Broken exhaust bolt on passenger manifold. Exhaust leak... Felt as though Carbon monoxide gas was entering cabin portion of truck. Smelling of exhaust in cabin of vehicle. Made wife and kids nauseated and lightheaded. Did research and found out that ford had a poorly designed manifolds and didn't utilize all exhaust bolts. In turn caused the #8 bolt to snap and manifold to warp and release exhaust fumes

- Zelienople, PA, USA

I have had the gasket for the oil pan fix two times. It is leaking again and told by ford that it will happen again. It is 1200 to have it fixed plus they have to keep it for a few days to make sure the seal is dry. If you do not check the oil all the time it could be low and lock up. I know other people that have had this problem. It is on the 2.7 Eco boost.

- Zanesville, OH, USA

I was traveling [XXX] near Liverpool, PA at 60mph, the truck flashed a quick code on the dash and then suddenly downshifted from 6th gear to 1st almost spinning the truck as the rear wheels locked up momentarily. It would not upshift past 3rd gear and had to travel 35 miles home like that. I called my local Ford dealer (Parsons) and they said bring the truck in for diagnostic testing, so I did. Meanwhile I searched the internet to see if others had the issue. Turns out they did, BUT my 2015 with the 6R80 was NOT in the recall notice. Ford said it was the lead frame and needed to be replaced. IF it was a known problem, why not inform owners of these trucks. That said, Ford wanted $1500 to fix it, BUT they did not have the part. So I drove the truck (never with my family in it ever again) after I cleared the code with my reader...again traveling [XXX] @ 75mph it downshifted IN TRAFFIC. Luckily I was in the right lane and made a quick move to the shoulder to avoid being run over. In Carlisle, PA there are hundreds of trucking companies and warehouses, so the truck traffic is very heavy. That was it. I searched out the part, paid for it myself and had a Ford mechanic that does work on the side fix the truck. I have been a loyal Ford guy for over 30 years...I reached out to Ford via telephone, chat and even Facebook. All they say is it is NOT under any recall. Hard to swallow that when I am driving a $75K truck THEY built and they will NOT stand behind a $2K fix. Well goodbye Ford, as a business owner for over 25 years. If I make an error I fix it NO MATTER what. I gave Ford the opportunity to stand behind truck and they did...JUST FAR behind it and passed me as I sit on the shoulder of the road. This in my opinion INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Newville, PA, USA

The contact owns a 2015 Ford F-150. The contact stated while driving at various speeds, the vehicle failed to maintain the desired speed while the accelerator pedal was depressed. Several unknown warning lights were illuminated. The vehicle was taken to a local independent mechanic, where it was diagnosed; however, the cause of the failure was unknown. The contact stated that unknown repairs were completed by the local independent mechanic. The vehicle was repaired but the failure reoccurred. The vehicle was scanned with an OBD2 scanner and DTC: P061C was retrieved. The local dealer was contacted. The vehicle was not diagnosed or repaired for the recent failure. The manufacturer was made aware of the failure. The failure mileage was approximately 147,000.

- Houston, PA, USA

[XXX]: check engine light was on and codes P2196 and P2198 were present. The dealer suspected it was the purge valve, causing the problem so they replaced it and reset the codes. 10/10/24: I brought the truck in to have it looked at due to the check engine light being on again. I was told the lead frame needed to be replaced but was on backorder. The bill to diagnose this was $196.80 and I was told I could still drive it. On [XXX], I had to bring my truck in to be inspected because while I was going about 70 mph it all of a sudden downshifted and jerked me forward like it was going to abruptly stop. The check engine light came on and I had to drive pretty slow to avoid a breakdown on the interstate. Very scary to have this happen in interstate traffic It could have easily caused an accident. At this time, It was brought to my attention that the downshifting could also be related to technical bulletin 1495. Since we couldn-??t get a real definitive answer on what was going on and the lead frame was on backorder, I decided to try and have the case connector in the bulletin removed and replaced as well as do a transmission tuneup on 10/23/24. This bill cost me $383.77. All codes were cleared and all appeared to be working correctly. On [XXX], I was driving on the interstate at about 70 mph and my truck seized up again and jerked forward, again scaring me and potentially causing an accident. I drove it very slowly directly to a repair shop. It was there until November 7, 2024 after the lead frame was replaced. That bill cost me $1321.68. I decided to file this complaint after I had seen a news article that this downshifting was being investigated for the same year as my 2015 Ford F150 for a safety issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Janesville, WI, USA

During the course of driving on the interstate at 70mph the vehicle decelerated and went to a lower gear. The dash panel of the truck did not show all of the gears available. An emergency stop on the side of the road and turning the vehicle off and back on temporarily resolved the issue. It occurred intermittently and without warning. The truck continued to show problems and was taken to a transmissions shop which checked the transmission, replaced a line for a small leak and said everything seemed to be in order. The cause was not found to be a lack of transmission fluid as the levels were normal. The truck continued to intermittently decelerate. The last time that occurred, the back wheels locked up while on the road. The truck is now sitting due to the safety risk it poses and the locked up transmission on the rear end. It is available for inspection upon request. My safety and that of others was at risk. The problem was not replicated in a service center. The vehicle was inspected beforehand but not after the last issue, (it needs a tow as the back wheels are frozen). There was a warning light for the engine camshaft that came on and the problem was diagnosed at Ford as a camshaft issue though they could not understand the deceleration issue. The truck was taken first to Ford then to an independent transmission shop. Due to the issue the truck is not in use.

- Belle Glade, FL, USA

Drive mode lights on dash (P, R, N, D, M,2,1) start alternating while driving then vehicle will not stay engaged in any drive mode, vehicle appears to go into limp mode with no drive mode lit on dashboard. This is extremely dangerous. Vehicle codes found are P0706 and P0707. Ford case number is [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Houston, TX, USA

The contact owns a 2015 Ford F-150. The contact stated that while the vehicle was in for a routine oil change, the mechanic discovered that engine oil was leaking from the oil pan. The contact was informed that the oil pan needed to be replaced. The vehicle was not repaired. The local dealer was notified of the failure, but no assistance was offered. The manufacturer was not notified of the failure. The failure mileage was 102,000.

- Abingdon, MD, USA

Exhaust manifold leak because of poor engineering at approximately 55000 miles

- Maple Park, IL, USA

The contact owns a 2015 Ford F-150. The contact stated that while the vehicle was parked, the vehicle started to leak coolant. The contact stated that while driving 65 MPH, the engine started to overheat. The temperature gauge registered a high temperature. The vehicle was not taken to be diagnosed. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 148,000.

- Stafford, KS, USA

The contact owns a 2015 Ford F-150. The contact stated that upon taking the vehicle to the dealer for an oil change, the dealer informed the contact that the vehicle was experiencing an oil leak. There was no warning light illuminated. The vehicle was then taken to Mark's Auto Repair, where the contact was informed that the plastic-based oil pan was deformed and was leaking. The mechanic determined that the oil pan needed to be replaced. The vehicle was not repaired. The contact related the failure to TSB Number: 19-2205. The manufacturer was notified of the failure and informed the contact that the VIN was included in the TSB. The failure mileage was approximately 163,000.

- Metolius, OR, USA

The contact owns a 2015 Ford F-150. The contact stated that the oil pan was leaking. There were no warning lights illuminated. The vehicle was taken to the local dealer, where it was determined that the oil pan needed to be resealed. The vehicle was repaired, but the failure recurred. The manufacturer was contacted, and informed the contact that there was no recall or warranty coverage on the vehicle for the repair. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 3,472.

- Myrtle Point, OR, USA

After driving until the engine is warm, the engine stalls when coming to a stop. It is intermittent. The engine restarts and acts normal. This happened a few years ago and then a few months ago and then a few weeks ago on [XXX] and [XXX]. It took two dealers to work on problem. There are no engine codes to point to problem. In the shop now. Apparently, it is the VCT solenoid. A known safety problem. [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Vienna, VA, USA

The contact owns a 2015 Ford F-150. The contact stated that upon taking the vehicle to the dealer for an oil change, the contact was informed that the oil pan was leaking oil onto the exhaust expander unit. The contact related the failure to Ford TSB Number: 23-2083; however, the dealer informed the contact that the vehicle was not covered under the TSB. The vehicle was not repaired. The manufacturer was notified of the failure and confirmed that the vehicle was not included in the TSB. A case was opened. The failure mileage was approximately 65,000.

- Mosinee, WI, USA

I bought the vehicle 3 to four weeks ago. For about a total of 6 or 7 times since I purchased the vehicle, the vehicle unexplainably goes into Limp Mode for no apparent reason. The engine is idling but will not accelerate at all, which in my case was extremely dangerous. In one instance, I was going up a mountain pass in an area that is steep with many sharp turns creating a blind turn issue. The truck suddenly went into limp mode just on the other side of a sharp turn. Vehicles behind me had absolutely no warning that I was stopped in the middle of the road. A second time, I was accelerating into heavy traffic when it occurred. This created all sorts of havoc as I tried to warn other drivers that I was disabled. THIS IS CRITICAL and needs to be investigated.

- Lewisville, TX, USA

The contact owns a 2015 Ford F-150. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated, and the vehicle lost motive power. In addition, the contact stated that there was black smoke coming from the exhaust pipes. The vehicle was taken to the dealer several times; however, the vehicle was not officially diagnosed. The contact stated that the oxygen sensor and the battery were replaced. In addition, the contact stated that the oxygen sensor on the passenger side was replaced three times however, failure reoccurred. The contact stated that the failure began in May 2024. Additionally, the contact stated that the failure was intermittent. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 189,500. The VIN was unavailable.

- Allenhurst, GA, USA

The exhaust manifold on the 2015 Ford F-150 EcoBoost engine is designed with only eight securing bolts. Owners have reported that this number of bolts is insufficient to adequately secure the manifold, leading to heat-induced warping and subsequent exhaust leaks. The leaks cause an audible whistling noise when the engine is under acceleration, which not only affects vehicle performance but may also lead to more severe engine issues if left unaddressed. Many owners of the 2015 Ford F-150 EcoBoost engine have experienced similar issues, indicating a widespread design flaw. While the immediate issue is the noise and potential performance degradation, prolonged exhaust leaks can lead to more serious problems, including increased emissions and possible engine damage. The warping of the manifold could also lead to more severe mechanical failures if not properly addressed. Detailed Description: The exhaust manifold on the 2015 Ford F-150 EcoBoost engine is designed with only eight securing bolts. Owners have reported that this number of bolts is insufficient to adequately secure the manifold, leading to heat-induced warping and subsequent exhaust leaks. The leaks cause an audible whistling noise when the engine is under acceleration, which not only affects vehicle performance but may also lead to more severe engine issues if left unaddressed. Affected Population: Many owners of the 2015 Ford F-150 EcoBoost engine have experienced similar issues, indicating a widespread design flaw. The problem typically arises in vehicles with relatively low mileage, highlighting a critical manufacturing oversight. The design of the exhaust manifold should be revised to include additional securing bolts to prevent future occurrences of warping and leaks.

- Springville, UT, USA

The contact owns a 2015 Ford F-150. The contact stated while attempting to drive from a complete stop, the vehicle failed to respond upon depressing the accelerator pedal. There was no warning light illuminated. The vehicle was towed to the dealer, where it was diagnosed and determined that the engine had failed and needed to be replaced. The vehicle was then towed to an independent mechanic, where the engine was replaced; however, the failure recurred. The vehicle was towed to the independent mechanic, where it was diagnosed that the engine needed to be replaced. The vehicle was then towed to another mechanic, where the same assessment was made. The mechanic notified the manufacturer of the failure, and the manufacturer covered the engine replacement. The vehicle was repaired. The failure mileage was approximately 50,000.

- Pelham, NC, USA

The truck only goes through 1 through 3 and then when it shifts into 4 it doesn-??t go anywhere and it throws a bunch of service codes that just go away when you turn the truck off it has dropped from 6th gear to 3rd and locked the tires up and spun me out almost causing me to wreck the truck

- Bridge City, TX, USA

My vehicle is a 4X4 Off Road F-150 crew cab. The concern is the vehicle had developed an oil leak due to the plastic oil pan developing a Crack init. Ford has issued to their dealer network a service letter describing the issue and fix. But the cost to repair this falls upon the owner to retrofit a metal oil pan. Cost for repair is approximately $1400. Ford put a plastic oil pan on an off road vehicle that should have never been done.

- Evansville, IN, USA