Brought the truck into local shop January 2013 with 163k miles for CEL. Briefed by Firestone Complete Auto Care Center that the intake is plastic & is possibly warped. They recommended remove & replace intake manifold gasket and replace intake with new one ($1,184). Upon completion the manager also suggested replacing the spark plugs ($200) in which I had both services done. It's now June, driving back from lunch and I hear a loud pop sound and the vehicle shakes violently. I had it towed to the closest shop, 2 miles away and was told it has a rod knocking. To repair the problem would not be economical and the shop owner suggested replacing the engine ($3,000 Used). I am very thankful that I have always had full coverage on my vehicles . . . the insurance adjuster has informed me that they will do an investigation, noting that a vehicle replacement plan is included with my coverage (USAA).

My short experience (less than a year) with this 2002 Ford F-150 has ruined the name of Ford for this prospective buyer. Since purchasing I have spent more than the amount paid for vehicle in total maintenance fees, only to have a truck that doesn't run. This engine problem is the worst I have encountered of the maintenance issues and came about with no warning in spite of routine ASE certified maintenance. Please update this vehicle to Lemon status and advise others to stay away at all cost.

When I returned to the truck, I turned the key to start it, then I heard a loud popping sound, like a gun shot. The engine became powerless. I had to have the truck towed to the Ford Service Department. I was told the problem was a spark plug blow out and I would have to have a helicoil repair of which there is no gaurantee of being a permanent fix , replace the cylinder head or replace the engine which would also repair the main crank shaft leak that was seen as a problem also. I'm opting to replace the engine which comes with a 100.000 mile warranty.