2025 Ford F-150 Problems: 11 Known Issues

On the 2024-2025 Ford F-150 3.5L EcoBoost V6 (3.5L GTDI), certain 2024-2025 F-150s built with the 3.5L GTDI (EcoBoost) V6 left the plant with a misaligned engine block cup plug (freeze/core plug). The plug can push out or leak, causing a rapid — not seeping — loss of engine oil. Ford issued two campaigns: NHTSA 24V851000 and NHTSA 25V198000 (Ford 25S30, 4,356 vehicles, also covering 2024-2025 Expedition and 2024 Navigator). Losing oil pressure at speed can seize or stall the engine, and oil sprayed onto hot exhaust components is a fire risk.

On the 2025 Ford F-150, a small production batch of 2025 F-150 engines was built with connecting rod and rod bearing components carrying manufacturing defects that lead to progressive engine damage and eventual failure. Ford recalled 156 vehicles under NHTSA 25V344000 (Ford 25S55) in June 2025; the same campaign covers 2025 Transit and 2025 Explorer. Because the failure is in the rotating assembly, the remedy is not a repair but a complete engine long block replacement. Owners typically hear a deepening knock or rumble from the bottom end under load before the engine lets go.

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 2024 F-150s with the 3.5L PowerBoost (Lariat/XLT/XL), Ford TSB 24-2264 says the upper air deflector can deform and restrict intake air to the right-side (passenger) turbocharger, causing turbo overspeed and damage (replacement deflector RL3Z-19E525-A); on 2021 PowerBoost trucks built on or before Sep 30, 2021, TSB 24-2257 traces P0299 to a restricted right air cleaner outlet pipe. 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.

On the 2025 Ford F-150 2.7L EcoBoost V6, on 2025.5 F-150s with the 2.7L EcoBoost V6, the heater-core coolant hose routing was relocated. The new routing lets the coolant hose contact the engine wire harness at the C-clip attachment, abrading the harness insulation over time. This can chafe the harness or disconnect powertrain control module (PCM) connector pins, causing the engine to stall and increasing crash risk. Ford issued recall 25S63 for affected 2.7L EcoBoost trucks.

On the 2025 Ford F-150, the Instrument Panel Cluster on 2025 F-150s can fail at startup, leaving the digital cluster blank or frozen so the driver has no speedometer, no fuel or temperature readings, and no telltale warning lights. Ford recalled 355,656 vehicles under NHTSA 25V540000 (Ford 25S88) in August 2025 covering the 2025 F-150 along with 2025-2026 F-250/F-350/F-450/F-550 Super Duty. Because the cluster is the sole display for FMVSS-required telltales, a failed startup means brake, airbag and charging warnings cannot be shown at all.

On the 2025 Ford F-150 3.5L PowerBoost full hybrid V6, recall 25V199000 / Ford 25S29 covers 47 specific 2025 F-150 full-hybrid vehicles that may have the wrong high-voltage battery junction-box fuse. Fuse failure can cause sudden loss of drive power. This does not apply to all PowerBoost trucks, and a warning/code alone does not identify the fault.

On the 2025 Ford F-150, on 2025 F-150s the Electronic Brake Booster module can malfunction while driving or while an ADAS feature (adaptive cruise, BlueCruise, automatic emergency braking) is active, causing a loss of power brake assist. Ford recalled 312,120 vehicles across the 2025 F-150, Expedition, Bronco, Ranger and Navigator under NHTSA 25V488000 (Ford 25S77) for this in July 2025. Drivers report a hard, high brake pedal requiring far more leg effort and a much longer stopping distance; with ADAS engaged the vehicle may fail to decelerate as commanded. A follow-on campaign, NHTSA 25V823000 (Ford 25SD4), covered 679 vehicles where the module itself is defective rather than the software.

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. At the time of filing Ford had identified 405 warranty claims and two owner complaints potentially related to the condition, and was not aware of any accidents or injuries. Drivers typically see a 'Trailer Brake Module Fault' message, a rapidly flashing turn-signal indicator, and sometimes a 'Blind Spot Assist System fault' message.

On the 2024-2025 Ford F-150, a limited build of 2024-2025 F-150s received automatic transmission main control valve bodies that were machined incorrectly. The defect causes reverse gear to fail outright, or — more dangerously — causes the truck to creep or lunge FORWARD while the shifter is in Reverse or Neutral. Ford recalled 269 vehicles under NHTSA 25V164000 (Ford 25S19) in March 2025, a campaign that also swept in 2024-2025 Bronco, 2024 Ranger, 2025 Mustang, 2025 Explorer and 2025 Aviator. The population is small and VIN-specific, but the failure mode is a rollaway hazard.

On the 2025 Ford F-150, on 9,181 2025 F-150s the lower intermediate steering shaft fasteners were improperly attached to the steering gear, allowing the shaft to work loose or fully detach from the rack. Ford recalled these trucks under NHTSA 25V309000 (Ford 25S46) in May 2025. A detached intermediate shaft means the steering wheel is no longer connected to the road wheels — complete loss of steering control. Owners typically feel increasing play or a clunk in the wheel before separation.

On the 2023-2025 Ford F-150, on certain 2023-2025 F-150s equipped with the Trailer Tow Max Duty package and the 9.75-inch heavy-duty 3/4-float rear axle, the rear axle hub bolt can fatigue and break. A failed bolt damages the axle hub splines, which can let the truck roll away when parked without the parking brake applied, or cause a loss of drive power. Ford recalled over 103,000 F-150s under this campaign, which expanded an earlier action (NHTSA 23V896). Owners are warned that a loosening bolt produces a clicking sound, and a broken bolt produces a rattling noise.