According to Au7o's analysis of 3,900+ owner reports, the 2022 Ford F-150 has 19 documented known issues, with 7 rated critical. The most serious are 10R80 10-speed transmission harsh/erratic shifting and torque-converter shudder ($150-$4,500 repair), Integrated Trailer Module Loses Communication — Loss of Trailer Brakes, Turn Signals, and Brake Lights While Towing (NHTSA 26V104) ($0-$0 repair), F-150 Lightning High-Voltage Battery Cell Defect — Internal Short Circuit and Fire Risk (Recall 25S18 / NHTSA 25V234) ($0-$0 repair), Rearview Camera Image Freezes, Blacks Out, or Delays When Reversing (SYNC 4 Recall 25S49 / NHTSA 25V315) ($0-$0 repair), 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head ($4,000-$8,000 repair), 3.5L PowerBoost Hybrid Exhaust Heat Exchanger Coolant Leak ($500-$1,500 repair) and 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power. at .
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, 2024 Expedition and 2024 Lincoln Navigator vehicles equipped with a 3.5L GTDI engine. The engines may have a misaligned engine cup plug, which can result in a rapid oil leak.
Campaign #24V85100020/12/2024
POWER TRAIN:AUTOMATIC TRANSMISSION:FLUID/LUBRICANT:VALVES/VALVE BODY
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, Bronco, 2024 Ranger, 2025 Mustang, Explorer, and Aviator vehicles. The transmission valve body may have been machined incorrectly, which can cause reverse gear failure, or unexpected forward movement in reverse or neutral gear.
Campaign #25V16400014/03/2025
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, Expedition, and 2024 Lincoln Navigator vehicles equipped with 3.5L GTDI engines. The engine may have a misaligned engine cup plug, which can result in a rapid oil leak.
Campaign #25V198000
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According to Au7o's analysis of 3,900+ owner reports, the 2022 Ford F-150 has 19 documented issues. The most frequently reported are: 10R80 10-speed transmission harsh/erratic shifting and torque-converter shudder, Integrated Trailer Module Loses Communication — Loss of Trailer Brakes, Turn Signals, and Brake Lights While Towing (NHTSA 26V104), F-150 Lightning High-Voltage Battery Cell Defect — Internal Short Circuit and Fire Risk (Recall 25S18 / NHTSA 25V234). Of these, 7 are rated critical and should be addressed promptly.
Is the Ford F-150 reliable?
The 2022 Ford F-150 has 19 known issues documented across 3,900+ owner reports. 7 issues are rated critical: 10R80 10-speed transmission harsh/erratic shifting and torque-converter shudder and Integrated Trailer Module Loses Communication — Loss of Trailer Brakes, Turn Signals, and Brake Lights While Towing (NHTSA 26V104) and F-150 Lightning High-Voltage Battery Cell Defect — Internal Short Circuit and Fire Risk (Recall 25S18 / NHTSA 25V234) and Rearview Camera Image Freezes, Blacks Out, or Delays When Reversing (SYNC 4 Recall 25S49 / NHTSA 25V315) and 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head and 3.5L PowerBoost Hybrid Exhaust Heat Exchanger Coolant Leak and 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power. 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, 10R80 10-speed transmission harsh/erratic shifting and torque-converter shudder, typically costs $150-$4,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2017-2023 Ford F-150 10R80 10-speed transmission harsh/erratic shifting and torque-converter shudder?
The 10R80 10-speed automatic (introduced on the 2017 F-150) is widely reported to shift harshly: jerking, clunking, banging on the 1-2 and 2-3 shifts, hesitation, gear hunting, and occasional limp-mode with a 'Transmission Not in Park' or 'drive mode not available' message. Many… Repairs typically run $150-$4,500. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
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On the 2022-2024 Ford F-150 Dual-motor BEV (SK Battery America cells), certain 2022-2024 F-150 Lightning EVs (built March 16, 2022 through August 14, 2024) have high-voltage battery cells from SK Battery America with a manufacturing defect that can misalign internal electrodes. The cathode aluminum tabs may contact the anode material, causing an internal short circuit when the pack is at a high state of charge. Over repeated charge/discharge cycles this can lead to a battery fire without warning. At the time of filing Ford was aware of 5 reported fires and 1 injury under investigation. This is a Lightning-specific high-voltage battery issue, separate from the earlier loose battery-junction-box nut recall.
Common Symptoms
High-voltage battery warning messages
Reduced range or charging anomalies
Risk of battery fire when charged to high state of charge
Smoke or thermal event from underbody battery pack
How to Fix
Ford's interim guidance is to limit charging to 80% of battery capacity until the truck is inspected. The remedy is dealer inspection and, where needed, replacement of the high-voltage battery array at no charge under recall 25S18 / NHTSA 25V234. Owners should park outside and away from structures if a battery warning appears and verify recall status by VIN at nhtsa.gov/recalls.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2021-2024 Ford F-150, on 14th-gen F-150s running SYNC 4 software versions 1.7 through 1.9, an improper operational sequence in the wireless communication subsystem can cause the center infotainment screen to freeze, go black, and reboot. If this happens while the truck is in reverse, the backup-camera image can freeze on a stale frame, disappear entirely, or be delayed, presenting a false view of what is behind the vehicle and increasing crash/backover risk. Ford recalled roughly 527,000 F-150s (and over 1 million total Ford vehicles) for this defect. This is distinct from the older infotainment lockups and is specific to the SYNC 4 generation in the 2021+ trucks.
Common Symptoms
Backup camera image freezes or shows a frozen frame in reverse
Center screen goes black and reboots
Rearview image delayed or missing when shifting to reverse
SYNC 4 infotainment system spontaneously restarts
How to Fix
Ford's remedy is a free software update to the Accessory Protocol Interface Module (APIM); on many trucks it is delivered over-the-air, otherwise the dealer reflashes the module at no charge under recall 25S49 / NHTSA 25V315. Owners can verify eligibility by VIN at nhtsa.gov/recalls or ford.com. A manual reboot (holding the power/volume controls) is a temporary workaround but does not fix the underlying software fault.
On the 2015-2023 Ford F-150, the HVAC blend door actuators can fail, causing clicking noises from the dashboard and inability to control air temperature. Air may blow only hot or only cold regardless of settings. Multiple actuators are used and any can fail.
Replace failed blend door actuator. Actuators are located behind dashboard and require some disassembly. Consider replacing multiple actuators if one fails as others may follow. OEM parts recommended.
Owner tips & cautions
TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
TipSearch Ford F-150 forums and owner groups for real-world experiences and DIY guides
TipGet multiple quotes from independent mechanics - dealer prices can be 2-3x higher for the same repair
High Confidence1,100 reportsLast reported by owners Feb 2024Reviewed Feb 2026
On the 2021-2024 Ford F-150 All engines (trucks equipped with the 12-inch SYNC 4 screen), 14th-gen F-150s with the 12-inch SYNC 4 infotainment display commonly suffer a black/blank or frozen screen at startup — sometimes with no Ford logo, sometimes stuck on the splash screen, and sometimes unresponsive for several minutes. Owners report it occurring intermittently (some 2023 trucks roughly 10% of startups) and note it worsened after certain over-the-air updates (e.g., the 4.2.2 and 6.8 OTA builds). With the center screen down, the backup camera, climate controls, radio, and drive-mode selection are unavailable, which is a real usability and visibility concern. A two-button hard reset usually restores it, but the recurrence is the complaint. This is distinct from the older SYNC 2/3 APIM failure and from the SYNC 4 rearview-camera recall — it is a SYNC 4 software/stability issue on the large screen.
Common Symptoms
Center 12-inch screen black or blank at startup
Screen frozen on the Ford logo / splash screen
Backup camera, climate, and radio controls unavailable
Random unresponsiveness requiring a button reset
Onset or worsening after an OTA software update
How to Fix
Perform a hard reset by pressing and holding the power and right-seek buttons for about 10 seconds until the screen reboots. Keep SYNC software current but be aware some OTA builds introduced the regression — check Ford's update notes and, if a recent update triggered it, ask the dealer about the latest stable build or a master reset. If resets stop working or the screen stays dead, the dealer can reflash or, in persistent cases, replace the APIM/display module. Allow extra time after large updates, during which the screen can be unresponsive for 2-15 minutes by design.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2018-2023 Ford F-150 All engines with Auto Start-Stop, f-150 owners frequently report that the Auto Start-Stop system stops functioning, throwing a 'Start-Stop not available — see owner's manual' message. The system requires the battery state of charge to stay above roughly 70%; the AGM battery setup and the high electrical load of these trucks lead to premature battery degradation, and dealers often diagnose a battery at well under full charge and replace it. Owners report the battery dropping below threshold repeatedly, with the feature disabling itself even on relatively new trucks. While the dropout itself is benign, the underlying weak/degraded battery can cause harder starts, electrical glitches, and repeat battery costs. Many owners ultimately install a start-stop 'eliminator' to keep the feature off rather than chase the battery.
Common Symptoms
'Start-Stop not available — see owner's manual' message
Auto Start-Stop intermittently or permanently stops engaging
Repeated battery replacements at low mileage
Slow cranking or hard starts
Battery warning light or low-voltage events
How to Fix
Load-test the battery and check state of charge — a battery below ~70% SOC or with reduced capacity is the usual cause and should be replaced with the correct AGM specification, not a cheaper flooded battery. Verify the BMS (battery monitoring sensor) and ground connections are clean and tight, and check for parasitic draw if the battery keeps discharging. Confirm the alternator is charging to spec. If the owner simply dislikes the feature, a memory-retaining start-stop disable module keeps it off without affecting the battery diagnosis.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2021-2024 Ford F-150 3.5L PowerBoost Full Hybrid V6 (7.2kW Pro Power Onboard), powerBoost hybrid F-150s equipped with the 7.2kW Pro Power Onboard generator commonly throw a ground-fault / generator fault that disables the bed and in-cab outlets. Owners and dealers have traced many cases to moisture intrusion — water collecting in the in-bed outlet/connector area ('wet = fault') — which trips the system's ground-fault detection. Separately, some units output an unusual 60/60-volt split rather than a proper 120V hot-to-ground bond, which prevents certain appliances (modern A/Cs, refrigerators with ground-fault protection) from running. Symptoms are constant error messages and the generator being unusable until the fault clears or the truck dries out, frustrating buyers who bought the feature specifically for jobsite/RV/backup power.
Common Symptoms
Pro Power Onboard ground-fault / generator-fault message
Bed and in-cab outlets stop supplying power
Fault appears or worsens when wet / after rain
Certain appliances (A/C, fridge) won't run on the outlets
Inspect the bed outlet box and its wiring connectors for water intrusion and corrosion; dry and reseal the connections, as moisture is the leading trigger of the ground-fault. Have the dealer check for TSBs/software updates addressing Pro Power fault logic and verify the neutral/ground bonding at the inverter output. For appliances that won't run due to the floating-neutral output, a properly wired neutral-ground bond at the outlet (where appropriate) can resolve the missing bond, but confirm the correct approach with Ford to avoid defeating the safety system.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2015-2022 Ford F-150 2.7L EcoBoost, 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-smelling exhaust, cold-start misfires, and oil emulsification ('mayonnaise' under the oil cap). Left unaddressed it can cause catastrophic engine damage. The defect is the subject of active consolidated federal class-action litigation covering 2.7L and 3.5L F-150, Bronco, and Edge as of 2026.
Diagnosis requires a coolant pressure/combustion-gas test and pulling spark plugs to confirm coolant in a cylinder. The fix is cylinder head replacement (or full long-block if damage is extensive); a head gasket alone will not cure a cracked head. Some repairs fall under Ford's extended coolant-intrusion warranty coverage for affected engines — owners should check warranty status before paying out of pocket, as quotes run $4,000-$8,000.
On the 2021-2023 Ford F-150 3.5L PowerBoost Hybrid, on 3.5L PowerBoost full-hybrid F-150s, cracks develop in the coolant spigots on top of the exhaust heat exchanger, causing an external coolant leak. The result is gradual coolant loss, possible engine overheating, and an illuminated MIL/temperature warning — in some cases leaving the truck undrivable. Ford documented the failure in service bulletins SSM 51103 and SSM 51485 covering 2021-2023 PowerBoost trucks. This is distinct from the conventional EcoBoost coolant-intrusion (cylinder head) failure and from the engine block heater fire recall.
The exhaust heat exchanger coolant spigots are serviced in pairs — Ford's procedure replaces the cracked spigots/heat exchanger assembly and refills/bleeds the cooling system. Owners should monitor coolant level and address any low-coolant or overheat warning promptly to avoid engine damage. Repairs may be covered under powertrain or hybrid-system warranty depending on mileage.
On the 2015-2023 Ford F-150, 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 O-rings on the quick-connects shrink. Owners chase a slow coolant loss and sweet smell that is hard to pinpoint because the crack only weeps under pressure or when cold. If ignored it can lead to low-coolant overheating.
Coolant residue around the overflow bottle or plastic fittings
Low-coolant warning / heater going cold
Leak worse when cold, reseals when hot
How to Fix
Pressure-test the cooling system to reveal the weep. Replace the degas bottle and any cracked plastic tee/Y quick-connect fittings as an assembly — a new hose/fitting will not seal reliably on an old bottle neck. Replace shrunken O-rings on quick-connects. Refill with the correct Ford orange/yellow spec coolant and burp the system.
Medium ConfidenceVerified0 reportsReviewed Jul 2026
On the 2017-2023 Ford F-150, the 10R80 10-speed automatic (introduced on the 2017 F-150) is widely reported to shift harshly: jerking, clunking, banging on the 1-2 and 2-3 shifts, hesitation, gear hunting, and occasional limp-mode with a 'Transmission Not in Park' or 'drive mode not available' message. Many trucks also exhibit a torque-converter lockup-clutch shudder felt as a vibration around 30-45 mph. Root causes traced in later TSBs include adaptive-calibration mismatch during break-in, CDF drum bushing migration, and valve-body bore wear/scoring. A class action (O'Connor v. Ford, N.D. Illinois) covers the defect.
Vibration/shudder at 30-45 mph (torque-converter lockup)
Limp mode or 'drive mode not available' message
How to Fix
Start with a Ford PCM/TCM reflash to the latest calibration and an adaptive-learning relearn drive cycle (early TSBs 18-2079/18-2274, later 23-2250 superseded by 24-2046). For shudder, a transmission fluid service with Mercon ULV plus friction modifier helps. Persistent harsh shifts with valve-body bore damage require main control valve body replacement (TSB 22-2428). Severe cases need converter or transmission overhaul.
On the 2017-2023 Ford F-150, the 10R80 10-speed automatic transmission can develop a shudder during light acceleration, typically between 25-50 mph. This is caused by torque converter clutch issues and affects many F-150s. Ford has released multiple TSBs and fluid updates to address this.
Perform transmission fluid flush with Motorcraft Mercon ULV and add Ford friction modifier. Adaptive learning reset via FORSCAN or dealer may help. Multiple fluid changes sometimes needed. In severe cases, torque converter replacement required under warranty extension.
Owner tips & cautions
TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
TipSearch Ford F-150 forums and owner groups for real-world experiences and DIY guides
TipGet multiple quotes from independent mechanics - dealer prices can be 2-3x higher for the same repair
High Confidence2,800 reportsLast reported by owners Feb 2024Reviewed Feb 2026
On the 2011-2024 Ford F-150, the wastegate on the 3.5L EcoBoost turbochargers fails, either sticking (carbon/corrosion binding the valve and actuator arm) on early vacuum-operated designs or through electronic actuator/position-sensor faults on 2015-and-newer electric-actuator turbos. A stuck-closed wastegate causes overboost (P0234) and a metallic rattle, while a stuck-open wastegate or sensor/actuator faults cause underboost (P0299) and trip the powertrain into reduced-power limp mode. Because Ford does not sell the electronic wastegate actuator as a separate service part on later trucks, the accepted dealer repair is replacement of the entire affected turbocharger assembly, making it an expensive failure. Ford also issued TSB guidance (e.g., wastegate-arm rattle spring kits on 2017 3.5L) for related linkage slack.
Metallic rattle at startup or when lifting off the throttle
Boost gauge showing over- or under-boost
Check engine light with turbo wastegate performance codes
How to Fix
Diagnose the boost-control fault and rule out unrelated causes first (charge-pipe/boost leaks, cracked intercooler pipe, BOV, solenoid, vacuum leaks). On early vacuum-actuator turbos the wastegate actuator/diaphragm or linkage can sometimes be serviced or freed; on 2015+ electric-actuator turbos Ford's procedure replaces the complete turbocharger assembly since the actuator is not sold separately. Replace oil feed line screens if oil starvation contributed.
On the 2011-2025 Ford F-150, p0299 sets when actual boost is about 4 psi or more below the commanded value for several seconds, dropping the truck into reduced-power limp mode (orange wrench light). On EcoBoost F-150s the most common causes are NOT the turbos themselves but cheaper upstream parts: a loose or popped cold-side intercooler boot/clamp, a torn orange rubber diaphragm inside the electronic turbocharger bypass (blow-off) valve, and cracked charge-pipe couplers. On 14th-gen (2021+) trucks a specific failure is the plastic upper radiator air deflector warping and blocking the passenger-side turbo intake snorkel, starving that turbo for air (updated part ML3Z-8310-D). Wastegate-actuator sticking can also contribute. Owners frequently — and wrongly — replace turbochargers when a smoke test would have found a hose or the bypass-valve diaphragm.
Always perform a high-pressure smoke test of the charge-air system before condemning the turbos. Reseat/replace the cold-side intercooler boot and clamps; inspect the electronic bypass valve for a torn diaphragm and replace if leaking. On 2021+ trucks setting P0299 on the passenger bank, inspect the upper radiator air deflector and replace with the updated part (ML3Z-8310-D) if warped. Check wastegate actuators for free movement. Only after leaks, the bypass valve, deflector, and wastegate are ruled out should a turbocharger be considered. A boot/clamp fix can be under $100; a turbo replacement runs into the thousands.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2021-2026 Ford F-150, a software fault in the Integrated Trailer Module (ITRM) can cause it to lose communication with the rest of the vehicle while a trailer is connected. This can result in loss of trailer brake and turn-signal lights, or complete loss of trailer brake function, dramatically increasing crash risk when hauling. Ford recalled over 4.3 million vehicles for this defect in early 2026, of which roughly 2.3 million are F-150s spanning 2021-2026. Ford reported it was aware of 407 incidents potentially related at the time of filing. Drivers typically see a 'Trailer Brake Module Fault' message, a rapidly flashing turn-signal indicator, and sometimes a 'Blind Spot Assist System fault' message.
Common Symptoms
'Trailer Brake Module Fault' message on instrument cluster
Loss of trailer brakes while towing
Trailer turn signals and brake lights stop working
Turn-signal indicator flashes rapidly
'Blind Spot Assist System fault' message
How to Fix
Ford's remedy is a free software update to correct the ITRM communication fault, delivered over-the-air (rollout began around May 2026) or at a dealer at no cost under NHTSA campaign 26V104. Until updated, drivers should treat any Trailer Brake Module Fault warning as a real loss of trailer braking, reduce speed, and avoid towing heavy loads. Verify eligibility by VIN at nhtsa.gov/recalls.
On the 2009-2024 Ford F-150, the foam gasket that seals the roof-mounted center high-mount stop lamp (CHMSL / third brake light) against the cab dries out, compresses and shrinks with heat and UV exposure, breaking the watertight seal. Rainwater then runs down inside the cab from the roof opening, soaking the headliner, rear seat area and carpet, and can corrode wiring or foster mold. It is one of the most widely reported non-powertrain complaints across multiple F-150 generations. Ford has issued TSBs on this failure over the years (e.g., 04-20-5 on the 2004 truck) and now sells an updated lamp assembly with a thicker gasket, tacitly acknowledging the original design flaw. NOTE: there is NO confirmed Ford 10-year/150,000-mile warranty extension for this repair — that program (TSB 23-074-23 / warranty extension XG1) belongs to RAM/Stellantis and was mistakenly attributed to Ford in some sources.
Water stains or wet spots on the headliner, especially rear corners
Damp or soaked carpet/floor behind the rear seats
Condensation or fog on the inside of the rear window
Water or condensation visible inside the third brake light housing
Musty/moldy smell in the cab after rain or a car wash
Occasional intermittent third brake light electrical failure from corrosion
How to Fix
Replace the CHMSL/third brake light assembly with the updated OEM lamp that uses a thicker, more durable gasket, or reseal the housing with fresh butyl tape (preferred over RTV so the bulb can still be serviced). Dry out and inspect the headliner and rear cab for water damage. Typically an inexpensive DIY or dealer repair; unlike RAM, Ford has no broad warranty-extension program covering it, so check individual model-year TSBs and any active coverage with a dealer.
On the 2015-2023 Ford F-150 All (body, engine-independent), on 2015+ aluminum-body F-150s with the power-locking/keyless tailgate, the electric tailgate lock actuator weakens and fails — it clicks but won't lock/unlock, operates intermittently (especially in cold weather), grinds, or quits entirely so the tailgate won't open from the key fob or handle. A second, well-documented failure mode is the tailgate releasing or unlocking on its own: a connector near the spare tire lets in snow, ice, and road salt, corroding the circuit and sending a false release signal to the BCM, which can open/unlock the tailgate unexpectedly (a security and cargo-loss concern). Ford addressed related tailgate-cable/routing issues in TSB 19-2024. It is a popular F-150 search and an easy DIY.
Common Symptoms
Tailgate clicks but won't lock/unlock
Tailgate won't open from fob or handle
Intermittent operation in cold weather
Tailgate opens or unlocks by itself
Grinding noise from latch before failure
How to Fix
For no-open/intermittent operation, replace the tailgate lock actuator motor — OEM GC3Z-9943170-E (also cross-referenced FL3Z-9943170-C / GC3Z-9943170-A/B) for 2015-2023 power-tailgate trucks; the manual handle remains as a backup. For self-opening/unlocking, clean and dielectric-grease the corroded connector near the spare tire (inspect every ~6 months in salt regions) and repair any chafed wiring; verify BCM isn't seeing a false signal. Actuator ~$60-$180; DIY replacement ~30-45 min, or $150-$250 at a dealer.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2015-2024 Ford F-150, 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 fit. Owners discover the problem during a roadside flat tire and are unable to remove the wheel, and over-torqued or distorted caps can also compromise proper clamping. The issue affects F-150, Expedition, and Navigator and was the subject of a (dismissed) class-action suit.
Permanent fix is to discard all factory two-piece lug nuts and install solid one-piece (forged steel) M14x1.5 lug nuts; an aftermarket set runs roughly $40-$90 versus ~$220 for genuine Ford pieces. Torque to 150 lb-ft. Avoid high-pressure washing directly at the wheels, which forces water under the caps. Swollen nuts can be removed in the field with a slightly undersized impact socket driven on.
On the 2004-2024 Ford F-150, ford's 4x4 F-150s use a vacuum-operated Integrated Wheel End (IWE) system instead of conventional locking hubs: vacuum keeps the front hubs UNLOCKED in 2WD and is released to lock them for 4WD. The system relies on vacuum lines, a hood-area solenoid, and a check valve that are highly vulnerable to water, road salt, and cracking. A single leak causes the hubs to partially engage, producing a loud grinding or clicking from the front wheels under acceleration/deceleration in 2WD — a hallmark symptom that typically disappears in 4-Auto/4-High because removing vacuum fully locks the hub. It is among the most-searched F-150 4x4 noise complaints and is covered by TSBs 20-2028 and 24-2189A.
Diagnose in steps: replace the cheap IWE check valve first, inspect/replace cracked vacuum lines and the IWE solenoid (often water-drenched below the cowl), then replace the IWE hub-lock actuators themselves if grinding persists. Confirm it is the IWE and not a failed wheel hub/bearing (IWE noise goes away in 4WD; a bad bearing does not). OEM IWE actuator part numbers: 7L1Z-3C247-A (2004-2014) and HL1Z-3C247-A (2015+); check valve and solenoid sold separately. Check valve ~$15-$40; actuators ~$80-$180 each; full system repair commonly $200-$700 with labor.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
On the 2011-2024 Ford F-150, both the 3.5L and 2.7L EcoBoost turbos use exhaust wastegates whose actuator arm/linkage develops play as the bushings wear. The result is a distinctive metallic rattle — most noticeable for the first ~30-60 seconds after a cold start and at light throttle — coming from the turbo area. It is one of the most-searched EcoBoost noises because it sounds alarming but is usually a wear/NVH issue rather than an immediate failure. Ford has issued TSBs: 3.5L wastegate-rattle bulletins and a 2025 TSB for 2024 2.7L trucks (built on/before Oct 4, 2024) where a missing wave spring between the wastegate actuator lever arm and the turbine housing causes the rattle on both turbos.
Metallic rattle from turbo area on cold start (~30-60 sec)
Rattle at light throttle / tip-in
Noise diminishes once engine warms
No performance loss in early stages
How to Fix
Confirm the noise originates at the turbo wastegate (not the timing chain or cam phasers). Per Ford's 2.7L TSB, the repair is installing wave springs between the wastegate actuator lever arms and turbine housings on both turbochargers. For worn 3.5L actuators with excessive arm play, the fix is a new wastegate actuator or, in severe cases, turbocharger replacement under warranty. Often deferred if purely cosmetic noise. Wave-spring/actuator repair typically $150-$600; turbo replacement is far more but usually warranty-covered when within coverage.
Medium ConfidenceVerified0 reportsReviewed Jun 2026
28/03/2025
EQUIPMENT:OTHER:LABELS
Ford Motor Company (Ford) is recalling certain 2025 F-150 vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Campaign #25V27100023/04/2025
STEERING
Ford Motor Company (Ford) is recalling certain 2025 F-150 vehicles. The lower intermediate shaft fasteners may be improperly attached to the steering gear, allowing the shaft to come loose or detach.
What is the 2021-2026 Ford F-150 Integrated Trailer Module Loses Communication — Loss of Trailer Brakes, Turn Signals, and Brake Lights While Towing (NHTSA 26V104)?
A software fault in the Integrated Trailer Module (ITRM) can cause it to lose communication with the rest of the vehicle while a trailer is connected. This can result in loss of trailer brake and turn-signal lights, or complete loss of trailer brake function, dramatically increas… Repairs typically run $0-$0. Severity: high.
What is the 2022-2024 Ford F-150 F-150 Lightning High-Voltage Battery Cell Defect — Internal Short Circuit and Fire Risk (Recall 25S18 / NHTSA 25V234)?
Certain 2022-2024 F-150 Lightning EVs (built March 16, 2022 through August 14, 2024) have high-voltage battery cells from SK Battery America with a manufacturing defect that can misalign internal electrodes. The cathode aluminum tabs may contact the anode material, causing an int… Repairs typically run $0-$0. Severity: high.
What is the 2021-2024 Ford F-150 Rearview Camera Image Freezes, Blacks Out, or Delays When Reversing (SYNC 4 Recall 25S49 / NHTSA 25V315)?
On 14th-gen F-150s running SYNC 4 software versions 1.7 through 1.9, an improper operational sequence in the wireless communication subsystem can cause the center infotainment screen to freeze, go black, and reboot. If this happens while the truck is in reverse, the backup-camera… Repairs typically run $0-$0. 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 2021-2023 Ford F-150 3.5L PowerBoost Hybrid Exhaust Heat Exchanger Coolant Leak?
On 3.5L PowerBoost full-hybrid F-150s, cracks develop in the coolant spigots on top of the exhaust heat exchanger, causing an external coolant leak. The result is gradual coolant loss, possible engine overheating, and an illuminated MIL/temperature warning — in some cases leaving… Repairs typically run $500-$1,500. Severity: high.
What is the 2011-2024 Ford F-150 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power?
The wastegate on the 3.5L EcoBoost turbochargers fails, either sticking (carbon/corrosion binding the valve and actuator arm) on early vacuum-operated designs or through electronic actuator/position-sensor faults on 2015-and-newer electric-actuator turbos. A stuck-closed wastegat… Repairs typically run $1,800-$5,000. Severity: high.
What is the 2017-2023 Ford F-150 10-Speed Transmission Shudder/Harsh Shifts?
The 10R80 10-speed automatic transmission can develop a shudder during light acceleration, typically between 25-50 mph. This is caused by torque converter clutch issues and affects many F-150s. Ford has released multiple TSBs and fluid updates to address this. Repairs typically run $200-$3,500. 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 2015-2024 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 2011-2025 Ford F-150 EcoBoost Turbo Underboost (P0299) — Boost Leaks, Bypass Valve Diaphragm, and Warped Air Deflector?
P0299 sets when actual boost is about 4 psi or more below the commanded value for several seconds, dropping the truck into reduced-power limp mode (orange wrench light). On EcoBoost F-150s the most common causes are NOT the turbos themselves but cheaper upstream parts: a loose or… Repairs typically run $50-$700. Severity: medium.
What is the 2009-2024 Ford F-150 Center High-Mount Stop Lamp (Third Brake Light) Gasket Leak — Water Intrusion into Cab?
The foam gasket that seals the roof-mounted center high-mount stop lamp (CHMSL / third brake light) against the cab dries out, compresses and shrinks with heat and UV exposure, breaking the watertight seal. Rainwater then runs down inside the cab from the roof opening, soaking th… Repairs typically run $40-$250. Severity: medium.
What is the 2004-2024 Ford F-150 IWE (Integrated Wheel End) Failure — Front-End Grinding and Partial 4x4 Hub Engagement?
Ford's 4x4 F-150s use a vacuum-operated Integrated Wheel End (IWE) system instead of conventional locking hubs: vacuum keeps the front hubs UNLOCKED in 2WD and is released to lock them for 4WD. The system relies on vacuum lines, a hood-area solenoid, and a check valve that are hi… Repairs typically run $100-$700. Severity: medium.
What is the 2015-2023 Ford F-150 HVAC Blend Door Actuator Failure?
The HVAC blend door actuators can fail, causing clicking noises from the dashboard and inability to control air temperature. Air may blow only hot or only cold regardless of settings. Multiple actuators are used and any can fail. Repairs typically run $100-$500. Severity: low.
What is the 2021-2024 Ford F-150 SYNC 4 12-inch Touchscreen Goes Black, Freezes, or Reboots on Startup?
14th-gen F-150s with the 12-inch SYNC 4 infotainment display commonly suffer a black/blank or frozen screen at startup — sometimes with no Ford logo, sometimes stuck on the splash screen, and sometimes unresponsive for several minutes. Owners report it occurring intermittently (s… Repairs typically run $0-$1,200. Severity: low.
What is the 2018-2023 Ford F-150 Auto Start-Stop Stops Working / Premature Battery Degradation and Repeat Battery Replacements?
F-150 owners frequently report that the Auto Start-Stop system stops functioning, throwing a 'Start-Stop not available — see owner's manual' message. The system requires the battery state of charge to stay above roughly 70%; the AGM battery setup and the high electrical load of t… Repairs typically run $200-$450. Severity: low.
What is the 2021-2024 Ford F-150 PowerBoost Hybrid Pro Power Onboard Generator Ground Fault — Onboard Power Cuts Out (Moisture Intrusion)?
PowerBoost hybrid F-150s equipped with the 7.2kW Pro Power Onboard generator commonly throw a ground-fault / generator fault that disables the bed and in-cab outlets. Owners and dealers have traced many cases to moisture intrusion — water collecting in the in-bed outlet/connector… Repairs typically run $0-$600. Severity: low.
What is the 2015-2023 Ford F-150 Power Tailgate Lock Actuator Failure / Tailgate Opens by Itself?
On 2015+ aluminum-body F-150s with the power-locking/keyless tailgate, the electric tailgate lock actuator weakens and fails — it clicks but won't lock/unlock, operates intermittently (especially in cold weather), grinds, or quits entirely so the tailgate won't open from the key… Repairs typically run $60-$250. Severity: low.
What is the 2011-2024 Ford F-150 EcoBoost Turbocharger Wastegate Actuator Rattle?
Both the 3.5L and 2.7L EcoBoost turbos use exhaust wastegates whose actuator arm/linkage develops play as the bushings wear. The result is a distinctive metallic rattle — most noticeable for the first ~30-60 seconds after a cold start and at light throttle — coming from the turbo… Repairs typically run $150-$700. Severity: low.
