Three problems related to manifold/header/muffler/tail pipe have been reported for the 2007 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2007 Ford F-150 based on all problems reported for the 2007 F-150.
Cracked or warped exhaust manifold. I've had it looked at by two auto mechanics and have read online with this widespread problem.
Water leaking from intake manifold coolant crossover line. Crossover is an aluminum pipe that connects to the plastic intake manifold. When manifold started leaking coolant, 1 & 2 spark plug holes filled with water causing spark plugs to short out and stall the engine at low speed. Per Ford the only repair is replacement of the complete intake manifold at a cost of over $1200. 00. This is a common problem with this engine. I have seen many complaints on F-150 forums via the internet of people having the same problem. My truck has only 105000 miles on it.
The contact owns a 2007 Ford F-150 5. 7 v8. The contact stated that his vehicle experienced a leak in the exhaust gasket manifold; which was letting off toxic fumes in the air. The dealership was contacted and diagnosed that the contact may need a new gasket or manifold. The failure was not repaired. The failure mileage was 45,000 and the current mileage was 70,000. Updated 07/21/11.