The contact owns a 2016 Ford F-150. The contact stated that the check engine warning light illuminated. The vehicle was taken to the local dealer where it was diagnosed and determined that the cylinder head needed to be replaced. The vehicle was taken to an independent mechanic who replaced the engine however, the failure recurred. The manufacturer was notified of the failure, but no additional assistance was repaired. The failure mileage was 56,749.

- Fremont, OH, USA

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

- Cheyenne, WY, USA

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.

- Stockton, MO, USA

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. 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.

- Chula Vista, CA, USA

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.

- Chassell, MI, USA

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.

- Tyrone, PA, USA

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.

- El Dorado, KS, USA

I recently took my truck in for a recall repair. They took care of the recall problem but was also suppose to look at the rattling (chirping) noise coming from front driver side wheel well. Cant remember mileage on truck when that was fixed. But im almost sure it was b4 80k was reached. My question is im doin research and there is a problem that ford is suppose to repair this issue if stated b4 80k miles or 10 yrs. Im just now seeing this and ive just surpassed 80k miles. Well they had said there were no issues. It was a ford thing. So i figured they knew whats best. Well. Id like my truck fixed if still possible because it is an emission issue. What can b done. Thank you

- Proctorville, OH, USA

Engines for the f150 stall out at idle and while on the road. This could leads to a variety of safety problems and for has shown a unwillingness to address the issue and an inability to fix it. i have found 10s of thousands of people online who have similar issues and have ( like me ) taken it to for at their own expanse and gotten no solution. Without action from NHTSA ford will not fix it as they have millions of income from customers paying to fix to no avail. I myself have spend over 5k at the dealership and hour of my time to resolve and yet no repair works for longer then a few weeks at best.

- Richmond, VA, USA

Oil pan leaking

- Coopersburg, PA, USA

The contact owns a 2016 Ford F-150. The contact stated that on multiple occasions while driving, the vehicle went into Limp Mode. The contact then stated that the brakes inadvertently engaged causing the vehicle to skid. The check engine and service maintenance warning lights illuminated. The vehicle was inspected by an independent mechanic and an unknown trouble code was retrieved. The dealer was notified of the failure and the contact was informed that the VIN was not included in a recall. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and the contact was advised to call the NHTSA Hotline. The failure mileage was approximately 80,000.

- Fuquay-Varina, NC, USA

The cylinder heads failed at 56,000 miles, causing the vehicle to violently jerk forward and backward on the highway at 75mph, the safety of myself, my family, semi-trucks and other passenger vehicles were at risk due to unexpected jerking at such high speeds. The Cylinder head failure, then caused the engine to need replacement. This was all sudden and unexpected. The manufacturer has a TSB for this problem, making it a known defect, but they never fixed it under warranty and are now attempting to charge $10,600 for the repair. The CEL did come on, but only after the failure began.

- Casa Grande, AZ, USA

Exhaust manifolds warped and leaking. Occupants are exposed to harmful emissions.

- Hampton, VA, USA

Vehicle idles rough than stalls after being at speed when stopped. Present a drivable condition in dangerous situations, no warning and throws no codes according to Ford service dealers. This condition has been present for over a year. It-??s my belief FMC knows about faulty VCT selinoids and cam phasers failure. They do have a TSB out on some of it. This condition does present a dangerous condition because there are no indications that the truck engine has died. FMC needs to recall vehicles with this condition and replace/ repair the faulty components at their cost.

- Sanford, ME, USA

Exhaust manifold on the 3.5 liter eco boost is warped and causing power loss, other engine and performance issues/ concerns.

- Montgomery, TX, USA

Both Right side and Left side exhaust manifolds warped resulting in stud bolt failure. The Right side failed at 69000 miles and the left side failed at 82000 miles. This failure results in "Emissions Leakage" and unsafe environment in the cab for occupants. Additionally, from an environmental standards requirement, all exhaust fails to make it through the "Catalyst" for cleansing and damages the "Catalyst" as a result of the engine adjusting to a lean mixture. Ford does not cover this expensive repair under its emissions warranty

- Shawnee, OK, USA

No engine light or warnings. At vehicle start up there is a loud ratteling sound. The variable valve timing system is causing due to the cam phasers being faulty. This is a known issue and some models have recalls but mine is not listed leading to around a $3600 repair on a vehicle that only has 60k miles.

- Madison Heights, MI, USA

3.5 liter EcoBoost engine had both exhaust manifolds warped and leaking with broken bolt. Two local Ford Dealers informed me that this is an issue plaguing many vehicles with the same engine having the same warped exhaust manifolds. The dealers also stated the only repair is to replace both exhaust manifolds with upgraded parts costing between $3000-$5000 (including labor). Having both exhaust manifolds leaking caused engine exhaust to leak into the engine compartment potentially causing danger during operation and maintenance of the vehicle. Repairs on my vehicle were completed on 6/27/2022 and the reason for delay in repairs was in part between parts ordering and dealership scheduling.

- Kamiah , ID, USA

My 2016 Ford F-150 will periodically stall. The stall could occur while stopped (at a light or to make turn), while in park and only idling, or when the vehicle was in motion at less than 25 mph. If it stalled while starting a turn, then there was a serious risk of major collision from oncoming traffic. If the oncoming vehicle did not recognized the vehicle was stalling, or had otherwise failed to properly evaluate the situation early enough then a collision would be likely. A scan of multiple Internet web sites found thousands of people, with similar model years and the same engine, 5.0L Coyote, having the same or similar issue.

- Wallingford, CT, USA

The contact owns a 2016 Ford F-150. The contact stated while driving at various speeds, the vehicle stalled with the check engine warning light illuminated. The contact shifted to park(P) and restarted the vehicle and the vehicle regained normal operation. The contact took the vehicle to the dealer who diagnosed that bank #2 Variable Camshaft Tuning (VCT) solenoids needed to be replaced. The vehicle had not been repaired. The failure recurred approximately 10-12 times and became more frequent. The manufacturer was not made aware of the failure. The approximate failure mileage was 50,000.

- College Station, TX, USA