The 2015 F-150 was Ford's first aluminum-body year and brought significant weight savings, but the EcoBoost engines—especially the 2.7L and 3.5L—have proven fragile under stress. We're seeing catastrophic internal engine failures and cam phaser problems well before 150k miles, plus trans cooler leaks that can destroy transmissions if ignored.
2.7L EcoBoost Catastrophic Engine Failure
Occasional · high severity
Typical onset: 80,000-140,000 mi
Symptoms: sudden loss of power and severe knocking, metal shavings in oil, low oil pressure warning, engine seizure in worst cases
Fix: Complete engine rebuild or replacement required—piston ring land failure causes debris circulation and bearing damage. 15-25 hours labor depending on full rebuild vs. shortblock swap. Often totals older trucks.
Estimated cost: $8,000-15,000
3.5L EcoBoost Cam Phaser Rattle and Timing Chain Stretch
Common · medium severity
Typical onset: 60,000-120,000 mi
Symptoms: cold-start rattle lasting 3-10 seconds, check engine light with timing-related codes, reduced power and fuel economy, rougher idle
Fix: Requires both cam phasers, timing chains, guides, and tensioners—front engine disassembly. Poor oil change habits accelerate this. 12-16 hours labor. Some 2015s got TSB 17-2166 update but problem persists.
Estimated cost: $2,500-4,200
Transmission Oil Cooler Line Leak into Coolant System
Common · high severity
Symptoms: milky/strawberry-colored transmission fluid, transmission slipping or harsh shifts, coolant level dropping with no external leaks, overheating transmission
Fix: Internal cooler in radiator fails, cross-contaminating fluids. Requires radiator replacement, complete trans fluid flush (sometimes multiple flushes), coolant system flush. If caught early: 4-6 hours. If trans is damaged: add rebuild at $3k-5k more.
Estimated cost: $800-1,400
Door Latch Freezing and Failure
Common · medium severity
Symptoms: door won't open from inside or outside handle, repeated warnings door is ajar when closed, door rattles while driving, power locks cycling randomly
Fix: Internal latch mechanism corrodes or freezes—multiple recalls (15S16, 16S30) but problem continues beyond covered VINs. Each latch runs 1.5-2 hours labor. Many trucks need multiple doors done over ownership.
Estimated cost: $350-550
5.0L Coyote Spark Plug Blowout
Occasional · high severity
Typical onset: 40,000-100,000 mi
Symptoms: sudden misfire with loud popping sound, check engine light, loss of power, hissing from engine bay, visible spark plug ejected from head
Fix: Aluminum head threads strip and eject spark plug. Requires thread repair insert (HeliCoil or TimeSert) at minimum—2-3 hours per hole. Severe cases need head removal and machine work: 10-14 hours.
Aluminum Body Panel Corrosion at Steel Contact Points
Occasional · low severity
Symptoms: white powdery corrosion at bed/cab junction, bubbling paint at frame mounting areas, rust staining running down from fasteners, body panel looseness
Fix: Galvanic corrosion where aluminum body meets steel frame without proper isolation. Cosmetic in early stages but can weaken mounting points. Repair involves disassembly, corrosion treatment, and proper insulation. Prevention is key—keep drain holes clear.
Estimated cost: $500-2,000
Owner tips
If buying EcoBoost, get full engine inspection and oil analysis—cam phaser noise on cold start is your warning sign, don't ignore it
Check transmission fluid color immediately and every 6 months—milky fluid means cooler leak and you have days before trans dies
Use quality 5W-30 synthetic and change every 5k miles max on EcoBoost engines—they're extremely oil-change sensitive
Test all door latches thoroughly in cold weather before purchase—frozen latch may only show up below 20°F
On 5.0L, verify proper spark plug torque spec (27 ft-lbs) and never overtighten—stripped threads are expensive
The 3.5L NA V6 and 5.0L V8 are safer bets; avoid high-mileage 2.7L EcoBoost entirely, and budget $3k-5k for eventual cam phaser work on any 3.5L EcoBoost—great trucks when maintained obsessively, but expensive when neglected.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Ford Motor Company (Ford) is recalling certain 2015-2017 F-150 vehicles. A loss of signal between the transmission range sensor and the powertrain control module can cause the transmission to unexpectedly downshift into second gear.
Consequence: Unexpectedly downshifting into second gear may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Dealers will update the powertrain control module software, free of charge. Interim letters, notifying owners of the safety risk, are expected to be mailed April 27, 2026. Additional letters will be sent once the final remedy is available, anticipated in July 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S28. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on April 15, 2026.
Tenneco Automotive (DRiV) is recalling certain MOOG K500359 ball joints, for aftermarket installation on 2015-2018 Ford F-150 trucks. The ball joint may have a misaligned dust boot and may be missing alignment hole and installation warning tag, which may lead to improper alignment of the ball joint.
Consequence: An incorrectly installed ball joint may cause the ball joint stud to break, which can compromise front wheel control, increasing the risk of a crash.
Remedy: DRiV will notify owners, and dealers will inspect, and if necessary replace the ball joint, free of charge. Owner letters were mailed May 5, 2021. Owners may contact Tenneco Automotive customer service at 1-877-489-6659.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 20V332000
2020-06-08 · RQ16001
Ford Motor Company (Ford) is recalling certain 2014-2017 F-150 pickup trucks equipped with 3.5L Ecoboost engines. The brake master cylinder may leak brake fluid into the brake booster.
Consequence: A loss of brake fluid may result in a change in brake pedal travel and feel, increased pedal effort and reduced front brake function, possibly requiring greater effort and distance to stop the vehicle. These conditions can increase the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the brake master cylinder and inspect the brake booster, replacing it as necessary, free of charge. Ford issued owners an interim notification on June 30, 2020. The recall began on October 28, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S31.
ENGINE · 20V098000
2020-02-21
Ford Motor Company (Ford) is recalling certain 2015-2016 F-150 pick-up trucks equipped with 3.5L GTDI engines and block immersion heaters that were potentially relocated from their originally installed location. The incorrect location could put the heater too close to hot engine components, possibly resulting in a damaged cable.
Consequence: A damaged cable could cause a resistive short, increasing the risk of overheated or melted wiring, increasing the risk of a fire.
Remedy: Ford will notify owners, and dealers will inspect the block heater's location and its cable, replacing components as necessary, free of charge. If the replacement parts are not available, dealers will disable the existing block heater cable from being used until parts become available. The recall began April 9, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S08.
ENGINE · 19V278000
2019-04-08
Ford Motor Company (Ford) is recalling certain 2015-2019 Ford F-150 and 2017-2019 Ford F-250 Super Duty, F-350 Super Duty, F-450 Super Duty, and F-550 Super Duty pick-up trucks equipped with an engine block heater and previously remedied under recall 18V894. During the previous repair, the block heater cable's splice connector may have been damaged.
Consequence: A damaged cable could cause a resistive short, increasing the risk of overheated or melted wiring, increasing the risk of a fire.
Remedy: Ford will notify owners, and dealers will disable the engine block heater from being used. When replacement cables become available, a second notice will be mailed and dealers will replace the engine block heater cord, free of charge. The recall began May 31, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S11.
ENGINE · 18V894000
2018-12-18
Ford Motor Company (Ford) is recalling certain 2015-2019 Ford F-150 and 2017-2019 Ford F-250 Super Duty, F-350 Super Duty, F-450 Super Duty, and F-550 Super Duty pick-up trucks equipped with an engine block heater. Water and contaminants may get into the block heater cable's splice connector causing corrosion and damage.
Consequence: When the heater is plugged in, prolonged corrosion could cause a resistive short, increasing the risk of overheated or melted wiring which can increase the risk of a fire.
Remedy: Ford will notify owners, and dealers will disable the block heater cable, free of charge. Once parts are available, Dealers will replace the engine block heater cable, free of charge. The recall began June 3, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 18S45.
SEAT BELTS:PRETENSIONER · 18V568000
2018-08-31 · PE18008
Ford Motor Company (Ford) is recalling certain 2015-2018 Ford F-150 Regular Cab and SuperCrew Cab vehicles. If a front seat belt pretensioner deploys as the result of a crash, the sparks may ignite materials such as carpeting or insulation within the B-pillar area.
Consequence: A vehicle fire could result if materials ignite inside the vehicle.
Remedy: Ford will notify owners, and dealers will remove the B-pillar insulation material and wiring harness tape, and install heat resistant tape, free of charge. The recall began September 28, 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 18S27.
LATCHES/LOCKS/LINKAGES:DOORS:LATCH · 17V652000
2017-10-16
Ford Motor Company (Ford) is recalling certain 2015-2017 Ford F-150, and 2017 F-250, F-350, F-450, and F-550 Super Duty trucks. The doors on these vehicles may have a bent or kinked actuation cable or the door latches may freeze after water gets into the latch. Either condition can result in the doors opening while driving although they appear to be closed.
Consequence: A door that opens while driving can increase the risk of injury.
Remedy: Ford will notify owners, and dealers will inspect the door latch actuation cables and repair if necessary, and install water shields over the door latches, free of charge. The recall began October 12, 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S33.
SEAT BELTS:REAR/OTHER · 17V526000
2017-08-28
Ford Motor Company (Ford) is recalling certain 2015-2017 F-150, and 2017 F-250 and F-350 trucks equipped with a crew cab. The left rear inflatable seat belt buckle assembly may be inadequately attached to its mounting bracket. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 210, "Seat Belt Assembly Anchorages."
Consequence: If the left rear inflatable seat belt buckle separates from it's mounting bracket, the seat occupant may not be adequately restrained, increasing their risk of injury.
Remedy: Ford will notify owners, and dealers will inspect the seat belt assembly, replacing the attaching rivet as necessary, free of charge. Interim notices informing owners of the safety risk were mailed October 18, 2017. Owners will receive a second notice when the remedy becomes available. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 17C12.
LATCHES/LOCKS/LINKAGES:DOORS:LATCH · 17V331000
2017-05-22
Ford Motor Company (Ford) is recalling certain 2015-2017 F-150, and 2017 F-250, F-350, F-450, and F-550 vehicles originally produced with black or body colored exterior door handles that may have been subsequently equipped with a chrome exterior door handle cover accessory kit purchased from a Ford dealer. These accessory door handle covers may cause the doors to unlatch in a side impact collision. As such, these vehicles may fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 206, "Door Locks and Door Retention Components."
Consequence: If the doors unlatch and open in a side impact collision, the occupants have an increased risk of injury.
Remedy: Ford will notify owners, and dealers will remove the accessory covers and refund the purchase price. The recall began July 13, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for the recall is 17C09.
SEAT BELTS:FRONT:ANCHORAGE · 15V867000
2015-12-22
Ford Motor Company (Ford) is recalling certain model year 2015 Ford F-150 SuperCrew trucks manufactured January 22, 2015, to March 17, 2015. The affected vehicles may be equipped with driver or front passenger seat belt anchorage assemblies whose pretensioner cable was not properly crimped. As a result, the seat belts may not properly restrain the seat occupant in the event of a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 209, "Seat Belt Assemblies" and 210, " Seat Belt Assembly Anchorages."
Consequence: An occupant that is not be properly restrained is at an increased risk of injury in the event of a crash.
Remedy: Ford will notify owners, and dealers will replace the driver and/or front passenger side seat belt retractor(s) and pretensioner(s), free of charge. The recall began on February 12, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15C17.
FORWARD COLLISION AVOIDANCE: ADAPTIVE CRUISE CONTROL · 15V614000
2015-09-30
Ford Motor Company (Ford) is recalling certain model year 2015 Ford F-150 trucks manufactured March 18, 2014, to August 6, 2015 and equipped with Adaptive Cruise Control (ACC). While using the Adaptive Cruise Control, the vehicle may falsely detect an obstacle in its path and may unexpectedly apply the brakes.
Consequence: A vehicle that unexpectedly brakes increases the risk of a crash.
Remedy: Ford will notify owners, and dealers will reprogram the cruise control module with updated ACC radar software, free of charge. The recall began on October 25, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S29.
STEERING · 15V279000
2015-05-12
Ford Motor Company (Ford) is recalling certain model year 2015 Ford F-150 trucks manufactured March 19, 2015, to March 30, 2015. The affected vehicles may have been built with a steering upper intermediate shaft that was improperly riveted.
Consequence: If the intermediate shaft was improperly riveted, it could separate from the intermediate shaft flex coupling, resulting in a loss of steering control and increasing the risk of a vehicle crash.
Remedy: Ford will notify owners, and dealers will inspect the intermediate shaft and replace it, as necessary, free of charge. The recall began on May 22, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S17.
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS · 15V251000
2015-04-28
Ford Motor Company (Ford) is recalling certain model year 2015 Ford F-150 vehicles manufactured January 30, 2015, to January 31, 2015. The affected vehicles may have loose or missing underbody heat shields.
Consequence: A missing underbody heat shield can lead to degradation or melting of the fuel or vapor lines, increasing the risk of a fire.
Remedy: Ford will notify owners, and dealers will inspect the vehicle for missing underbody heat shields and fasteners, and will install the missing components as required, free of charge. The recall began on May 13, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S12.
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