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Catalytic Convertor Problems of Ford F-150

Ford F-150 owners have reported 11 problems related to catalytic convertor (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford F-150 based on all problems reported for the F-150.

car image   Catalytic Convertor problem of the 2012 Ford F-150 1
Failure Date: 04/13/2013

The contact owns a 2012 Ford F-150. The contact stated that while driving 10 mph, the vehicle failed to accelerate. The contact stopped the vehicle and the vehicle eventually began to respond to acceleration attempts. The vehicle was taken to a dealer for diagnosis and the contact was informed that the catalytic converter would need to be replaced. The failure and current mileage was 11,000.

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car image   Catalytic Convertor problem of the 2012 Ford F-150 2
Failure Date: 01/12/2013

This write up is for a 2012 Ford F-150 truck with the 3. 5l ecoboost v-6 installed. Jan, 2013-while driving on I-24e, I was pulling out from the rest stop, just north west of exit 1. I went to pass a 18 wheeler and my truck came "unglued". It practically died in the passing lane when I pressed the gas peddle. It shuddered so hard; I didn't think I would be able to get off of the road before it died. It was missing and shuddering like crazy. I pulled off exit 1, shut the truck down and restarted. It ran ok without that same thing happening on the way home. I had a pretty descent "miss" in 6th gear, running down the interstate at 75mph. Something very strange happened here. It was the first issue i¿ve had with my truck. Although i¿ve noticed recently the mpg is down by 2. 0 mpg or more for the last three weeks, and this from refueling at different locations, and the same driving style. Ford applied the TSB to reprogram the pcm/tcm to latest level, installed a deflector shield on the intercooler and possibly replace the drivers side catalytic convertor if needed. July, 2013- this weekend while driving on I-65n, I had the same issue happen. The truck now has 17,000 miles on it. I've had the vehicle back into my local Ford dealer four times for this issue. The vehicle exhibits this issue when it's rainy and has been driven in the rain for several (50 or more) miles. In heavy traffic this is a very dangerous issue. The vehicle goes into some type of safe mode and will barely limp off the road. If this issue were to occur while crossing a four lane hwy, and sputtered one could be seriously injured or injure someone else.

car image   Catalytic Convertor problem of the 2005 Ford F-150 3
Failure Date: 07/19/2007

The contact owns a 2005 Ford f150. While driving at speeds over 20 mph, the vehicle would shake and vibrate violently. He also observed black smoke emitting from the exhaust pipe and a strong gasoline fuel odor from the vehicle interior. The vehicle was taken to the dealer where they replaced the fuel injectors (performed under Ford customer satisfaction program 07m08, NHTSA service bulletin number : 07m08, fuel system, gasoline:fuel injection system:injectors) and made repairs to the brake booster (performed under NHTSA campaign id number: 08v208000: component: service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings). Immediately after the repairs, when putting the vehicle into the drive position, there was a rattling noise under the vehicle. The vehicle was taken back to the dealer who stated that the catalytic converter was damaged due to the fuel injector failure. The dealer was advised by the manufacturer that the catalytic converter would not be covered and they would take no liability for the failure. There were no repairs made to the catalytic converter, to date. The contact has all service records, if needed. The failure mileage was 35,742 and the current approximate mileage was 84,000.

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car image   Catalytic Convertor problem of the 2006 Ford F-150 4
Failure Date: 02/27/2007

The contact owns a 2006 Ford F-150. The engine light illuminated and the vehicle began to vibrate while in traffic. The vehicle was towed to dealer, american Ford. The dealer replaced the # 6 fuel injector. At 9,670 miles, the same failure recurred, and the dealer replaced the # 5 fuel injector. At 9,735 miles, the engine light illuminated again. The dealer stated that the catalytic converter failed because of the fuel. The current mileage is 10,765, and failure mileage was 7,462.

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car image   Catalytic Convertor problem of the 2006 Ford F-150 5
Failure Date: 10/10/2006

Two separate occasions I experienced a fuel injector failure on my '06 F-150 while traveling on I-65 on 10-10-06 and on I-10 on 10-14-06. I was told by a dealer in culman alabama that I could drive it on to memphis with the engine light on. Upon arrival in memphis dobbs Ford told me there was nothing wrong and I had to take his word. On my trip back to tampa the engine light came on again and I had to towed to american Ford in tallahassee. The replaced #6 fuel injector. Later, while in memphis #5 injector failed and was replaced at landers Ford in collierville. A few days later the engine light came on again and this time it was the catalytic converter, which had to be replaced.

car image   Catalytic Convertor problem of the 2006 Ford F-150 6
Failure Date: 09/02/2006

After one week of ownership, on 9/2/06 the truck dieseled when started for about 5 minutes before idling. It could not be turned off. When it finally idled, the check engine light was lit, it idled rough, knocked when accelerating or under a load and the gas mileage dropped as I was driving about 2 miles per gallon. From this point on, it was hard to start. This happened with 1000 miles on the truck. It was taken for service and the dealer told us that the catalytic converter and oxygen sensor was defective? this seems to be the result of this problem and not the problem as upstream fuel/air mixture problems cause leaning/riching which will manifest itself as cat or oxy sensor defects. These parts were replaced and 1 week later the check engine light has re appeared.

car image   Catalytic Convertor problem of the 2001 Ford F-150 7
Failure Date: 08/25/2004

Vehicle stalled . Consumer took vehicle to dealer and was told that a right solenoid gasket was defective, and catalytic convertor malfunctioned. Warranty expired, however dealer was willing to meet the consumer half way on the expense.

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car image   Catalytic Convertor problem of the 1997 Ford F-150 8
Failure Date: 10/12/2003

Heat shields loose on the catalytic converter. Two clamps were replaced again. I had this fixed 2 years, previously. I was charged $70. 50 for this to be corrected again. It seems that there is a problem with the quality of the clamps that are being used by Ford.

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car image   Catalytic Convertor problem of the 1998 Ford F-150 9
Failure Date: 11/09/2002

The transmission is going out in my 1998 Ford F-150.

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car image   Catalytic Convertor problem of the 2000 Ford F-150 10
Failure Date: 06/06/2000

Vehicle idled roughly. Vehicle warmed up and idled roughly. Also there was an exhaust leak. Dealership told consumer that he needed a new catalytic converter because there was a bad smell, like rotten eggs.

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car image   Catalytic Convertor problem of the 1997 Ford F-150 11

Design of the catalytic converter and shield allows for accumulation of grass and other debris, fire resulted from grass burning.