Ford F-150 owners have reported 12 problems related to frame rust (under the structure category).
Frame so rusted can't get a sticker, original paint on truck. Ford was factory undercoated with rubber type undercoating. Which pealed off and left lots of rust on entire frame. Not safe for inspection. Told by garage, to junk it. Bought new in 1998.
See all problems of the 1998 Ford F-150.
Tl-the contact owns a 2005 Ford F-150. The contact stated that the vehicle was taken to and independent mechanic for scheduled maintenance service. While the vehicle was on the lift noticed that the entire frame was severely rusted and there were fracture areas in front of the wheel well both sides. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 67,000. Bp.
See all problems of the 2005 Ford F-150.
2004 Ford F-150. Consumer writes in regards to vehicle frame rust problems. Consumer sent additional correspondence. The vehicle had to be towed to the repair shop, because the brakes went out. The rear brake lines, hoses, calipers, master cylinder and pads were replaced. Updated 03/09/15.
See all problems of the 2004 Ford F-150.
In 2012, I replaced my gas tank because severe corrosion had eaten numerous small holes into the top of the tank so it could not be filled over 3/4th without leaking. Flakes of rust were falling onto the top of the tank from the frame x-member causing these holes. The frame x-member was not addressed and the new gas tank began to leak within a year and a half of replacement. The engine was just recently tuned up by a Ford dealer because it was intermittently vibrating. Within 6 months of this tune up, the engine lost full power with finding of grossly contaminated fuel. The 2 year old tank was pulled and the top of the tank was revealed to be metallic swiss cheese equivalent, this time with numberous very large holes that rain was easily penetrating into the tank via the cab-bed space opening. The x-member frame support was corroded in half. The dealer could not fix it and I paid for a second new tank and fuel pump($350 with shipping to hi), por 15 coated the top of the new tank myself, and paid a local body shop$1042. 00 to pull the x-member and replace it with a used part as Ford no longer stocks (likely rusted to bits in their warehouse). The new tank and used x-member are now installed and awaiting an engine mechanic to address why the engine won't start up despite new tank/fresh fuel/pump/filter. Likely another $500 to clean fuel injection/engine bringing 2 year total for rotted x-member and two gas tanks to well over $3000. Perusing your data base, the frame rust issue seems to be a recurring theme particularly for the 1997 year model. My assessment is there was something very rotten in 1998 f150 frame components and or corrosion protections used. Lessons learned: don't fix the tank until you fix the x-member problem first and Ford f150 frames/corrosion protections circa 1998 are getting a bad reputation which is likely deserved.
Truck was at dealership for repairs, when I was told not to have repairs done because the frame is cracked and rusted thru. They said the vehicle is unsafe to drive. The truck is now worthless. In my 50 years of owning and driving numerous vehicles in the northeast, I never had a rusted frame issue. Ford will not help nor investigate the situation.
See all problems of the 2006 Ford F-150.
7/14/2011 - my mechanic replaced rotting gas tank straps 10/3/2011 - Ford dealer (after receiving recall notice on gas tank straps) applied reinforcement straps on gas tank straps. No indication given to me that these were not secured onto frame. 10/12/2011 - brought my truck into my mechanic for oil change. He noticed that the gas tank straps and reinforcement straps were not connected onto the frame on drivers side rear. 10/12/2011 - brought truck back to Ford dealer to fix the safety recall that last week they had applied. I mean, it is hard to believe that a week later, and the straps failed. Was told that they only install the gas tank straps and that's it. Whether they are connected to frame or not that is rusting is not their concern and is not covered by the recall. This is preposterous. Since the same metal was probably used throughout the truck and caused the recall of the gas tank straps -- a safety recall, shouldn't they be sure to apply these to known good structure and if such structure suffers from the same problem as the gas tank straps, shouldn't that be covered? I really think Ford should stand behind its products and its safety recall installations and take care of the frame that holds these rotting gas tank straps. The cause of failure is the same. Rusting frame is same rusting as the gas tank straps.
My truck front cross member that supports radiator and the body to the frame is just about rusted gone. Dealer stated that truck is 11 years old and will not repair. I am sending this for record in the event I am killed due to any failure in which I discribe. I have read two cases on this website , one is a 2001 F-150 that had a cross member support rusted out in 2003 with 48,000 miles and another was a 2001 F-150 had a tag attached to the frame which read ( defective material do not use l/s performance . I expect a full investigation on this complaint and I do want my vehicle inspected by NHTSA.
See all problems of the 2000 Ford F-150.
My truck front cross member that supports radiator and the body to the frame is just about rusted gone. Dealer stated that truck is 11 years old and will not fix. I am sending this for record in the event I am killed due to any failure. Have read two cases on your website. One is a 2000 F-150 that a cross member support rusted out in 2003 with 48,000 miles. Another was a 2000 F-150 that had a tag attached to the frame stating defective material do not use! l/s performance . I expect a full investigation on this and want my vehicle inspected. The consumer was informed the brakes lines needed to be replaced as the vehicle was unsafe to drive. Updated 01/06/12.
Brake line is rusted could cause failure of brakes. Gas tank and supports are rusted replaced once but still all rusted. All frame underneath is rusted impossible to do repairs.
See all problems of the 1999 Ford F-150.
I have a 1997 Ford F-150, I was changing the front brake pads and noticed a lot of rust on the frame and basically every thing else under the body. I took a screwdriver and pushed it all the way through the suspension travel stop. There are big chunks of rusty metal falling off of it at least every three or four months apart. I can take my finger and push through the front bumper. All the bolts on the exhaust manifolds and collectors are rusted off or all most rusted off. To fix the exhaust it will cost around $700. 00, if the dealer done the repairs it would cost much more. The gas tank straps looks real rusty also. In my 54 years of life I have never seen a frame and the underside of a vehicle rust so bad. I live in the south so the truck did not see much salt.
See all problems of the 1997 Ford F-150.
My mechanic told me that his father's 1999 or 2000 F-150 was rusting on the frame and was about to rust in two, a screwdriver could be stuck through the metal. This was discovered when the straps holding the gas tank rusted and the gas tank was almost touching the ground. So I asked him to look at the frame of my 1998 F-150, and he discovered the same problem. The main crossmember of the frame is almost rusted in two. The straps holding the gas tank are severely rusted. One of the bed crossmembers is already in two, and two others show severe rusting. My mechanic has told me that if the crossmember breaks, I could lose control of the vehicle. If I were driving in heavy traffic, this could pose a serious threat. The body of my truck is in good shape. If you did not know of the frame problems, you would not know to check these out. I feel that if nothing else, the public needs to be made aware so that they can have their vehicles checked out.
The contact owns a 1997 Ford F-150. The contact stated that the spare tire cable, exhaust system manifold, fuel tank strap, brake line, bolts, erg valve, and the frame were rusted. The vehicle was not repaired. The manufacturer was made aware of the failure and denied to buy the vehicle back or provide any assistance. The failure mileage was 220,000 and the current mileage was 322,000.