Frame Rust Problems of Ford F-150 - part 1

The vehicle that is talked about in this is a 2006 Ford F-150 that recently went in for an annual nys safety inspection and failed due to an excessively rusted frame that resulted in cracks on both frame rails. This truck has only ~50,000 miles and it is unknown how long the frame has actually been cracked and still driven.

See all problems of the 2006 Ford F-150 🔎.

Frame rusting terribly and frame cracking near drivers side forward leaf spring mount. Truck has only 128,000 miles. Do not haul or tow any where near the trucks capacity. Normal driving and minor off road use.

See all problems of the 2005 Ford F-150 🔎.

Purchased vehicle Feb 2021 from private owner. Took vehicle in for servicing. Service department informed me that the oil change could not be completed, because they were afraid to place the vehicle on the lift due to the fact that it might split due to the frame being rusted completely through. Further, I was told that the vehicle was unsafe to drive due to the extensive corrosion of the frame on both the passenger and driver side. I was informed that at any time, if I hit a bump or was hit from behind, the vehicle would fold in half. Complaint id #: odi 11413329.

I brought my 2006 f150 in for service the other day, and my mechanic pointed out a rust hole on my frame that showed up. After I scraped some of the surface rust off, I found that a large portion of my drivers side frame rail had significant rot spreading. My truck had just barely above 90,000 miles on it, with no other rust on any of the body panels. I drive a company vehicle during the week, and my truck barely gets driven all year. It seems as though the frames on these mid 2000's f150's are very prone to rot due to the lack of weep holes in the bottom of the frame. Corrosive elements get inside, then have no way out of the frames interior. With this poorly designed detail on the frame, consumers are left with next to no choice but anxiously wait for the premature decay of the most crutial element of their vehicle. At this rate, junk yards are going to filled with low milage Ford trucks that rusted out before their prime. Ford should be held responsible for their poor structural engineering. Consumers buy a Ford truck for their "Ford tough" reputation, not for the inadequately built trucks that they sold under that "Ford tough" guise and now refuse to stand behind. I believe a recall should be issued due to the sheer number of incidents I've read about, all of which are central to the mid 2000's f150. How can a problem this public go unaddressed? how many unsuspecting people are driving a rusted deathtrap at this moment, but would never suspect a thing due to low miles and a great body? Ford should make this right to the people that supported them for years.

Went to have truck lined up and was told it had rusted the frame almost into in the rear. In more than one place.

Tl the contact owns a 2005 Ford F-150. After replacing the tires on the vehicle, the contact heard a cracking noise when the vehicle was placed on a lift. The independent mechanic confirmed the frame was rusted through to the point that it was unsafe to place on the lift. The vehicle was taken back to frederick motor company (1 waverley dr, frederick, MD 21702, (800) 734-9118). The contact was informed that they could not assist since the vehicle was not included in a recall. The manufacturer was not contacted. The failure mileage was 57,000. The VIN was unknown.

This vehicle is otherwise in good condition with very little body rust limited to the back corner of the passenger cabin. However the left frame rail starting 14 inches ahead of the front attachment point of the leaf spring. The rust hole extends the width of the frame rail for a distance of 17 inches. One finger size hole was observed. The frame bottom steel was easily stripped away with two fingers and a thumb to the length and width described. The remainder of the frame has extensive surface rust but no hole and otherwise fair condition. The licensed state vehicle inspection shop failed the vehicle due to the frame rust at this location. Otherwise, with some minor mechanical issues, the truck is in good condition and could be safely used for a number of more years. Online this rust problem at this point has a large number of complaints in Ford F-150 trucks in 2004 and 2005. Obviously there was a manufacturing issue frame forming to cause this rust through in so many trucks at this frame location and not elsewhere.

See all problems of the 2004 Ford F-150 🔎.

The entire frame is rusting out. Everywhere I look theres rust. All of the cross frame from front to back down sides and across bottom of bed and where floor boards attach like was expensive truck Ford has to know.

I have a 2007 f150 with 96,460 miles. Drives on PA roads never off road and no hauling. Driver side frame rail is rusted at a point immediately behind the forward mounting bracket of the rear leaf spring. The amount of rust is extensive. The inner wall of the rail is rusted through creating a hole approx. 10 inches long and ranging from the height of the rail tapering rearward to about 3/4 of an inch. The bottom of the frame rail is also rusted through at a point where it meets the spring's mounting bracket. Although the metal appears somewhat intact there is no structural integrity. This leaves only the upper portion and outside wall of the frame rail intact but also rusted. Based on my observation this truck cannot be driven safely. I am not aware of any solution other than to replace the frame but this will be determined by a professional in the near future. As to the cause I do not know. This damage was first noted today 8/14/2019 and was not detected during an inspection in 12/2018.

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Bought truck least week took in for a oil change and was told that the front half shaft is rotten to the point it's pitting. The steering shaft is rusted out and the majority of the frame is rusted out near where all the important parts of the vehicle are held in place. As I do research on this problem I'm finding it is a common problem. The truck only has 61000 miles on it and it shouldn't have this much wear on the body of the truck. Ford really needs to look into a recall because there are thousands of trucks with this same issue. I have never owned a Ford and never will again. The car is basically worthless and it's a matter of time when it rusts all the way thru. Stationary issue. I don't have any photos as of right now. I will be taking more the oil shop has pictures that he showed me.

2006 f150 frame rusted through making the vehicle unsafe to drive and worthless, the vehicle was always stored inside and only other minor rusting however the frame has rusted through on both sides of the truck where the cab meets the bed of the truck.

My 2004 Ford F-150 has 61,000 miles and no rust on the outside of the vehicle. I've kept the truck well maintained and it looks almost new. The frame however right where the rear leaf spring attaches to the frame is rusted right through. It is incredible that this has not been recalled as of yet. Hopefully it will be recalled. While driving a part of the exhaust heat shield fell onto the driveshaft. When I went to inspect the underside I found a hole in the frame and I was able to put my finger right through it.

Tl the contact owns a 2005 Ford-f150. The contact stated that the frame was rusted to the point that it could not be repaired. The rust could prevent the vehicle from passing inspection. The dealer was not contacted. The manufacturer was contacted and did not assist. The vehicle was not repaired. The failure mileage was 120,000.

Tl - the contact owns a 2007 Ford F-150. The contact stated that the vehicle frame had rusted. The vehicle was taken to an unknown dealer who diagnosed the vehicle and stated that the frame was fractured, but the vehicle was not repaired. The manufacturer was notified and referred to NHTSA. The failure mileage was 119,000. Jc.

Extensive frame rust compromising vehicle integrity. Cracked frame.

Frame on f150 is rusting through causing frame to become vulnerable to breaking. Rusting and cracking taking place between back of cab and rear wheel mounts. Found during oil change at Ford dealership and body shop did not even want to provide estimate to fix due to complexity of fix and legal implications.

Same deal as every other memo I read. Major highlighting points: - premature frame corrosion and rust. - mechanic informed me that the frame on the rear half. - rusted and cracked under bed and rear wheel wells - frame would no longer support weight of vehicle - rust thru holes and longitudinal cracks formed on the bottom and side frame surfaces at the stress point before the rear wheel bend. - extremely unusual, truck has been generally been garage kept and maintained in good mechanical condition. - the exterior body does not exhibits spots or surface rust on visible body panels. - no evident signs of rust or degradation of structure. - meticulously maintained vehicle otherwise. (new transmission, drive shaft, engine retimed, spray bed liner, etc. ) - catastrophic failure of the frame structure was imminent and that the vehicle was no longer safe to drive. - cannot be repaired and is unsafe. - cannot pass a state safety inspection. - cannot even be put on a lift because it has no structural strength.

The frame is rusted to the point that it is unsafe to drive. Using my hand to get leverage to look under vehicle as exhaust was dripping water. The frame crumpled and broke with the force of my hand. I understand 2001-2004 vehicles were recalled for the same reason.

The truck was taken into mechanic. The mechanic put it up, and saw that entire frame was rusted. It is not fixable. Contacted john lance Ford, where it was purchased. They advised to take truck to nearest Ford dealer. We took it to Ford in port clinton, ohio. The service manager took pictures and sent it to corporate office. It has been longer than 6 weeks, and have not heard back.

Tl � the contact owns a 2004 Ford F-150. The contact stated that when he looked underneath the vehicle the entire bottom of the frame had rusted. The dealer (liberty Ford 1-410-504-2897) was contacted and informed that the frames are absolute and the vehicle was not repaired. The manufacturer was not notified. The failure mileage was approximately 78,000. Jc.

Premature frame corrosion and rust failure, during recent routine maintenance, my mechanic informed me that the frame on the rear half of my 2005 Ford F-150 had rusted under the bed and rear wheel wells to the point of failure where the frame would no longer support the weight of the vehicle on his lift. Rust thru holes and longitudinal cracks had formed on the bottom and side frame surfaces at the stress point before the rear wheel bend. This seems extremely unusual because the truck has been generally been garage kept and maintained in good mechanical condition. The exterior body only exhibits light spots of surface rust on the visible body panels. Providing no hints of the degradation occurring below. My mechanic has told me that catastrophic failure of the frame structure was imminent and that the vehicle was no longer safe to drive. Which in itself is concerning in that I had been totally unaware of the vehicle's deteriorating condition. Had I not taken the vehicle in for maintenance I would likely continued driving the vehicle until one day being totally surprised when the back half of my truck separated from the front.

Frame has rusted to the extent that the bed has dropped and is about to fall off. When I was replacing the fuel tank, which had rusted through, I discovered that the entire frame has holes and cracks from rust. I have now been hearing that this problem has been reported by many, but no answer or recalls from Ford. Why do these trucks rust so badly. Is there no recourse for those of us who have a truck that falls apart?.

See all problems of the 2002 Ford F-150 🔎.

�takata recall� the frame is rusted really bad and almost rusted into. The truck bed is rusted in bottom and rusted all over. I bought this truck thinking Ford didn't rust like this. Please help me. Truck is too dangerous to drive but I can't afford to get a new frame and truck bed.

My trucks frame has rusted out from the cab corners to the rear part of the frame rails. Ford motor company wont do anything about this problem. Numerous complaints have been filed, yet they wont do anything about it. Im not selling my truck because its a rare version of the 04 new style F-150. This is a very serious problem that people can die from and Ford wont back them up on the 04-08 trucks.

My truck frame has rusted through just behind the right rear wheel! this is a 2002 Ford f150 supercab that has only 75500 miles on it. The frame broke just after I left the interstate and drove to my son's house. I inspected the truck and saw the break in the frame as I described. A picture is attached. I was lucky not to have wrecked on the interstate! what is going on with Ford that the chassis rusts through like this!!! what is going on with Ford?.

When changing the brakes on my 2005 f150 I found the frame completely rusted thru the exterior is in great shape with minimal corrosion.

Extensive main frame rail rust rending truck unsafe to drive now. Started around 2010.

Frame rusted and cracked, 72,000 miles. I'm the original owner. Note, all other underbody components appear normal for age and miles; though I don't have too much faith in rear drive shaft. Location is in front leaf spring attachment bracket adjacent to fuel tank.

Frame is completely rusted through to the point that it cannot be repaired and is unsafe. It cannot pass a state safety inspection and has deteriorated to the point where it cannot even be put on a lift because it has no structural integrity. There are large holes rusted through and where it hasn't entirely rusted through, the metal has deteriorated to being less than half of its original thickness. The problem went unnoticed because the rest of the truck showed no signs of any advanced deterioration.

The frame is completely rusted. The bolts are coming through the bed of the truck. Bumper is rusted away from frame. Unsafe to drive.

See all problems of the 1999 Ford F-150 🔎.

Frame rusted in half,.

Gas tank fell out of vehicle,tearing filler hose. Tank straps and supporting structures rust thru, failure. Drivers' side rear shock dropped from vehicle because metal bracket it was attached to rotted thru. Bed rails completely rusted thru. Frame has rusted thru holes. Complete rust failure. Vehicle has only 90k miles always maintained, washed underneath weekly in winter. Vehicle in motion when parts fell on rte 58 and the shock on town street. . $900 to repair gas tank. Shock incident happened today 11/26/2017, gas tank 9/12/2016.

See all problems of the 2001 Ford F-150 🔎.

The frame under my f150 is rusted through. I only have 81k miles on it and I don't understand why the frame is rusting so badly. It has already cost me 2,400 to have a certified welder replace some of the sections that were rusted out. I know just found another part of the frame that is rusted under the leaf spring. That is now going to cost me another $500. 00.

Frame rusting out prematurely causing a safety hazard.

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 🔎.