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Frame Rust Problems of Ford F-150



Ford F-150 owners have reported 8 problems related to frame rust (under the structure category).

car image   Frame Rust problem of the 2006 Ford F-150 1
Failure Date: 12/30/2013

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.

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car image   Frame Rust problem of the 1998 Ford F-150 2
Failure Date: 10/12/2011

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.

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car image   Frame Rust problem of the 2000 Ford F-150 3
Failure Date: 09/27/2011

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.

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car image   Frame Rust problem of the 2000 Ford F-150 4
Failure Date: 09/27/2011

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.

car image   Frame Rust problem of the 1999 Ford F-150 5
Failure Date: 07/14/2011

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.

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car image   Frame Rust problem of the 1997 Ford F-150 6
Failure Date: 09/18/2010

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.

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car image   Frame Rust problem of the 1998 Ford F-150 7
Failure Date: 05/20/2010

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.

car image   Frame Rust problem of the 1997 Ford F-150 8
Failure Date: 09/01/2009

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.


Other Common Structure related problems of Ford F-150