely cover the repair. The vehicle was not repaired. The failure mileage was approximately 18,500.

NHTSA ODI 11517821

The contact owns a 2016 Ford F-150. The contact stated he became aware of an oil leak from the drain plug. The contact took the vehicle to the local dealer, where it was diagnosed with needing the engine to be replaced. The vehicle was repaired but continued to experience the failure. The manufacturer had been informed of the failure. The failure mileage was approximately 53,000.

NHTSA ODI 11517899

2016 Ford F-150 3.5L LH Exhaust Manifold Failure. Resulting in the potential release of exhaust fumes into the passenger cab. Recently experienced severe flutter noise and loud exhaust noise from the Left Hand Side of my engine. After diagnosing the flutter noise upon start up and acceleration was coming from the LH turbo charger "Waste Gate" the turbo was removed and prior to replacement it was found that the two aft exhaust manifold studs were also sheared off. After several attempts to remove the two studs failed, and some internet investigation (including this NHTSA website) it was decided it was best to remove and replace the complete exhaust manifold and studs. Fortunately FORD found it in their favor to increase the number of rear port studs from 2 to 3. After installation of the new exhaust manifold, gaskets, studs and turbo charger for a total cost of approximately $3,000 the truck runs exceptionally well once again.

NHTSA ODI 11516646

2016 F-150 XLT V8 windshield wipers run uncontrollably with key turned on, can't turn wipers off, had to pull fuse. With wipers inoperable truck is operating unsafely with reduced visability. I changed wiper relay and turn signal stalk and problem persists. I called FMC customer service and they could not assist. Ford dealer made appt 4 weeks from now.

NHTSA ODI 11516680

I went for service to the Goodyear dealer where I bought my tires for an oil change and tire rotation. They were able to do the oil change, but unable to rotate the tires due to what is, apparently, a very common issue. The manager apologetically told me I had swollen lug nuts, that it was caused by the use of aluminum clad steel nuts, and even if they got the lug nuts off, it was quite possible they wouldn't be able to put them back on safely. He said they didn't have any replacement lug nuts and suggested I buy solid steel (chrome plated) aftermarket Dorman lug nuts (costing upwards of $5 to $7 each), offering to install them for free when I brought the truck back for tire rotation. He also indicated that it was a safety hazard, because if I had a flat tire, it was quite likely that I would be unable to change it. I have verified his statements. In fact, I was shocked to find that this is a very common, very well-known issue, and wonder why you haven't already done something to compel Ford to issue a recall? Leaving thousands of motorists stranded on the side of the road because they were blindsided by this issue is bound to lead to some potentially serious repercussions. I have no file to upload. Thankfully, I found out about this the easy way. Shame on you if you sit idly by while others are finding out the hard way.

NHTSA ODI 11516488

Jerking when accelerating

NHTSA ODI 11516540

While driving on a highway at a constant 45 to 50 miles per hour, the transmission suddenly downshifted into second gear which made the engine rev to approximately ~5000 rpm and suddenly jerked to car to slow down. This was followed by a orange wrench light and a message to see owners manual. The problem has not been reproduced because I have parked the vehicle until I can diagnose or take it to a mechanic. Our safety was at risk due to the violent and sudden nature of the shift which could have caused a loss of control if we had not been on a dry flat road.

NHTSA ODI 11516182

On 2/14/23 my 2016 Ford F-150 experienced an intermittent loss of steering while driving. There was a total loss of steering. I would turn the steering wheel, and the wheels would not respond. The steering wheel would turn freely, with no connection to the wheels. Upon parking my vehicle and turning it off, and removing the key, the steering wheel continued to "tick" and turn on its own. There were no warning lamps or messages. Once I restarted the vehicle the steering was not responding like normal. My safety was at risk had this happened at a greater speed, or in a different area I would have crashed. I had the truck towed to the local Ford dealership. It has now been there for 7 weeks . They have been unable to replicate the problem, or identify any solutions. I was told I could just pick up the truck or trade it in on a new truck since they could not identify the problem. I told them I was not comfortable driving it or selling it for someone else to drive with an issue that could prove catastrophic or deadly.

NHTSA ODI 11515540

I was driving down the road approximately 50-55 mph and after taking my foot off the gas to slow for an upcoming traffic light, the transmission instantly downshifted from 6th or 5th gear to first gear, locked up the back wheels and caused my truck to screech to a jolted stop before the traffic light. Approximately one week later, the truck did the exact same thing. The wrench light came on both times and at the subsequent start up was off, but the system did trigger OBD codes. I am very concerned with the fact that this exact same issue was deemed worthy of a recall on 2011-2013, Ford recall #19S07/NHTSA Recall 19V-075, but it is still happening on many many F150s with the 6R80 transmission after the model years covered by the recall.

NHTSA ODI 11515620

The exhaust manifold is leaking, google searches and asking to local Ford dealers it is a very common issue with this that FORD will not take responsibility for or do anything about.

NHTSA ODI 11515627

The trucks box frame is completely rusted. The truck is 6 years old, only been in Florida and has 36k miles. The safety of this vehicle is compromised and this matter is urgent.

NHTSA ODI 11515692

The contact owns a 2016 Ford F-150. The contact stated that while driving approximately 60 MPH, the vehicle downshifted to a lower gear and the rear wheels locked-up. The contact pulled over to the side of the road and restarted the vehicle. The contact stated that the powertrain malfunction warning light was illuminated. The vehicle was taken to a dealer where the vehicle was diagnosed that the transmission lead frame needed to be replaced. The vehicle was not repaired, and the dealer stated that the vehicle was not included in an open recall. The manufacturer was not notified of the failure. The failure mileage was approximately 100,800.

NHTSA ODI 11515180

Vehicle loss of power due to bad lead frame module for transmission.A picture of a wrench appeared on my dash a couple of days before loss of power. The Ford garage said it was okay to drive as long as the wrench light didn't blink.After the loss of power I didn't feel comfortable driving it so I took it in for repair. From what I have read this is the same problem as the 2011-2013 models, to which they have been recalled.My vehicle is currently at the ford garage for repair.

NHTSA ODI 11514934

The contact owns a 2016 Ford F-150. The contact stated that on various occasions, the transmission was downshifting into first gear and causing the vehicle to come to sudden stops. The check engine and power train malfunction warning lights were illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed that the transmission control module (TCM) and lead frame needed to be replaced. The VIN was not included in NHTSA Campaign Number: 19V433000 (Power Train). The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was 56,736.

NHTSA ODI 11514866

Broken exhaust manifold bolts causing loss of power when passing, going up steep grades or hauling heavy loads. The safety concern is loss of control due to loss of power during critical needs for power performance.

NHTSA ODI 11513378

I'm writing in concern about my 2016 F150 brake lights. This concern is due to the rear break light assembly is breaking for no reason. I am on my third set of break light assembly. The driver and passenger side rear break light assembly keeps breaking on its own. There have been no accidents involving the rear end of the truck . It's becoming a safety concern . Looking to see if any other incidents have been reported. Please see attached photos of the most recent break light assembly and take note when the break light assembly clips into the truck the mounts are completely broken . The plastic where the screws would be going from the bed of the truck are severely cracked.

NHTSA ODI 11513505

Passenger side exhaust manifold failed at 56,000 miles and was repaired through emissions warranty. Driver-side exhaust manifold failed at 74,000 miles and Ford will not cover it. I believe both manifolds should have been replaced at 56,000 miles or the current failure should be replace through warranty.

NHTSA ODI 11513251

Lead Frame failure. Electrical component attached to valve body on transmision. On multiple occassions my truck would downshift from 6th gear to 2nd gear. The first time I was traveling at 55mph with an engine rpm of 1500/1600s, on flat ground with no load and not attempting to speed up or slow down. This caused the engine to rev up to 4500 rpm causing me too very sudden and violent jerk forward. After a few seconds normal driving resumed. I contacted my local dealership for service and over the next couple of days had a wrech symbol pop up twice and that said SEE MANUAL. Nothing in my owners manual helped me solve that. And the truck would only accelerate very slowly until you got up to around 35mph then normal driving resumed. . On the next occassion a few days later, while driving to the dealership for service regarding this issue the problem occurred again under nearly identical conditions. This time the at faster/express way speed of 70mph. This cause not only a sudden jerk forward but also caused me to jerk my steering wheel sending me into another lane. No other drivers were next to me and no one was hurt, injured, or damaged. Normal driving resumed after a few seconds. While researching this issue online I was able to discover hundreds of accounts for drivers wanting to know why their transmissions suddenly downshifted on them too. These issues are problematic at best and deadly at their worst. In 2013 you determined these issues were so bad as to result in a national recall. The same problem is still occurring. I reached out to Ford and this is my problem they say.

NHTSA ODI 11513008

The contact owns a 2016 Ford F-150. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was taken to the dealer and was diagnosed with a clock spring failure. The manufacturer was made aware of the failure and referred the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 60,000.

NHTSA ODI 11512753

The contact owns a 2016 Ford F-150. The contact stated that the vehicle occasionally accelerated and decelerated independently while driving at various speeds. The contact stated that the power train warning light had flashed on the screen; however, the light quickly disappeared. The contact had taken the vehicle to a dealer and was informed that the lead frame on the transmission was defective. The manufacturer was notified of the failure and referred him to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was 119,067.

NHTSA ODI 11512837

The contact owns a 2016 Ford F-150. The contact stated that oil was leaking from the vehicle onto his driveway. The vehicle was taken to an independent mechanic and the mechanic stated that the vehicle was experiencing the failure listed in TSB: 20-2051 and referred the contact to the manufacturer. The dealer was contacted and informed the contact the VIN was not under recall. No further assistance was provided. The manufacturer was contacted and referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was 67,000.

NHTSA ODI 11511798

The contact owns a 2016 Ford F-150. The contact stated that while driving at 35 MPH, the brake pedal went to the floorboard while depressed. The vehicle failed to stop immediately rear-ending another vehicle. No air bags deployed. The contact sustained injuries to his neck and back but did not receive medical attention. A police report was filed. Additionally, the contact stated the vehicle consumed an excessive amount of oil and the key fob failed to function as needed. The vehicle was taken to the dealer; however, the vehicle was not diagnosed nor repaired by the dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 85,000.

NHTSA ODI 11511503