The exhaust manifold on the drivers side has sheared a bolt on the back of the manifold, and has warped. This is more noticeable when the engine is cold, but is also noticeable after the engine has been off for 10-15 minutes. On acceleration, there is a chirping noise that will go away when the metals have expanded and "sealed" the leak. When cold, exhaust fumes can be smelled in the cabin of the vehicle. This issue appears to be common among the truck variant of the 3.5L EcoBoost V6 engine (11-16 F150, 15-17 Expedition/Navigator, 15+ Transit). There are numerous posts online from many different forums about this exact issue. Ford has even redesigned the manifold to include an additional stud hole, but there is no TSB or FSA from them to replace this on affected vehicles (BL3Z-9430-D, DL3Z-9431-D) This issue was determined through my own inspection of the vehicle. I can bring the vehicle into a shop for an official diagnosis if necessary. There are no warning lights or messages on my vehicle. This initially started around April 5th.

- Omaha, NE, USA

The contact owns a 2015 Ford F-150. The contact stated that while her husband was approaching the vehicle, there was a fluid leak underneath the vehicle. The check engine warning light was illuminated. The vehicle was taken to a local dealer, where it was diagnosed that the oil pan and engine needed to be replaced. The vehicle remained at the dealer awaiting the repair. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was 56,288.

- Palmyra, MO, USA

The contact owns a 2015 Ford F-150. The contact stated while driving at low speeds and attempting to park the vehicle, the vehicle inadvertently went into reverse, then accelerated forward. The vehicle failed to stop and jumped the curb and abruptly stopped. There was an abnormal clacking noise detected. There were no warning lights illuminated. The vehicle was restarted and drove as designed. The contact called the local dealer who informed him to schedule an appointment. The vehicle was not diagnosed or repaired. The manufacturer was contacted but no assistance was provided. The failure mileage was approximately 153,000.

- Ennis, TX, USA

The exhaust manifolds keep failing on the truck because of a poor design that Ford is aware of with TSB and updated parts it cost $2200 the first time to repair now I am looking at replacing the same exhaust manifold when the manifold fails it let-??s exhaust fumes and gases into the cabin of the truck

- Salisbury, MA, USA

Went to get an oil change and was told about a leak, this is the third leak and the oil pan is back ordered. This needs to be rectified asap. The last two times over $1,000 cost to the dealer to replace oil pan.

- Lathrop, CA, USA

My 2015 Ford F150 has 108K miles. While driving on 2/21/23, the engine started missing, several engine warning light began illuminating. I was able to pull to the shoulder and stop the engine which was missing badly. After allowing the engine to completely stop and turning the ignition off, I allowed it to settle for a moment, then I restarted the engine. I placed it in gear and attempted to drive again, but the same missing and instrument cluster faults recurred. At this point, I had it towed to Loveland Ford, in Loveland Colorado. After evaluation, I was notified the Throttle Body had failed which also caused the instrument cluster faults. Upon reading about the Throttle Body, one of the articles indicated this has been and issue for Ford F150 years 2014 -2016 produced in Dearborn and Kansas, but that Ford had voluntarily repaired vehicles with issues via extended warranty when reported. My vehicle falls in the date range and was produced in Dearborn. This is a very dangerous condition and had this occurred on a busy highway, would be a danger to me as well as other vehicles.

- Loveland, CO, USA

The contact owns a 2015 Ford F-150. The contact stated that while he was inspecting the vehicle, he noticed an excessive amount of oil leaking from the oil pan. The vehicle was taken to the dealer, where the oil pan and valve cover were replaced; however, the failure recurred. The vehicle was taken back to the dealer, where they placed a temporary seal around the oil pan. The manufacturer was made aware of the failure. The failure mileage was approximately 68,000.

- Mokena, IL, USA

Exhaust manifolds warped - Very common and expensive failure. Only 8 bolts on original manifold. When the manifolds heat and cool over time due to the turbos, they warp and break the bolts requiring extraction and replacement. Ford realized their design flaw and when the manifold inevitably warps, the replacement manifolds are now made with 9 bolts. Other aftermarket manifolds are made with 11 bolts.

- Pewaukee, WI, USA

The exhaust manifold warps under excessive heat due to the proximity of the turbochargers to the manifold in the 3.5L EcoBoost engine, causing the manifold to separate from the engine and will frequently break studs (most notably the rear stud) causing exhaust leaks, power loss, emissions problems, and can lead to mixture problems which will cause further damage to the engine if not addressed immediately. This could also lead to engine failure and crashes or fires.

- Hockley, TX, USA

1-the Brake System Light has come on and brakes are extremely hard to press and use. I was having issues with the brake pedal slowly going to the floor while sitting at a stop. Today they will not go down at all and brakes are very difficult to press. very dangerous to drive and a safety issue. I see that my VIN does not show a recall for it, but there is recall #20S31 that relates. 2-The engine has an exhaust leak while driving and it smells as though the exhaust is getting into the cab of the truck. I was told the manifold is bent because of a design flaw in the manifold missing a bolt. been making this noise since the truck was rear-ended by semi truck.

- Thornton, CO, USA

Exhaust manifold bolts are failing, causing leaks that could cause potential fire. Also exhaust leaks before the catalytic converter, emission control.

- Batavia, IL, USA

Failing Exhaust manifold and studs

- Overton, NV, USA

Repeatedly faulty exhaust manifold stud bolts. They continue to break.

- Overton, NV, USA

Engine shutting off at stop this is not the auto shut off model, this has happened 3 times and many other owners have already contacted Ford about recall

- Belton, SC, USA

Exhaust Manifolds warping. This issue is not only very disappointing that Ford hasn't addressed this issue but is a safety concern as well. This allows exhaust fumes to escape not only into the air but potentially inside the cab. This could result in serious lung issues and needs to be addressed. Thank you!

- Bellevue, NE, USA

Manifold bolts broken causing an exhaust leak inside vehicle.

- Troy, IL, USA

My Ford dealer replaced the defective throttle body on my 2015 F150 Ford truck. I was charged for the repair and Ford advised me that the extended warranty on this component did not apply to my vehicle. My trucks engine completely shut down while I was driving. I was very luck I was on a back road and was able to coast until it was safe to pull off the road. After restarting my truck, in a few miles, it did the same thing. Again, I was very lucky to still be on a back road and able to coast to a safe spot to pull off the road. I restarted the truck and made it to my Ford dealer a few miles away without further incident. Both times my truck engine quit, there was a warning light on the dash board that lite during the event. I believe it said -??maintenance required-?? but not sure. I was preoccupied looking for a safe place to pull off the road. No warning came before the event. This engine shutdown could have put myself and others in danger had it occurred on the freeway.

- Fayetteville , GA, USA

Truck sporatically fails to start or motor shuts down within five minutes of driving. Starter remains ingaged even in run position, needs to be cycled to off position to dissengage. After cooling at least 10 minutes truck usually starts and runs normally for a few days until it does it again. Dealer cannot find anything wrong and refuses to look any further. Shuting down at speed on the road safety hazard. Almost impossible to stear or break after engine shutdown. No engine codes or warning lamps.

- Inglis, FL, USA

My vehicle has a factory feature called "Hill Decent Control". this past week I have been getting a Default Message "Hill Decent default" and the accelerator pedal stops working. This has happened in the middle of the road (in traffic) for no apparent reason, where I have to stop the vehicle, turn off the engine, then restart. I have read on line where other Ford F-150s have experienced this same issue. I contacted ford, and they said they have no Recalls or TSB's regarding this unsafe issue. I now need to find a reputable shop to diagnosis the exact cause and repair needed.

- Long Beach, CA, USA

The exhaust manifold rear stud broke causing leaking emissions to potentially be released into the cab of the vehicle putting the driver and any passengers at risk. This is a known problem with Ford's 3.5L twin turbo eco-boost engines and they are failing to recognize this problem. It has been confirmed that this is the issue and no other entity has been involved in this issue. There is no, nor has been any warning lamps or messages with this issue. It is available to be inspected if needed.

- Cedar Rapids, IA, USA