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

Both Exhaust manifolds warped, broken rear exhaust studs, exhaust leaking into passenger compartment. This is a known issue with this engine and ford has a TSB for the transit with the same engine to replace the manifolds with a newer version.

NHTSA ODI 11495075

Had multiple leaks from both driver and passenger side exhaust manifolds cause by broken stud bolts. This resulted in loss of power and emissions.

NHTSA ODI 11494197

Was told the Steering Wheel Control Module needed replaced. Was driving and the blinkers stopped working, window washerfluid button doesn’t work, and anything pertaining to the hazard switch is not working. This is very dangerous to not have working blinkers and windshield wipers not working as they should. Was told that the part is on back order until December or January. Hopefully we will see it before that since it’s a primary vehicle and I don’t feel safe driving it with my children in the car.

NHTSA ODI 11493448

Passenger door fails to latch

NHTSA ODI 11493333

While driving on a hilly and curvy 2 lane highway the engine lost all power. Warning lights came on such as a wrench and “see manual”, service advancetrac, hill assist not available. The car was steerable but stalled out in the traffic lane as there was no suitable shoulder to pull over. The car was idling a bit rough, but there was no throttle response. Turning the ignition off, the car then restarted and ran perfectly with no warning lights…til it did it again a few miles later. Restarted it, drove to a safe place. Put a code reader on it. P2112 (Throttle actuator stuck shut). Took to a Ford Dealer where for $714 they replaced the Electronic Throttle Body. Driven about 1000 miles and no further problems as of yet. I believe this is a serious safety issue due to the unpredictable nature of the car stalling, and risk of accident while in heavy traffic.There should be a better “limp mode”, than to shut off all throttle response to what is otherwise a perfectly working engine. This truck has low mileage, trouble free (til now) and we’ll maintained. Unfortunately I forgot to ask to see the removed ETB.

NHTSA ODI 11491580

Vehicle was parked, pressed brake pedal to start it and pedal went to floor. Found right front flex brake hose failed. Brake fluid spraying out just below the top fitting. Brake fluid low indicator came on while troubleshooting problem. OEM part not available from dealership replaced part with non-oem part.

NHTSA ODI 11491422

The throttle body caused the vehicle to post a Hill start assist not available, service advance trac and service light to display on dashboard on two separate occasions. Each time the vehicle lost almost all forward propulsion. On one occasion it happened on 4 lane highway and almost resulted in a serious accident. The other time (first time) it caused me to block a lane of traffic on a busy 2 lane road. The vehicle was able to restart each time after a brief amount of time with no check engine of service light displayed. The fact that it restarted without any service indication prompted me to drive it again, which almost resulted in a serious accident. I took the vehicle to the dealer and he indicated it was a faulty throttle body. The throttle body problem does have a TSB issued (TSB 16-0139). How this is simply a TSB and not a safety recall does not make sense. This is a well known problem and well reported in different forums on the internet.

NHTSA ODI 11491406

The contact owns a 2016 Ford F-150. The contact stated that while reversing, the backup camera display was fuzzy. The camera display then went from dim to blank. The backup light was illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted but no additional assistance was provided. The failure mileage was unknown.

NHTSA ODI 11491313

It was raining and the rear window was fogging up, so I turned on the rear defrost. About 30 seconds go by and I smell a burning smell. Not sure what it was. I parked and was outside waiting on the bus to go into work and about 5-6 minute later the rear window shattered. It has a sliding window but the sliding portion didn’t shatter just the entire rest of the window.

NHTSA ODI 11490918

Having a horrible screeching sound and after being diagnosed its the exhaust manifolds warping on both sides by the turbos. Local shop is telling me this in a known issue and cannot figure out why Ford has not addressed this issue due to it being a emissions issue technically and they have replaced several for same issues.

NHTSA ODI 11490837

Body scratches were repaired on the truck after minor scrapes done while parking vehicle. Passenger side door repaired scrapes and after repaired door would not open from either inside or outside. Repair place sent us to Ford dealer for repair of door latch, then Ford dealer told us it was not covered by recall. Amount charged was 189.99 and we still have problem with an estimate of around 700.00 for fixing the problem. We were told the latch problem was related to the aging of the latch. This truck is 2016.

NHTSA ODI 11490857

Door will not latch while its cold Door will not stay closed when cold outside

NHTSA ODI 11489901

Transmission refused to down shift from 5th gear or go over 55 mph. Truck began to shutter and the powertrain wrench error code appeared on the dash. Truck also began to have a clanking sound. The truck jerked violently at 50 mph causing the safety of myself and 3 other passengers at risk. The Marshal Mize Ford dealer in Hixson, TN confirmed the transmission lead frame was faulty, just like the Ford recall for the 2011-2013 F150 truck.

NHTSA ODI 11489946

Used the remote start and came out to the truck and got in to a cab full of smoke, shut the truck off and found a electrical fire in the rear defrost system

NHTSA ODI 11489645

The exhaust manifold system on my F-150 failed and the Ford Motor Company is making me pay for repairs that costed approximately $4,000.00. At the time of repairs my truck had around 78,000 miles and yet the Federal Emissions Warranty is supposed to cover my vehicle for 80,000 ,miles or less for components that could adversely effect the vehicle's emissions status while in the continental United States. I have been bringing my vehicle to Ford-Service for it's regularly scheduled maintenance intervals. I have been maintaining my vehicle in accordance with the Ford Vehicle's manual for 2016 F-150. Failure of the F-150 exhaust manifold system is common on Ford Vehicles with the 3.5L Eco Boost Engine. This is due to the metallic warping of the cast iron manifold system over time. To address this issue, Ford has issues a 2021 Special Service Message Sep 1 2021 2979 - 2015-2021 Transit - 3.5L EcoBoost - New Exhaust Manifold Part Numbers - Built On Or Before 01-Dec-2020. The proper repair and replacement parts calls for stainless steel parts that will not warp over time. Failure of the existing manifold parts on these engines could result in the unplanned loss of these critical emission components directly onto the road and into the path of other drivers while operating the vehicle. Ford should be issuing a recall in addition to it's already published Special Service Message for these components so that the safer components can be installed on all affected vehicles. If Ford does not feel any pressure from the NHTSA or any other federal agency in regards to vehicle safety, then it will take a series of tragic accidents involving emission component failures and personnel death/injuries to get the proper amount of attention to force a recall. This is my attempt to notify the NHTSA of a possible critical safety flaw in their 3.5L Ecoboost designs and to get Ford to issue a recall as soon as possible, before getting into extremis.

NHTSA ODI 11489467

I was on my way to work the truck started just fine ran just fine the day prior. I was leaving my neighborhood and my truck felt like it was stuck in 3rd or 4th gear. So i pulled to the side of the road after existing the neighborhood. Nearly causing an accident. Shut the truck off. And started the back back up and seemed like everything was fine. I started to head toward work again and the dash lights lit up and the truck started to down shift really hard. I easy the truck off the road and called my father. As i waited for him to get there to plug the truck up. Once he plug in his scanner i got the p0706, p0705 code. The truck would not start back up. I had a toad to Ford and they Advise me that it was the lead frame the simiconductor Needed to be replaced. I don't understand why Ford is putting Customer's lives at risk This has been an ongoing problem with these transmissions some customers have to pay for them some customers don't. I believe #FORD should be held responsible. I could have been seriously injured. But since corporate America Holds all the power and persuasion this complaint will go on notice

NHTSA ODI 11488420

Both exhaust manifolds have broken manifold studs at 95,000 original miles. This has caused the manifolds to warp and potential leak exhaust into the passenger compartment. Both exhaust manifolds are leaking exhaust at the cylinder heads. The vehicle is currently at my mechanic. His estimate for the repair is $2,700.

NHTSA ODI 11488245

The brake fluid reservoir cap cracked for reasons unknown allowing debris and contaminants to enter my braking system. I noticed this while checking the engine air filter. I went to the dealership to purchase a new cap and the parts salesman inform me that this is a very common issue... I'm concerned that issues my arise in the future relating to this problem.

NHTSA ODI 11487792

Exhaust manifold failure on an F-150 with a 3.5L Ecoboost engine with only 65000 miles. Exhaust fumes enter the truck cab when the engine is running and the truck is stationary. One exhaust manifold was replaced under an emissions system warranty. The other is also leaking at about 70000 miles and Ford doesn’t think they need to replace it as a manufacturing design issue.

NHTSA ODI 11487000

The contact owns a 2016 Ford F-150. The contact stated that while driving at an undisclosed speed, the brake pedal was depressed, however, the vehicle failed to respond as needed. The low brake fluid and service brake warning lights were illuminated. The vehicle was taken to the dealer where it was diagnosed that the brake master cylinder leaked into the brake booster and the brake master cylinder needed to be replaced. The vehicle was repaired; however, the part was defective. The contact stated that he was waiting on parts to complete the repair. The contact referenced NHTSA Campaign Number: 20V332000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure and the contact was aided with the repair. The failure mileage was approximately 101,000.

NHTSA ODI 11486634

The truck will die at alight or stop after been driven for about 25 mins.rpm’s also go down u set 500.

NHTSA ODI 11486811

I have a 2016 F-150 Platinum (VIN [XXX]) and live in West Palm Beach, FL where it rains almost every day. I have noticed over the last several months that I can't open or close (without slamming them) three of the doors. This is a safety issue and one that needs to be addressed ASAP. I have two little kids in car seats and I don't feel safe driving my truck with them in it as is. I have taken my truck in to two different Ford dealerships in the area and neither of them are able to fix the problem. There are two current notices (20M04 and 18N03) that I have received and Ford says it doesn’t apply because I live in Florida. I bought my truck in North Carolina and lived there for 2 years and it does freeze there so my truck should be covered under this. Again, with the way the doors are currently I feel that this is a major safety issue where in the event I need to get my kids out of the truck in an emergency I won’t be able to. This needs to be fixed quickly and thoroughly so this issue doesn’t happen again. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI 11486612

It’s a known problem that the wiring for the defrosters causes the rear window to shatter. I was driving down the road and I heard a loud bang. It took me a few minutes to realize my rear window just exploded.

NHTSA ODI 11486275

It’s a known problem that the sunroof will stop working. It’s happened to me once when the truck was under warranty and it just happened again. My sunroof will not close all the way. This could be a safety issue especially here in Florida when it rains just about everyday. Again, it’s a known problem and constantly discussed on message boards.

NHTSA ODI 11486276

Truck exhibits an intermittent lack of engine RPM when coming to a stop while towing. Engine actually dies at stop sign upon exiting interstate. will start and die repeatably until accelerator is depressed slightly, and RPMs are kept to 1,000 or more. Was not a serious problem until I got caught in bumper-to-bumper traffic on I25 north out of Denver. I could only operate with left foot braking and right foot keeping RPM above 1K. Three days at dealer with no luck. I have discovered TSB 18-2249 and 22-2264 that addresses problem to 2018 and 2019 but no mention about my 2016 F150 2.7L.

NHTSA ODI 11486023