Three problems related to manifold/header/muffler/tail pipe have been reported for the 2006 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2006 Ford F-150 based on all problems reported for the 2006 F-150.
This problem is related to Ford 5. 4 liter triton v8 24 valve engines and frequent failures of the exhaust manifolds. A search of online literature from automotive experts and mechanics report an unusual number of these manifolds warping, cracking, and breaking the mounting studs. Repairs are very expensive, in the range of $1000 - $2000 per manifold. Last fall 2018, my 2006 F-150 5. 4 triton, with only 83,000 miles, began leaking exhaust from the right side manifold. I took it to a Ford dealer for repairs. (some independent repair shops stated they will not work on these Ford model manifolds anymore. ) the total cost to replace the manifold was over $1800. The parts and materials were only about $300. There was a lot of labor involved because 6 of 8 mounting studs had to removed and replaced. The dealer also recommended replacing the left side manifold because the mounting studs on that side were showing signs of impending failure. In fact, some of the studs may be broken already, but the left manifold is not yet leaking, so I did not replace the left manifold at that time. I am a retired mine engineer/manager. I was heavily involved in the maintenance of trucks and equipment. I believe there is a design problem in these manifolds and/or the heads they mount on. (these are the heads that prompted the 5. 4 triton spark plug settlement. ).
Upon starting of the vehicle there was a loud pop followed by smoke entering the cab through vents and then complete loss of brakes, dealer said it was a problem with the intake manifold.
The contact owns a 2006 Ford F-150. While driving approximately 60 mph, the contact's foot became stuck to the accelerator pedal when he attempted to apply the brake. The vehicle fails to brake properly unless the pedal is touching the floor. The dealer was unable to determine the cause of failure. When turning the steering wheel, the contact hears a squealing noise and it becomes difficult to maneuver. The dealer replaced the power steering pump, but the squealing noise is still audible. The current mileage is 37,000 and failure mileage was 9,346. The consumer stated the brake and gas pedal were designed too close together. The consumer has mistakenly hit the gas pedal when trying to brake. The master cylinder had an internal leak. The muffler had a leak. Updated 06/06/07.