Body Problems of Ford F-150 - part 1

Bolt in the hood latch fell out and nearly causing the hood to open on the interstate.

See all problems of the 2023 Ford F-150 🔎.

Tailgate opened.

See all problems of the 2018 Ford F-150 🔎.

The sunroof of my vehicle burst while I was driving on the highway. There was no warning and the vehicle was not hit by anything. The glass shattered and came into the truck cabin. Air starting getting in the vehicle as well. It was a dangerous situation as I was driving and glass was coming in. The vehicle was towed to the dealership. The dealership is refusing to repair the vehicle and they can’t confirm why the sunroof broke. The glass is caved outward. I have filed a claim with my insurance company to have the vehicle repaired.

Please see Ford TSB ssm50543. In my case the driver's door has been freezing in the lock position. Door will not unlock and cannot be opened either from the inside or outside. The key in the outside will not unlock the door and pulling up on the knob inside cannot be done (even tried with pliers). The electric door locks for the frozen door do nothing. This made it possible for me to only get out of or into the driver's seat by climbing in/out from the passenger's side. I also tried to not lock the driver's door, and this just made the door frozen in the unlock position. Very inconvenient, but I am especially concerned if I had to exit or enter the driver's side in an emergency. Ford knows about this as can be seem from the issued TSB. This had happened more than once and goes away when the inside of the truck gets really warm, or the weather gets above sufficiently over freezing.

See all problems of the 2021 Ford F-150 🔎.

Door latches seize in cold temperatures. If you can get the door open, it won't latch when you close the door. I must hold the door shut and lock the door for it to latch. Then, the handle becomes incredibly difficult to pull and open the door. I have pulled out only to be alerted that my door was open, but I have also exited the vehicle, closing the door behind me, not realizing that the door did not latch and was open and unlatched the entire time. The inability to secure my vehicle and the risk of entrapment is concerning. A door should work. This has been happening the entire time I've owned the vehicle but I typically make do and get through the winter but I recently saw this had a recall once upon a time though I show no record of that for my vehicle.

See all problems of the 2016 Ford F-150 🔎.

Tried to open door to put my 2 year old in her car seat and it wouldn't open, assume this was due to the extreme cold. So I took our other vehicle, few days later when it warmed up I again went to leave with my daughter and this time the door opened but will no longer latch shut. Tried toggling child lock messing with lock mechanism on top of the door tried both interior and exterior handles but it will not latch no matter what I do. Now all my lights are staying on and door ajar light and icon are on and won't go off. I currently have the door ratchet strapped inside the vehicle to hold it close and I cannot drive it due to the safety concerns if the strap let's loose and the door flings open. . . There is a recall for frozen door mechanism my vehicle falls in this range and I was notified previously I qualified for the recall. Now that it actually happened it shows my vehicle isn't listed and the dealership wants to charge me for a safety recall that should be covered.

In cold weather all four vehicle doors would open randomly when driving, forcing occupants to manually hold them shut. Owner found recall 18n03 was active for vehicle and took the vehicle to Ford dealership for service of recall. The issue continued after service and the owner inspected vehicle following the recall procedure distribution from NHTSA to discover the dealership partially and incorrectly completed the work listed. Additionally, recall 18n03 refers to recall 17s33 for the rear doors in super cab models. This vehicle has water shields from 17s33 installed but the rear door latches are still unreliable in cold weather.

Door latches freeze, and door won’t stay closed. Operator must drive while holding the door shut. Super-unsafe.

I can have the vehicle available for inspection. I have to hold the truck door shut while driving it when the issue happens. There has been no confirmation of the issue by a dealer or independent service center. There has been no inspection of the problem by the insurance company, manufacture, police or others. This year during cold weather the issue started. I bought the vehicle used. -------------------------------------------------------------------------------------------------------------------------------------------- I have a 2015 f150 and when it gets cold I can open my driver's side door, but when I go to close the door, it won't latch.   the inside door handle is really loose, like it's not attached to anything.  once the vehicle heats up, the door handle gets stiffer, like it is connected and I'm able to close the truck door.  this only happens when it's extremely cold outside.  I was told by a Ford dealer that this is not a recall door actuator problem.  they think it may be the door cable that connects to the inside door handle.  they stated it may or may not be a warranty replacement and not a recall.  they say it would be around $149 to diagnose the door problem, and if it's not a warranty replacement, I will have to pay the diagnosis cost and repair cost.  they say the only way to know if the door repair is under warranty is for them to go inside the door and diagnose.   so this is my concern.  I have an extended warranty on the truck and it runs out at 147,000 miles.  I'm at 144,000 miles.  if I take the vehicle to them and they take the door apart and then say it's not a warranty or recall issue, this could cost a lot of money.  with all the problems that the f150 has with the door lock problems when the temperature gets cold, it seems to me that Ford should know right away that my truck door problem is a common problem and it should be covered immediately under a recall or warranty.  I bought the truck used.  let me know your thoughts on this.

See all problems of the 2015 Ford F-150 🔎.

My 2021 Ford F-150 lariat has a door latch defect that occurs in freezing or near-freezing temperatures. The failure occurs without warning in cold conditions, causing the door latch to freeze and not fully engage. When this happens, the door is able to freely swing open while the vehicle is in motion and also freely open when the vehicle is parked. This creates a serious safety hazard, including the risk of occupant ejection and loss of vehicle control. The vehicle has no aftermarket modifications and is maintained per manufacturer recommendations. The issue is temperature-dependent and has occurred on multiple occasions. Ford has issued recalls for similar door latch freezing defects on multiple other Ford vehicles and model years. Despite this, my vehicle has not been included, even though it exhibits the same failure mode. This defect presents a significant safety risk and should be investigated for potential recall inclusion.

As I was driving the right rear door flung open and would not engage when pulled back in. Had to drive home with a door that would not shut. Yes safety was at risk for kids in back seat. Confirmed by previous reports and service department at dealership. No warning lamps that were noticed.

I closed the passager side door and the back window shattered and blew out.

Frame is rusted through along the bottom weld. Most likely water, sand and debris entered the frame from side openings and this corrosive mixture sat in the bottom of the frame as there were no drain holes nearby. The problem was discovered by a Ford mechanic and the dealership said they could not repair it, and to try a collision center. An auto body said they could not strengthen the frame as Ford does not allow welding but they could replace the frame for $9,179 plus other cost for draining fluids, etc.

My 2025 F-150 tremor (5. 0 v8, 402a package with modular front bumper) has a large open area in the front bumper. Through this opening you can clearly see the front of the engine and related components. This appears to be a design issue rather than a one-off build problem. Other 2025 tremor owners with the same 402a modular bumper are reporting the same concern and asking whether a cover is missing from the factory. My concern is that the exposed opening could allow rocks, road debris, or off-road obstacles to directly impact vital components at highway speed or when driving on rough/uneven surfaces. This may increase the risk of damage, fluid leaks, or sudden loss of power/steering if components are struck. It also appears inconsistent with typical under-engine protection on off-road-oriented trims. I am asking NHTSA to review whether this bumper configuration provides adequate protection for critical components on the 2025 F-150 tremor and whether a design change or shield/plate is needed for safety.

See all problems of the 2025 Ford F-150 🔎.

Customer states that the frame of the vehicle has been compromised by corrosion. The vehicle only has 163,844 miles on it and it has major holes in the frame. The chassis could break in half prohibiting the use of this vehicle on the roadway due to the safety of occupants. I advised the customer of this of which they bought a frame repair kit (pre-cut over frame c-channel steel) to weld onto the frame to support a longer lifespan. The truck is now safe for the roadway.

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

The hood is peeling the clear coat. The upper cab on both drivers side and passengers side from front to back is down to bare metal. Top of the pickup box is down to the bare metal along both sides. Tailgate top is down to bare metal. These spots are clearly do to the prep and paint work.

A certified independent inspection company discovered welding on the main chassis of my Ford F-150. The welding is located on the front left frame area. I purchased the vehicle brand new, and it has never been in any accident or collision. This welding on a critical structural part creates a serious safety risk. Frame integrity may be compromised in normal driving or in the event of an impact. I transport my children daily in this vehicle, and I am afraid to drive it due to the possibility of structural failure. The official Ford dealer inspected the vehicle and kept it for approximately three weeks but provided no explanation or repair. The regional Ford office has delayed their technical report for more than five months with no response. The defect has been confirmed and is permanent. No warnings or lights appeared prior to discovering the issue. This is a manufacturing-related structural defect affecting vehicle safety, stability, and integrity. A proper safety resolution is required.

The rear passenger window rolled down and is stuck in down position. This is the second time this has happened in our F-150. It happened when we first bought the truck nearly two year ago and was fixed. I worry it was replaced with another faulty component. There have been numerous complaints of this happening and the issue is within the driver side door components.

Ford f150 1ftew1cpxffc58647, caught fire while parked and unoccupied. Princeton, TX fire dept was not able to identify cause and origin of ignition / fire. Vehicle is available for inspection. Vehicle caught firer while we where asleep. Vehicle was looked at by fire dept and origin of fire was undetermined.

Track of rear cabin sliding door came unglued and popped off track while driving down highway in rain. Water entered vehicle. Looked online and found numerous complaints for 2015-2020 Ford F-150. Why is there no repair for this? [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

After a repair at ted russel Ford that swapped my battery, the skid plate fell off while traveling in a parking lot. Fortunately this didn’t occur on the interstate.

Water entering cabin on front passenger side of truck. Causing mold and mildew. Dealer 'fixed' this three weeks ago and now it is back again. . .

The frame is rotting through. It was on a lift for a new starter; this resulted in the frame bending. It will not pass inspection. Ford refuses to repair /replace the frame as it is past their 5 year rust warranty. The vehicle has only 15000 miles. It has never been immersed in fresh or saltwater. The undercarriage has been sprayed off regularly when driven in the winter.

The moonroof leaks causing water to spill into the cabin thru the headliner flowing onto the dash and coming into contact with electrical equipment dome lights infotainment system and could cause a potential issue with water and electrical system!!!.

See all problems of the 2022 Ford F-150 🔎.

The dash pad in front of steering wheel is coming apart and peeling back. It appears to a defect in installation, material use or wasn't glued down properly.

This is an extended cab - 4 door - the rear doors are half doors with a a handle allowing entry and exit to and from the rear passenger seats. (it is not a crew cab 4 door). The doors locked and the handles failed with a child in the rear seat. The doors cannot be opened. The child and his mother had to climb over the center console to exit the vehicle. The vehicle is at a mechanic who states no part are available to repair this faulty and unsafe door mechanism. Both rear doors are locked. Qualified mechanic estimates the cost to rig a fix, in absence of any left door mechanism parts will be near or over $500. 00. The mechanic reports that the control cables from the handles to the door latch stretched and failed. If there had been a collision or engine fire, rear seated passengers would be trapped inside the vehicle. This needs to be addressed and repaired by Ford.

The passenger door does not open from the outside. It only opens from the inside. It is unclear what caused this, as there has been no accident or slamming of the door. There is already a technical safety bulletin for this issue, but this needs to be a recall as it poses a significant safety risk and does not appear to be caused by negligence or collision.

Bought used at 10k miles less than a year ago, has a severe leak from the passenger side windshield/cowl area that pours down the body seam saturates the floor, wire channel, and bcm area. This is a safety issue as you can smell a burnt/wet wire smell and the incoming water saturates critical wiring, and is nearby airbag wiring. Vehicle in question has only been owned for a year (of 3 year warranty) but any warranty repairs are being refused as it is 4100 miles outside of comprehensive warranty. However, this is not believed to be due to a component that failed due to mileage but rather a manufacturing defect/quality control in the body adhesive not being applied properly near the firewall/cowl/inner fender frame joint.

The side rails that come out when door is opened to assist with getting inside the truck does not work properly. It has come out and will not go back in. The door is closed and I have to drive the truck with the rails hanging down. That is a hazard.

Bought new a year and a half ago, has a severe leak from the passenger side windshield/cowl area that pours into ac box and then saturates the floor. This is a safety issue as you can smell a burnt/we wire smell and the incoming water saturates critical wiring, and is nearby airbag wiring. Vehicle in question has only been owned for a year and a half (of 3 year warranty) but any warranty repairs are being refused as it is 2500 miles outside of comprehensive warranty. However, this is not believed to be due to a component that failed due to mileage but rather a manufacturing defect/quality control in the windshield or cowl seal.

Rear window Ford part number 1542006 - back window glass has 1" cracks in glass where the glass connects to the body on the left passenger side of the crew cab. Cracks have caused leaks into the cab interior and has caused the modem, mounted behind the rear passenger set on the back wall to stop working as water has infiltrated the electronics. Vehicle was inspected at dealership and their 3rd party glass leak specialists discovered the cracks in the glass connection. I have no idea as to how long this has been going on, estimate a few months as I recently discovered I could not communicate with the vehicle through the Ford connect app and called Ford connect, they identified an issue with the modem and when I pulled back the upholstery to see, there was water dripping inside the vehicle. Unknown if cracks will propagate, however they are leaking when it rains. I will be replacing the glass to prevent further leaks from occurring. I have extended warranty through Ford and "glass" is not covered. Reached out to Ford care and they would not cover. Suggested that I put in a report here so that if later recall or other action, I might be able to get refund for the repair that I am now going to have to pay for to replace the glass and possibly the modem. No other symptoms other than the filaure of the modem that alerted to the issue.

See all problems of the 2019 Ford F-150 🔎.

Seems to be a defect with the rear door saying it is ajar on the display screen also it wound lock or u lock with the key fob or pin code. I have confirmed the door is completely shut. Defective wiring harness or something else may be the issue.

See all problems of the 2013 Ford F-150 🔎.

The saggy diaper is a hazard and major manufacturer defect that must be corrected ASAP. It needs to be metal period the end. The paper like cover bolted on the undercarriage is an awful engineering hazard. I have changed this item four times. The dealerships well established pattern of services for this issue and google searches speak for themselves. I don’t know why Ford refuses to address this concern and blow me off.

Pant is flaking off roof and tail gate in 1/8 to 1/4 inch pieces. Offord white paint. Clearly a manufacturing defect . 2018 f150 has approx. 27,000 miles on it, filed a claim with Ford dealer gosch in murrieta CA 92563.

The rear light bar and reversing lamp assembly, which was part of a safety recall, is filled with water and the lights are malfunctioning again. Ford is telling me that the replacement part has a 1 year warranty so that I would have to pay over $1600 for a replacement. This is a widespread issue with many of these trucks. Ford admitted that it was a manufacturing defect with the original part. However, the replacement part has the same issue so it is my belief that Ford has not fulfilled their duty to adequately repair an obvious safety issue and should be held responsible for the replacement of this part at no cost to the vehicle owner.