My exhaust manifold leak occurred in June of 2023. Paid $1650 in costs. At the time. In had 86552 miles in the truck. Only three bolts were replaced. Now, with 123000 miles, I have a new exhaust manifold leak. It appears ford is aware of this problem-?"they created a new exhaust manifold. It also appears ford originally designed the engine to be much more durable as there are at least three more bolt holes for additional bolts-?"this would help dissipate the head that causes the heat that causes the warping manifold. As a result of a poor design, the truck could (and does) lose power will traveling on the roadway. This is a well-known problem with the ford 3.5 ecoboost.

- Boerne, TX, USA

The contact owns a 2016 Ford F-150. The contact stated that while driving into a parking area, the vehicle lost all electrical and motive power. The contact was able to coast into the parking area, where the vehicle failed to restart. No warning lights were illuminated. The vehicle was towed to the dealer, who diagnosed a failure with the cam phasers. The vehicle was not repaired. After investigating the failure, the contact related it to Customer Satisfaction Program 21N03. The manufacturer was notified of the failure, and a case was opened. The failure mileage was 42,000.

- Maple Valley, WA, USA

I'm writing regarding an issue I had with my 2016 Ford F150 with the 2.7L Ecoboost engine and a recent article I read regarding a NHSTA investigation into the 2021-2022 model year 2.7L engines ( [XXX] ). In October of 2022, the engine in my truck cut off on the highway and would not restart. The Ford Dealership said it needed a completely new engine due to a valve problem. It is the same problem described in the article. The engine failed with only 45,000 miles on it but was already out of warranty. It took over 7 months for Ford to replace the engine and cost me thousands of dollars (Ford case # [XXX]). Ford did next to nothing in helping me...no rental assistance and no loaner. I am writing to request the investigation expand to cover the 2016 model year as there were numerous articles discussing the same problem in earlier model years. It is the same problem I encountered and now fear will happen again with the 2nd engine I had to purchase. I have saved all of the interactions I had with Ford as well as the repair invoices and would be happy to share or answer any questions you may have. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Manassas, VA, USA

Engine failue. Yet another 2.7l V6 ecoboost that blew up. Known engine failure/design from Ford you are already investigating. Ford refused to cover new engine replacement cost (EVEN WHILE UNDER WARRANTY!). $10,000 out of pocket expense.

- Venice, FL, USA

2016 FORD F150 WITH 55,000 MILES.STARTED DRIVING VEHICLE, ENGINE RPM DROPPED, ENGINE MISSING AND SHAKING. NO THROTTLE RESPONSE. VEHICLE JUST IDLED HORRIBLY. DASH HAD LARGE WRENCH SYMBOL AND AN "ACCUTRAC SERVICE NEEDED" WARNING. i TURNED OFF IGNITION, RESTARTED VEHICLE. SAME RESULTS. I DID THIS 4-5 MORE TIMES. LAST TIME VEHICLE IDLED OKAY AND ACCELERATED. DROVE THE VEHICLE 60 MILES HOME WITH NO THER ISSUES. CHECKED WITH AN OBD-II DIAGNOSTICS AND GAVE 2 CODES: P2111 THROTTLE CONTROL SYSTEM-STUCK OPEN AND P2112 THROTTLE ACTUATOR CONTROL SYSTEM-STUCK CLOSED. NOW, NOW WARNING LIGHT OR ANY INDICATION OF PROBLEM ON DASH. NO WARNING LAMPS PRIOR TO PROBLEM. SAFETY WAS AT RISK BECAUSE WITHOUT WARNING, PULLING OUT INTO HEAVY TRAFFIC AND LOSING THE ABILITY TO ACCELERATE WITH TRAFFIC COULD CAUSE A SERIOUS ACCIDENT. LOOKING THIS PROBLEM UP IN AN ONLINE FORD F150 FORUM INDICATES THIS IS A FAIRLY COMMON PROBLEM. WHY HAS THERE BEEN NO RECALL FOR THIS POTENTIALLY DEADLY ENGINE FAILURE CIRCUMSTANCE?

- Arvada, CO, USA

Faulty exhaust manifold design has created a dangerous situation in my truck. Broken exhaust manifold is causing catalytic converter to get very hot and potentially dangerous. I feel this is a poor design in the gen 1 f150, ford should be responsible for taking care of this. They knew about the problem and I have since redesigned the manifold It cost upwards of 2000 dollars to have this replaced

- Saint Cloud, MN, USA

On three occasions my vehicle went into a -??FAIL-SAFE MODE-??. The first occurrence happened while I-??m driving on dry pavement at approx 45mph. Unexpectedly the engine shakes and slowed the vehicle to 5mph while I-??m in medium to heavy traffic. I was on a two lane road and had to quickly pull off to the shoulder. The second occurrence was while I was merging in heavy traffic and accelerating into the flow of that traffic. As the FAIL-SAFE MODE made my vehicle rapidly slow the cars behind me had to swerve and make fast lane changes. I engaged my emergency flashers to caution other drivers until I could escape the roadway on to a private driveway. The third occasion was similar to the first. Each time the FAIL-SAFE MODE happened a warning message appeared on my dash with a description of the problem and a large wrench appeared. Two different messages appeared. Twice the message was regarding a failure in the TRACTION. CONTROL. Once the message was about a problem with the HILL DESCENT CONTROL. After each event I turned off the engine, waited a few minutes, restarted the engine and was able to drive away like nothing happened. The owners manual instructed me to stop driving and have the vehicle towed to the dealer. The dealer has now had my vehicle for a month. They computer on this vehicle erases the code when the engine is restarted. So they cannot fix this problem. I asked the service manager at the dealership to reach out to the manufacturer which he did. The manufacture-??s response was -??without a code we can-??t diagnose the problem, give the vehicle back to the guest-??. This is a serious safety issue, a vehicle that would come to a crawl while in traffic. This would put myself and other drivers at risk. The dealer wants me to drive the vehicle to have the issue duplicate itself and then what?

- Traverse City, MI, USA

I have replaced four turbos directly from board on the driver side only and now my transmission decided to lock up on me on the freeway at 75 mph and they're saying that it was a lead frame problem which Ford doesn't have any they're on backorder for months

- Seville Ohio, OH, USA

Plastic oil pan is warped and is leaking oil. Gap has formed between the pan and the RTV gasket. There is a known TSB 23-2083 from Ford outlining the issue. The has recently been redesigned. I was told that there is a design issue in the oil system and I could possibly have to replace the valve covers. So, now due to a known issue with the design of the oil system, I am getting charged $3000 to replace system.

- Yorktown, VA, USA

I was driving normally to work one morning. I was stopped at a light and made a right turn onto highway. Engine was running fine up to that point, but all of a sudden it started shaking uncontrollably and all power (throttle) was lost. Ford inspected and told me valve seals were bad and that oil had leaked as a result causing metal shavings in multiple cylinders. I come to find out that it is a known issue based on service bulletin posted on NHTSA site explaining to techs how to fix issue IF owners reports it.. My concern is that I was never informed of anything, I had no warning lights display any kind of alerts leading up to this incident, and was just due for oil change. I am now being quoted $19,000 for cylinder head replacements (which is what is listed on service bulletin) or $17,000 for new engine install. Vehicle just stopped in middle of road, between multiple cars.

- Tampa, FL, USA

The contact owns a 2016 Ford F-150. The contact stated while driving 20 MPH, the contact heard an abnormal sound coming from the vehicle. No warning light was illuminated. The vehicle was diagnosed by a dealer and confirmed that the failure was related to the turbo charger. The vehicle had not been repaired. The manufacturer was made aware of the failure and confirmed that the vehicle was not under warranty. The failure mileage was approximately 62,000.

- Washington, DC, USA

The contact owns a 2016 Ford F-150. The contact stated that the vehicle would shutoff while at a complete stop. The contact stated that the failure occurred intermittently, causing the contact to depress the brake pedal and the accelerator pedal simultaneously to prevent the failure from occurring while at a complete stop. Additionally, the contact stated that while driving at various speeds, the vehicle hesitated to respond while depressing the accelerator pedal. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed that the intake manifold had failed and needed to be replaced; however, the part was not available for the repair. The vehicle was not repaired. The local dealer was contacted and informed the contact that the parts were on backorder. The manufacturer was not notified of the failure. The failure mileage was approximately 80,000.

- Mountain Home, AR, USA

The ford 2.7 liter eco boost engine has a design flaw that leads to the engine oil pan to leak around the seal which creates an environmental concern for leaking oil on the ground and also poses a fire risk as the oil could potentially contact something hot and could flame up. This is a known issue that many 2.7 liter eco boost engine owners have had to deal with and some of them have had to make the costly repair more than once. Ford only has issued a TSB 23-2083 for this issue and will not do a recall unless the NTSB says per their customer service at Ford corporate who handled my case that I had opened up.

- Downing, WI, USA

I went to start my 2016 F-150 Lariat one morning and it took a little longer to start up than usual and it was shaking at idle, something it had never done before. I took it to a shop where it was hooked up to the obd2 reader and it showed that it was most likely needing new spark plugs and possibly coils for cylinders 2 and 3 which made sense because there was less than 74,000 miles on the truck. When I got them replaced the same thing was happening but now there were check engine lights. I took it to the dealership for them to work on they said that cylinders 2 and 3 were cracked. With the issues that the 2.7 Eco boost engines have been having a recall or ford should make this right. A 10,000 dollar repair for a known issue is not the right way to conduct business.

- Twentynine Palms , CA, USA

Three things happened simultaneously: 1. The exhaust manifold warped, causing a loss of power, a whistling sound and other issues to occur. 2. Integrated locking 4WD Hubs lost vacuum causing my drivers side front-wheel to attempt going into 4WD while going down the highway at 70mph. 3. Spark Plugs went bad again. I had to change all spark plugs at 50K and now again at 100K.

- Spokane, WA, USA

My 2016 Ford F150 XLT would stall when stopped at red lights or stop signs. My dealership advised they ran codes and could not find anything wrong. I continued to drive the truck and the problem persisted. I had another location run for codes and found that I had a defective intake manifold where the valves would stick closed and not allow enough air to the engine causing it to shut down. I returned to my dealership and advised them of the codes I learned about. I also conducted research on the internet and found that F150s with a 5.0 engine had this problem. My intake manifold now needs to be replaced. I believe should the truck stall while driving or not start again when at a red light, it could cause a safety issue with possibly being rear-ended and a traffic hazard to myself, my family, or other motorists. This is a defective part that is intregral to the operation of a vehicle.

- Signal Mountain, TN, USA

Unknown which system is failing as Ford is unable to repair it. The truck codes include underpowered, turbo, catalytic converter, misfire. Truck cannot accelerate. Happens sporadically. The spark plugs, manifold, catalytic converter, brakes, rotors and turbo have all been replaced. Truck continues to have issues accelerating and running. At several points the cab of the truck filled with exhaust. Another point radiator fluid spewed all over under the hood. This truck is a threat to the health and safety of those driving it. The F150 forum states it is a common occurrence and the dealerships are replacing the same parts every few months and the problem never full resolves. Please recall this truck. The date below is when the problem started occurring but has been ongoing since.

- Altha, FL, USA

The contact owns a 2016 Ford F-150. The contact stated that while driving approximately 30 MPH and ascending a hill, and while hauling a trailer, the vehicle would lose motive power. The contact stated while depressing the accelerator pedal the vehicle slowly responded. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed that the intake manifold needed to be replaced. The contact stated that the mechanic had retrieved DTC Code: P2005. The contact stated that the mechanic verified with the dealer that intake manifolds were on a national backorder. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 77,000.

- Mountain City, TN, USA

Driving up a hill on interstate 70MPH when an engine light with Hill Climb Assist disabled error came on. Accellerater shut down and had to coast to side of road. I shut vehicle off and started back up and was able to proceed till I got off highway and proceeded up another hill and same thing happened stalled and came to a stop. I found dozens of other F150 owners having the same problem stalling in the highway. All the posts indicate they had a bad "Throttle Body". Ford has had similar problems on other models but doesn't aknowledge this one.

- Lenexa, KS, USA

The contact owns a 2016 Ford F-150. The contact stated that while driving at various speeds, the vehicle started to shake with the check engine warning light became illuminated. The contact stated that the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. Additionally, on several occasions, there was white smoke coming from the exhaust pipe. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 65,000.

- Delanson, NY, USA