Ford F-150 Problems

RepairPal has identified the most common problems with the 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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Known Problems

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

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

Failure to change the power steering fluid can cause the fluid to become gray with metal particles. The contaminated fluid can damage the power steering pump resulting in a growling noise when the wheel is turned; the damaged pump will require replacement to eliminate the noise.. Life of the power steering gearbox and pump will be shortened if the fluid is not serviced regularly.

The front brakes may stick, bind, or grab. This can happen when the front brake caliper pins become corroded. Cleaning or replacing the caliper pins will be necessary to correct this problem.

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 EGR orifices in the intake manifold may plug with sludge. If the truck has high mileage, this may cause engine misfire when first accelerating because too much EGR gas is directed into the cylinders of the unplugged orifices. This makes the mixture lean, which causes a gradual stumble that increases in severity until repaired.

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.