Ford · Known Issues
2016 Ford F-150 Problems: 33 Known Issues
2016 model year · 3,576+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2016 model year · 3,576+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
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According to Au7o's analysis of 3,576+ owner reports, the 2016 Ford F-150 has 33 documented known issues, with 9 rated critical. The most serious are Brake Vacuum Pump Failure (EcoBoost) ($300-$800 repair), Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss ($0-$600 repair), P0700 — Transmission Control System Malfunction (MIL Request) from Failed 6R80 Molded Leadframe ($300-$1,200 repair), 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power ($1,800-$5,000 repair), 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle ($1,800-$3,200 repair), 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head ($4,000-$8,000 repair), Door latch failure - doors won't latch or open while driving ($0-$350 repair), Electric Power Steering (EPAS) Assist Fault — Sudden Loss of Power Steering Assist ($1,000-$1,900 repair) and Front seat belt pretensioner fire risk ($0-$0 repair). The most commonly reported issue is HVAC Blend Door Actuator Failure with 1,100 owner reports. Across all issues with published estimates, repair costs range from $40 to $8,000. DIY maintenance guides at au7o.io.
STEERING:COLUMN
Ford Motor Company (Ford) is recalling certain 2024 F-150 vehicles. The steering column lower shaft may have been secured to the steering gear assembly with an incorrect fastener, which can result in the separation of steering components and cause a loss of steering control.
VISIBILITY:WINDSHIELD
Ford Motor Company (Ford) is recalling certain 2024 F-150 vehicles. The windshield may not have been properly bonded to the vehicle, allowing it to detach during a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 212, "Windshield Mounting."
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, 2024 Expedition and 2024 Lincoln Navigator vehicles equipped with a 3.5L GTDI engine. The engines may have a misaligned engine cup plug, which can result in a rapid oil leak.
EQUIPMENT:OTHER:LABELS
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
STEERING
Ford Motor Company (Ford) is recalling certain 2024 F-150 vehicles. The steering gear assembly may have been assembled with an incorrect rack, which can cause the gears to fracture.
+ 51 more recalls. Check all on NHTSA.gov
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According to Au7o's analysis of 3,576+ owner reports, the 2016 Ford F-150 has 33 documented issues. The most frequently reported are: Brake Vacuum Pump Failure (EcoBoost), Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss, P0700 — Transmission Control System Malfunction (MIL Request) from Failed 6R80 Molded Leadframe. Of these, 9 are rated critical and should be addressed promptly.
The 2016 Ford F-150 has 33 known issues documented across 3,576+ owner reports. 9 issues are rated critical: Brake Vacuum Pump Failure (EcoBoost) and Brake Master Cylinder Fluid Leak into Booster Causing Front Brake Loss and P0700 — Transmission Control System Malfunction (MIL Request) from Failed 6R80 Molded Leadframe and 3.5L EcoBoost Turbocharger Wastegate Failure — Stuck Wastegate / Reduced Engine Power and 3.5L EcoBoost Primary Timing Chain Stretch — P0016 and Cold-Start Rattle and 2.7L EcoBoost Coolant Intrusion from Cracked Cylinder Head and Door latch failure - doors won't latch or open while driving and Electric Power Steering (EPAS) Assist Fault — Sudden Loss of Power Steering Assist and Front seat belt pretensioner fire risk. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford F-150 issues range from $0 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Brake Vacuum Pump Failure (EcoBoost), typically costs $300-$800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The vacuum pump that provides brake assist on EcoBoost F-150s can fail, resulting in a hard brake pedal and reduced braking assist. Since turbo engines don't produce intake vacuum like naturally aspirated engines, they rely on this pump. Repairs typically run $300-$800. Severity: high.
The brake master cylinder rear cup seal can roll or fail, allowing brake fluid to leak from the front-circuit reservoir into the brake booster. This drops fluid in the front brake circuit and can reduce or eliminate front-wheel braking (rear brakes remain). Drivers report a long/… Repairs typically run $0-$600. Severity: high.
On the F-150, P0700 is a generic "MIL request" companion code the PCM stores whenever the transmission control strategy has logged an underlying transmission fault — it points to a problem but never names it by itself. On the extremely common 6R80 six-speed automatic (F-150 2011-… Repairs typically run $300-$1,200. Severity: high.
The wastegate on the 3.5L EcoBoost turbochargers fails, either sticking (carbon/corrosion binding the valve and actuator arm) on early vacuum-operated designs or through electronic actuator/position-sensor faults on 2015-and-newer electric-actuator turbos. A stuck-closed wastegat… Repairs typically run $1,800-$5,000. Severity: high.
Distinct from the cam-phaser cold-start rattle, the first-generation (2011-2016) 3.5L EcoBoost suffers genuine primary timing-chain wear ('stretch') because of its long chain routing and the high loads of a twin-turbo direct-injection V6. As the chain pins and rollers wear, the c… Repairs typically run $1,800-$3,200. Severity: high.
Ford's 2.7L EcoBoost (and related small-displacement EcoBoost engines) is prone to micro-cracks forming in the cylinder head around the exhaust ports, allowing coolant to seep into the combustion chamber. This produces unexplained coolant loss with no external leak, white sweet-s… Repairs typically run $4,000-$8,000. Severity: high.
Water can enter the door latch and freeze, and the latch actuation cable can become bent or kinked. Either condition can leave a door that appears closed but is not fully engaged with the striker, allowing it to open while driving, or a door that will not open or will not close a… Repairs typically run $0-$350. Severity: high.
The 12th-gen F-150 uses a belt/column electric power-assist steering (EPAS) system that replaced the old hydraulic pump. Owners report the dash lighting up with a 'Power Steering Assist Fault — Service Now' or wrench warning, after which the assist cuts out and the wheel becomes… Repairs typically run $1,000-$1,900. Severity: high.
When a front seat belt pretensioner deploys in a crash, it can generate excessive sparks/hot gas that ignites insulation, carpet, or wiring inside the B-pillar, potentially starting a vehicle fire. Ford recalled about 2 million 2015-2018 F-150 trucks (about 1.6 million in the U.S… Repairs typically run $0-$0. Severity: high.
The EcoBoost engines can develop oil leaks from the oil pan gasket. The leak often appears at the rear of the oil pan and can drip onto exhaust components, causing a burning oil smell. This is common on trucks with higher mileage. Repairs typically run $400-$1,200. Severity: medium.
The two-piece driveshaft uses a center support (carrier) bearing that can wear out, causing vibration and noise. The rubber support degrades over time, especially in hot climates or with heavy towing. Ford TSB addresses this issue. Repairs typically run $300-$700. Severity: medium.
Ford modular V8s (and the EcoBoost V6 turbo manifolds) are notorious for snapping the small (8mm) exhaust-manifold-to-head studs/bolts. They are installed without anti-seize and corrode/fatigue from repeated heat cycling; on the turbo EcoBoost engines, a large share of the turbo/… Repairs typically run $50-$700. Severity: medium.
The sealed, non-serviceable front hub/bearing assemblies on 13th-gen F-150s wear out and produce a speed-dependent humming or grinding that gets louder with speed and can shift with cornering load, plus steering-wheel/floor vibration. Because the wheel-speed sensor lives in the h… Repairs typically run $300-$750. Severity: medium.
Ford's 4x4 F-150s use a vacuum-operated Integrated Wheel End (IWE) system instead of conventional locking hubs: vacuum keeps the front hubs UNLOCKED in 2WD and is released to lock them for 4WD. The system relies on vacuum lines, a hood-area solenoid, and a check valve that are hi… Repairs typically run $100-$700. Severity: medium.
First-generation 3.5L EcoBoost F-150s use direct injection only (no port injection), so fuel never washes the back of the intake valves. Oil vapor from the PCV system bakes onto the valves and forms hard carbon deposits that restrict airflow and disturb valve sealing. Owners typi… Repairs typically run $400-$900. Severity: medium.
The 6R80 six-speed automatic (2009-2017 F-150) is generally durable but is widely reported for a harsh, banging 1-2 upshift and erratic/flaring shifts, with thousands of NHTSA complaints. The internal solenoid body 'lead frame' (the mechatronic wiring carrier) can crack or develo… Repairs typically run $250-$1,500. Severity: medium.
The Accessory Protocol Interface Module (APIM) — the computer behind the SYNC 2 and SYNC 3 touchscreen — is a very common failure on 2013-2020 F-150s. Its internal electronics and onboard flash storage degrade over time, producing a black/unresponsive screen (sometimes with backl… Repairs typically run $0-$900. Severity: medium.
The foam gasket that seals the roof-mounted center high-mount stop lamp (CHMSL / third brake light) against the cab dries out, compresses and shrinks with heat and UV exposure, breaking the watertight seal. Rainwater then runs down inside the cab from the roof opening, soaking th… Repairs typically run $40-$250. Severity: medium.
The plastic pressurized coolant degas (overflow/expansion) bottle and the plastic quick-connect tees/Y-fittings that route coolant between the block, radiator, and bottle develop hairline cracks and seep, especially at seams and hose necks and in cold weather where the square-cut… Repairs typically run $150-$450. Severity: medium.
F-150 trucks equipped with the large twin-panel (panoramic) sunroof have reports of the tempered glass spontaneously shattering or 'exploding' with a loud bang, sometimes at highway speed, raining glass into the cabin. Owners and a class action attribute it to the ceramic enamel… Repairs typically run $500-$1,500. Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.