1996 Ford F-150 Problems

RepairPal has identified the most common problems with the 1996 Ford F-150 as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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7
Known Problems

The engine oil pan gasket can develop a leak. Leaking oil may accumulate on the exhaust system resulting in a burning smell. Replacing the gasket should correct this leak.

If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, there is an updated differential clutch kit available.

Our technicians tell us the spark plugs in this engine can be very difficult to remove. Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head.

The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.

1. Break the spark plugs loose when the engine is warm.
2. Turn each plug 1/8 to 1/4 turn and soak the treads with 1/2 to 3/4 teaspoon of Motorcraft Carburetor Tune-Up Cleaner or a quality penetrating oil. Do not try to remove the plugs at this time.
3. Let the threads soak for at least 15 minutes.
4. After the soak period, tighten and loosen each spark plug, working it back and forth until the turning effort is reduced. Then, you can remove the spark plug.

There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor time, over and above the quoted spark plug replacement cost, for the removal of each broken spark plug.

The gears for the timing chain can strip, causing the engine to crank but not start.

Tubes for the EGR system (exhaust gas recirculation) can break, causing an exhaust leak and noise under the hood.

If there is a vibration or noise at highway speed, it could be from the frontdrive shaft and may require replacement of the double cardan joint. A double cardan joint is a type of driveshaft joint that uses two universal joints.