Cars

Ford F-150 Problems: Engine Reliability and Recalls Guide

JH
John H
Senior Cars Expert
8 min read

Ford F-150 Problems: Engine Reliability and Recalls Guide

The Ford F-150 is one of the most popular trucks in the United States, consistently topping sales charts for decades. Known for its rugged performance, versatile towing capabilities, and advanced technology, the F-150 appeals to a wide range of drivers—from construction workers and farmers to families and tech-savvy commuters. However, even the most reliable vehicles can encounter issues, and the F-150 is no exception. In this comprehensive guide, we’ll dive deep into Ford F-150 problems, focusing specifically on engine reliability and manufacturer recalls across various model years. Whether you’re considering buying a used F-150 or already own one, this article will help you understand potential engine concerns and what recalls may affect your truck.

Why Engine Reliability Matters in the F-150

As a full-size pickup truck, the Ford F-150 is expected to deliver dependable performance under heavy loads, adverse weather, and tough driving conditions. The engine is the heart of this performance, powering everything from daily commutes to off-road adventures and towing heavy trailers. When the engine fails or experiences chronic issues, it can lead to costly repairs, downtime, and safety risks.

Understanding the engine reliability of various F-150 models helps buyers and owners make informed decisions. While Ford has made significant strides in engine technology over the years—introducing EcoBoost V6 engines, high-output variants, and hybrid powertrains—some models have had more reported problems than others.

Most Common Ford F-150 Engine Problems by Model Year

Let’s take a closer look at engine-related issues reported across different generations of the Ford F-150.

Ford F-150 (2004–2008): 5.4L Triton V8 Engine

One of the most notorious problems in Ford F-150 history involves the 5.4L Triton V8 engine used in models from 2004 to 2008. This engine was widely used in both the F-150 and Ford’s larger SUVs, but it earned a reputation for reliability issues.

Problem: Spark Plug Ejection and Coil-on-Plug (COP) Failures
A major issue with the 5.4L engine was spark plug ejection—where spark plugs would literally blow out of the cylinder head due to a combination of weak aluminum threads and high heat cycles. This was often caused by repeated thermal expansion and contraction, leading to stripped threads in the cylinder head. As a result, the spark plug could loosen and eventually be ejected, causing misfires, rough idling, or even catastrophic engine damage.

Ford addressed this issue through multiple Technical Service Bulletins (TSBs), recommending repairs using inserts like “Timesert” to reinforce the spark plug holes. While not a formal recall, many owners found themselves paying out of pocket for repairs that could cost over $1,000 if not caught early.

Additional Issues:

Ford F-150 (2009–2014): 3.5L EcoBoost V6 Engine

Introduced in 2011, the twin-turbocharged 3.5L EcoBoost V6 was a game-changer for the F-150. It offered V8-level power with better fuel economy and reduced emissions. However, early EcoBoost engines experienced their share of teething problems.

Problem: Oil Leaks and PCV System Failures
One of the most common complaints with the early 3.5L EcoBoost was oil leaking into the intake manifold. This was due to a flawed Positive Crankcase Ventilation (PCV) system that allowed oil to accumulate in the intercooler and intake tract. Over time, this led to carbon buildup, reduced engine performance, and in some cases, hydrolock—where liquid oil enters the combustion chamber and causes severe engine damage.

Ford redesigned the PCV system in later models (2013–2014) to address the issue, but many owners of 2011–2012 models still report problems. The fix often involved replacing the PCV valve, oil separator, and cleaning the intake system—costing several hundred dollars.

Other Issues:

Ford F-150 (2015–2020): Engine Upgrades and Hybrid Introduction

The 2015 redesign of the F-150 brought significant changes, including an all-aluminum body to reduce weight and improve fuel economy. Engine options included the 3.5L EcoBoost, 2.7L EcoBoost, 5.0L Coyote V8, and a 3.3L naturally aspirated V6. Most of these engines proved more reliable than earlier versions, but issues still surfaced.

Problem: Turbocharger Failures in 2.7L and 3.5L EcoBoost Engines
Owners of 2015–2017 F-150s equipped with EcoBoost engines reported premature turbocharger failures. Symptoms included loss of power, excessive smoke from the exhaust, and check engine lights. The root cause was often attributed to oil coking in the turbo oil lines due to inadequate cooling after hard driving or towing.

Ford issued a TSB recommending improved oil cooling and revised maintenance intervals. While not a full recall, extended warranty coverage was offered in some cases. Regular oil changes with high-quality synthetic oil became essential to prolong turbo life.

Problem: High-Pressure Fuel Pump (HPFP) Failures
Another issue affecting the 3.5L EcoBoost engines was premature failure of the high-pressure fuel pump. This component is critical for direct fuel injection systems. When it fails, drivers experience rough starts, hesitation, and loss of power. Replacement can cost over $1,000 and requires significant engine disassembly.

Ford F-150 (2021–Present): PowerBoost Hybrid and Reliability Improvements

The current generation of the F-150 introduced the PowerBoost hybrid powertrain—a 3.5L twin-turbo V6 paired with an electric motor. While this setup offers impressive towing (up to 12,700 lbs) and better fuel economy, early adopters have reported a few issues.

Problem: Hybrid System Glitches and Battery Management
Some 2021–2023 PowerBoost models have experienced software-related glitches, including unexpected shutdowns of the hybrid system and inaccurate battery charge displays. Ford has issued multiple over-the-air (OTA) updates to resolve these issues, highlighting the growing complexity of modern truck electronics.

Problem: Engine Misfires in Cold Weather
A few owners have reported occasional misfires during cold starts, particularly in northern climates. Ford attributes this to cold fuel mixture calibration, with software updates aimed at improving cold-start performance.

Ford F-150 Recalls: Engine-Related Safety Alerts

In addition to reported problems, the National Highway Traffic Safety Administration (NHTSA) has issued several recalls affecting the Ford F-150’s engine systems. Here are the most significant ones.

Recall 21V-681 (2021): Fire Risk Due to Turbocharger Oil Leak

Model Affected: 2021 Ford F-150 with 3.5L EcoBoost engine
Number of Vehicles: Approximately 95,403

Issue: A potential oil leak from the turbocharger could accumulate on the exhaust manifold, creating a fire hazard. Ford reported that if oil leaks onto a hot surface, it could ignite and cause an engine compartment fire—even when the vehicle is turned off.

Solution: Dealers installed a turbocharger oil return hose shield to prevent oil from contacting hot components. Owners were advised to park outdoors until repairs were completed.

Recall 22V-051 (2022): Oil Cooler Tube Leak in 3.5L PowerBoost Hybrid

Model Affected: 2021–2022 F-150 PowerBoost Hybrid
Number of Vehicles: Around 138,000

Issue: A manufacturing defect in the oil cooler tube could lead to engine oil leakage. If oil contacts hot engine parts, it may cause a fire. Some incidents were reported before the recall was issued.

Solution: Dealers replaced the oil cooler tube assembly free of charge. Ford also updated inspection procedures at manufacturing plants to prevent future defects.

Recall 18V-486 (2018): Engine Stall Due to Fuel Pump Failure

Model Affected: 2018 Ford F-150 with 2.7L EcoBoost V6
Number of Vehicles: Over 512,000

Issue: The high-pressure fuel pump could fail, leading to a sudden loss of engine power or stalling while driving. This posed a significant safety risk, especially at high speeds.

Solution: Ford replaced the fuel pump module with an improved version. The recall was conducted in phases due to part availability.

Recall 15V-175 (2015): Engine Fire Risk from Oil Leaks

Model Affected: 2015 F-150 with 3.5L EcoBoost V6
Number of Vehicles: About 1.5 million

Issue: Oil leaks from the high-pressure fuel pump could lead to fires in the engine compartment. NHTSA received over 70 reports of engine fires before the recall was initiated.

Solution: Dealers replaced the high-pressure fuel pump with a redesigned unit that included improved seals and materials.

How to Check if Your F-150 Has an Open Recall

Staying informed about recalls is essential for safety and long-term reliability. Here’s how to check if your Ford F-150 has any unresolved recalls:

  1. Use the NHTSA Website: Visit NHTSA.gov/recalls and enter your Vehicle Identification Number (VIN). This will return any open recalls specific to your truck.
  2. Visit Ford’s Recall Page: Go to Ford.com/support/recall and enter your VIN. Ford often provides additional details and repair scheduling options.
  3. Contact Your Local Dealer: Ford dealerships can check your VIN in their system and inform you of open recalls. They can also perform the necessary repairs at no cost.
  4. Set Up Recall Alerts: NHTSA and Ford allow you to register your vehicle to receive email or text alerts if new recalls are issued.

Remember: Recalls are free repairs. If a dealer tries to charge you, contact Ford Customer Service immediately.

Signs Your F-150 Engine May Have a Problem

Early detection can save you thousands in repair costs. Here are warning signs that your F-150 engine may be experiencing issues:

How to Improve Ford F-150 Engine Longevity

While some engine problems stem