What is the 2015-2018 Ford F-150 Front seat belt pretensioner fire risk?

When a front seat belt pretensioner deploys in a crash, it can generate excessive sparks/hot gas that ignites insulation, carpet, or wiring inside the B-pillar, potentially starting a vehicle fire. Ford recalled about 2 million 2015-2018 F-150 trucks (about 1.6 million in the U.S… Repairs typically run $0-$0. Severity: high.

What is the 2013-2018 Ford F-150 Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss?

The brake master cylinder rear cup seal can roll or fail, allowing brake fluid to leak from the front-circuit reservoir into the brake booster. This drops fluid in the front brake circuit and can reduce or eliminate front-wheel braking (rear brakes remain). Drivers report a long/… Repairs typically run $0-$600. Severity: high.

What is the 2015-2022 Ford F-150 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head?

Ford's 2.7L EcoBoost (and related small-displacement EcoBoost engines) is prone to micro-cracks forming in the cylinder head around the exhaust ports, allowing coolant to seep into the combustion chamber. This produces unexplained coolant loss with no external leak, white sweet-s… Repairs typically run $4,000-$8,000. Severity: high.

What is the 2011-2017 Ford F-150 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle?

Distinct from the cam-phaser cold-start rattle, the first-generation (2011-2016) 3.5L EcoBoost suffers genuine primary timing-chain wear ('stretch') because of its long chain routing and the high loads of a twin-turbo direct-injection V6. As the chain pins and rollers wear, the c… Repairs typically run $1,800-$3,200. Severity: high.

What is the 2015-2020 Ford F-150 EcoBoost Oil Pan Leak?

The EcoBoost engines can develop oil leaks from the oil pan gasket. The leak often appears at the rear of the oil pan and can drip onto exhaust components, causing a burning oil smell. This is common on trucks with higher mileage. Repairs typically run $400-$1,200. Severity: medium.

What is the 2015-2020 Ford F-150 Driveshaft Carrier Bearing Failure?

The two-piece driveshaft uses a center support (carrier) bearing that can wear out, causing vibration and noise. The rubber support degrades over time, especially in hot climates or with heavy towing. Ford TSB addresses this issue. Repairs typically run $300-$700. Severity: medium.

What is the 2011-2020 Ford F-150 3.5L EcoBoost Fuel Injector Failure — Startup Misfire, Rough Idle, and Fuel-Injector DTCs?

The 3.5L EcoBoost's high-pressure direct (GDI) injectors run at diesel-like pressures and are a common failure item, especially at higher mileage and after heat-soak. A stuck-open or electrically failing injector floods a cylinder and can wash down neighboring cylinders on the sa… Repairs typically run $650-$1,500. Severity: medium.

What is the 2015-2023 Ford F-150 Coolant Degas / Overflow Bottle Cracks and Quick-Connect Fitting Leaks?

The plastic pressurized coolant degas (overflow/expansion) bottle and the plastic quick-connect tees/Y-fittings that route coolant between the block, radiator, and bottle develop hairline cracks and seep, especially at seams and hose necks and in cold weather where the square-cut… Repairs typically run $150-$450. Severity: medium.

What is the 2015-2020 Ford F-150 Panoramic / twin-panel sunroof spontaneous shattering?

F-150 trucks equipped with the large twin-panel (panoramic) sunroof have reports of the tempered glass spontaneously shattering or 'exploding' with a loud bang, sometimes at highway speed, raining glass into the cabin. Owners and a class action attribute it to the ceramic enamel… Repairs typically run $500-$1,500. Severity: medium.

What is the 2015-2024 Ford F-150 Swollen Two-Piece Lug Nuts Preventing Tire Removal?

Ford's two-piece factory lug nuts (a steel core with a thin chromed/stainless decorative cap) trap moisture between the layers. The steel core corrodes and the resulting rust bloom swells the cap outward, so the standard 21mm/22mm socket and the truck's own lug wrench no longer f… Repairs typically run $40-$200. Severity: medium.

What is the 2009-2017 Ford F-150 6R80 6-Speed Automatic Harsh 1-2 Upshift / Erratic Shifting and Lead-Frame Solenoid Body Failure?

The 6R80 six-speed automatic (2009-2017 F-150) is generally durable but is widely reported for a harsh, banging 1-2 upshift and erratic/flaring shifts, with thousands of NHTSA complaints. The internal solenoid body 'lead frame' (the mechatronic wiring carrier) can crack or develo… Repairs typically run $250-$1,500. Severity: medium.

What is the 2004-2020 Ford F-150 Exhaust Manifold Studs / Bolts Break — Exhaust Leak and Cold-Start Ticking?

Ford modular V8s (and the EcoBoost V6 turbo manifolds) are notorious for snapping the small (8mm) exhaust-manifold-to-head studs/bolts. They are installed without anti-seize and corrode/fatigue from repeated heat cycling; on the turbo EcoBoost engines, a large share of the turbo/… Repairs typically run $50-$700. Severity: medium.

What is the 2004-2020 Ford F-150 Rear Differential Pinion Bearing / Ring-and-Pinion Whine and Howl?

The rear axle (commonly the 8.8-inch) develops a speed-dependent whine or howl as the pinion bearing and ring-and-pinion gears wear, often the most common source of axle noise on Ford trucks. The noise typically appears under acceleration or on deceleration and changes with throt… Repairs typically run $500-$1,600. Severity: medium.

What is the 2013-2020 Ford F-150 SYNC 2 / SYNC 3 APIM Failure — Black Screen, Freezing, and Reboot Loops?

The Accessory Protocol Interface Module (APIM) — the computer behind the SYNC 2 and SYNC 3 touchscreen — is a very common failure on 2013-2020 F-150s. Its internal electronics and onboard flash storage degrade over time, producing a black/unresponsive screen (sometimes with backl… Repairs typically run $0-$900. Severity: medium.

What is the 2015-2020 Ford F-150 Front Wheel Hub Bearing Assembly Failure — Humming Noise and ABS Light?

The sealed, non-serviceable front hub/bearing assemblies on 13th-gen F-150s wear out and produce a speed-dependent humming or grinding that gets louder with speed and can shift with cornering load, plus steering-wheel/floor vibration. Because the wheel-speed sensor lives in the h… Repairs typically run $300-$750. Severity: medium.

Ford · Known Issues

2016 Ford F-150 Problems: 33 Issues Every Owner Should Know

2016 model year · 3,576+ owner reports · Updated July 2026

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According to Au7o's analysis of 3,576+ owner reports, the 2016 Ford F-150 has 33 documented known issues, with 9 rated critical. The most serious are Brake Vacuum Pump Failure (EcoBoost) ($300-$800 repair), Door latch failure - doors won't latch or open while driving ($0-$350 repair), Front seat belt pretensioner fire risk ($0-$0 repair), Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss ($0-$600 repair), 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head ($4,000-$8,000 repair), Electric Power Steering (EPAS) Assist Fault — Sudden Loss of Power Steering Assist ($1,000-$1,900 repair), 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle ($1,800-$3,200 repair), 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power ($1,800-$5,000 repair). at .

Frequently Asked Questions

What are the most common Ford F-150 problems?

According to Au7o's analysis of 3,576+ owner reports, the 2016 Ford F-150 has 33 documented issues. The most frequently reported are: Brake Vacuum Pump Failure (EcoBoost), Door latch failure - doors won't latch or open while driving, Front seat belt pretensioner fire risk. Of these, 9 are rated critical and should be addressed promptly.

Is the Ford F-150 reliable?

The 2016 Ford F-150 has 33 known issues documented across 3,576+ owner reports. 9 issues are rated critical: Brake Vacuum Pump Failure (EcoBoost) and Door latch failure - doors won't latch or open while driving and Front seat belt pretensioner fire risk and Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss and 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head and Electric Power Steering (EPAS) Assist Fault — Sudden Loss of Power Steering Assist and 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle and 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power and P0700 — Transmission Control System Malfunction (MIL Request) from Failed 6R80 Molded Leadframe. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford F-150 problems?

Repair costs for known Ford F-150 issues range from $0 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Brake Vacuum Pump Failure (EcoBoost), typically costs $300-$800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2015-2020 Ford F-150 Brake Vacuum Pump Failure (EcoBoost)?

The vacuum pump that provides brake assist on EcoBoost F-150s can fail, resulting in a hard brake pedal and reduced braking assist. Since turbo engines don't produce intake vacuum like naturally aspirated engines, they rely on this pump. Repairs typically run $300-$800. Severity: high.

All 33 Known Issues

Other Ford Models

Frequently Asked Questions

What are the most common Ford F-150 problems?

Is the Ford F-150 reliable?

How much does it cost to fix common Ford F-150 problems?

What is the 2015-2020 Ford F-150 Brake Vacuum Pump Failure (EcoBoost)?

What is the 2015-2017 Ford F-150 Door latch failure - doors won't latch or open while driving?

2011-2017 Ford F-150: 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle#

2011-2024 Ford F-150: 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power#

2015-2020 Ford F-150: EcoBoost Oil Pan Leak#

2011-2025 Ford F-150: EcoBoost Turbo Underboost (P0299) — Boost Leaks, Bypass Valve Diaphragm, and Warped Air Deflector#

2011-2016 Ford F-150: 3.5L EcoBoost (Gen 1) Intake Valve Carbon Buildup — Misfire, Rough Idle, Power Loss#

2015-2020 Ford F-150: Brake Vacuum Pump Failure (EcoBoost)#

2013-2018 Ford F-150: Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss#

2015-2017 Ford F-150: Door latch failure - doors won't latch or open while driving#

2015-2020 Ford F-150: Panoramic / twin-panel sunroof spontaneous shattering#

1997-2020 Ford F-150: Water Leak at Rear Window / Third Brake Light — Wet Headliner, Carpet, and Cab-Corner Rust#

2004-2017 Ford F-150: Rocker Panel and Cab-Corner Rust from Clogged Internal Drains#

2009-2024 Ford F-150: Center High-Mount Stop Lamp (Third Brake Light) Gasket Leak — Water Intrusion into Cab#

2015-2023 Ford F-150: Power Tailgate Lock Actuator Failure / Tailgate Opens by Itself#

2015-2018 Ford F-150: Front seat belt pretensioner fire risk#

2015-2020 Ford F-150: Warped / Cracked Dashboard at Defrost Vents (TSB 19-2041) — XL & XLT Instrument Panel Separation#

2015-2022 Ford F-150: 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head#

2015-2023 Ford F-150: Coolant Degas / Overflow Bottle Cracks and Quick-Connect Fitting Leaks#

2011-2020 Ford F-150: P0700 — Transmission Control System Malfunction (MIL Request) from Failed 6R80 Molded Leadframe#

2009-2017 Ford F-150: 6R80 6-Speed Automatic Harsh 1-2 Upshift / Erratic Shifting and Lead-Frame Solenoid Body Failure#

2011-2016 Ford F-150: Electric Power Steering (EPAS) Assist Fault — Sudden Loss of Power Steering Assist#

2015-2020 Ford F-150: Driveshaft Carrier Bearing Failure#

2004-2020 Ford F-150: Rear Differential Pinion Bearing / Ring-and-Pinion Whine and Howl#

2004-2024 Ford F-150: IWE (Integrated Wheel End) Failure — Front-End Grinding and Partial 4x4 Hub Engagement#

2015-2024 Ford F-150: Swollen Two-Piece Lug Nuts Preventing Tire Removal#

2015-2019 Ford F-150: Aluminum Body Panel Paint Bubbling & Corrosion (Hood, Roof, Doors) — Iron-Contamination / Primer Defect#

2004-2020 Ford F-150: Exhaust Manifold Studs / Bolts Break — Exhaust Leak and Cold-Start Ticking#

2011-2024 Ford F-150: EcoBoost Turbocharger Wastegate Actuator Rattle#

2013-2020 Ford F-150: SYNC 2 / SYNC 3 APIM Failure — Black Screen, Freezing, and Reboot Loops#

2015-2023 Ford F-150: HVAC Blend Door Actuator Failure#

2011-2020 Ford F-150: 3.5L EcoBoost Fuel Injector Failure — Startup Misfire, Rough Idle, and Fuel-Injector DTCs#

2015-2020 Ford F-150: Front Wheel Hub Bearing Assembly Failure — Humming Noise and ABS Light#

2012-2020 Ford F-150: A/C Evaporator Core Leak — Weak/Warm A/C and Musty Smell#

2011-2020 Ford F-150: EVAP Canister Purge Valve Stuck Open — Hard Start After Refueling, Rough Idle, P0455/P0496#

What is the 2015-2018 Ford F-150 Front seat belt pretensioner fire risk?

What is the 2013-2018 Ford F-150 Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss?

What is the 2015-2022 Ford F-150 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head?