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Ford F-150 Problems

RepairPal has identified the most common problems with the Ford F-150 based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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28
Known Problems

The 2004-2014 Ford F-150 with manual temperature and fan controls may have problems with the the blower motor only blowing air on certain settings. Most commonly the fan will only run on the highest setting. This is a well documented problem, and is caused by a failing blower motor resistor.

Correcting the problem is straight forward, and requires replacement of the small resistor. The resistor is normally found behind the glove box, next to the blower motor.

On higher mileage vehicles, one or more EGR orifice in the intake manifold may plug with sludge. This can cause the engine to misfire when first accelerating because too much exhaust gas is directed into the cylinders where the orifice is not plugged. Cleaning the clogged passages should correct this concern.

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.

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. The valve and sensor must be replaced together to correct this concern.

An illuminated Check Engine Light could indicate that one or more of the ignition coils has failed due to excessive spark plug gap. To fix this problem, the ignition coils that have failed, the spark plugs, and all coil boots should be replaced.

If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing differential clutch kit. An updated differential clutch kit available.

An oil leak may develop from the the right side head gasket.  Oil from this type of leak will commonly drip onto the starter. Our technician tell us an updated head gasket is available to correct this concern.

A ticking noise may develop from the engine due to a warped exhaust manifold. Damaged exhaust manifolds will require replacement to correct this issue.

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.

Catalytic converters can go bad and potentially plug the exhaust, hurting engine efficiency and performance.

New TSB may be available

 

According to Ford Bulletin 06-04-04

Some 2003 + INDEPENDENT REAR SUSPENSION (IRS) AXLE F-150 vehicles equipped with a 9.75″ or 8.8″ limited and Mustang vehicles equipped with  limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from the front axle or the steering gear.

First verify the condition. On 4X4 trucks ensure that Modifier (XL-3) for fifteen (15) minutes prior to the vehicle is in 2WD, to isolate the rear axle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack.

The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.