2007 Ford F-150 Body & structure Problems

Frame has rotted away

NHTSA ID

11620769

Incident

Oct 17, 2024

The contact owns a 2007 Ford F-150. The contact stated that while the vehicle was parked, she became aware that the sub frame, underneath the vehicle, was cracked. The contact stated that the frame was loose and was visible by standing in front of the vehicle. The vehicle was taken to an independent mechanic who confirmed that the frame was cracked and needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was approximately 190,000.

NHTSA ID

11592180

Incident

Jan 1, 2022

Mileage

190,000 mi

I’m wondering why there is no recall on the frames my truck has 96k and the frame is almost gone 2007 f-150

NHTSA ID

11564898

Incident

Jan 11, 2024

Yesterday I discovered that the frame of my truck is completely rusted through in at least 2 places on the passenger side. I cannot confirm these are the only areas. The passenger side appears much worse than the driver side.

NHTSA ID

11426939

Incident

Jul 28, 2021

FRAME, BRAKE LINES AND ALL METAL UNDER CARRIAGE CORRODED TO THE POINT OF BEING UNSAFE. BODY ONLY HAS MINIMAL RUST ON REAR CORNER PILLARS. UNSAFE TO OPERATE.

NHTSA ID

11331494

Incident

Jun 27, 2020

Mileage

96,000 mi

I WENT TO HAVE MY BRAKES REPLACED ON MY F-150 WITH 54,000 MILES ON THE ODOMETER AND THE MECHANIC TOLD ME THE FRAME WAS COMPLETELY RUSTED OUT AND THAT HE WAS ABLE TO PUT A SCREWDRIVER THROUGH IT. HE DIDN'T WANT TO INSTALL THE BRAKES. I HAVE OWNED THIS TRUCK SINCE NEW AND IT HAS (MOSTLY) BEEN GARAGED THROUGHOUT. THE BODY PANELS, INTERIOR , TRANSMISSION, ENGINE, ETC. ARE IN EXCELLENT SHAPE. IT APPEARS TO BE THE SAME PROBLEM REPORTED BY MANY OTHERS, SO I'M NOT SURE WHY THERE HASN'T BEEN A FORD RECALL ON THIS DANGEROUS SITUATION. IT'S OBVIOUSLY BEEN GOING ON FOR SOME TIME, BUT I NEVER LOOKED UNDER THE TRUCK TO SEE THE EXTENT OF THE RUST, GIVEN THAT THE BODY WAS IN GREAT SHAPE (NO RUST).

NHTSA ID

11259024

Incident

Sep 30, 2019

Mileage

54,000 mi

I HAVE A 2007 F150 WITH 96,460 MILES. DRIVES ON PA ROADS NEVER OFF ROAD AND NO HAULING. DRIVER SIDE FRAME RAIL IS RUSTED AT A POINT IMMEDIATELY BEHIND THE FORWARD MOUNTING BRACKET OF THE REAR LEAF SPRING. THE AMOUNT OF RUST IS EXTENSIVE. THE INNER WALL OF THE RAIL IS RUSTED THROUGH CREATING A HOLE APPROX. 10 INCHES LONG AND RANGING FROM THE HEIGHT OF THE RAIL TAPERING REARWARD TO ABOUT 3/4 OF AN INCH. THE BOTTOM OF THE FRAME RAIL IS ALSO RUSTED THROUGH AT A POINT WHERE IT MEETS THE SPRING'S MOUNTING BRACKET. ALTHOUGH THE METAL APPEARS SOMEWHAT INTACT THERE IS NO STRUCTURAL INTEGRITY. THIS LEAVES ONLY THE UPPER PORTION AND OUTSIDE WALL OF THE FRAME RAIL INTACT BUT ALSO RUSTED. BASED ON MY OBSERVATION THIS TRUCK CANNOT BE DRIVEN SAFELY. I AM NOT AWARE OF ANY SOLUTION OTHER THAN TO REPLACE THE FRAME BUT THIS WILL BE DETERMINED BY A PROFESSIONAL IN THE NEAR FUTURE. AS TO THE CAUSE I DO NOT KNOW. THIS DAMAGE WAS FIRST NOTED TODAY 8/14/2019 AND WAS NOT DETECTED DURING AN INSPECTION IN 12/2018

NHTSA ID

11244061

Incident

Aug 14, 2019

TL* THE CONTACT OWNS A 2007 FORD F-150. THE CONTACT STATED THAT WATER DRAINED ONTO THE FRONT PASSENGER SIDE FLOORBOARD WHEN IT RAINED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND REFERENCED TECHNICAL SERVICE BULLETIN NUMBER: 07-13-5. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 137,000.

NHTSA ID

11229305

Incident

Jun 19, 2019

Mileage

137,000 mi

THIS IS REGARDING A 2007 FORD F150 SUPERCREW. DURING THE VEHICLES YEARLY INSPECTION IT WAS DISCOVERED THAT THE FRAME OF THE VEHICLE UNDER THE CAB IS COMPLETELY RUSTED OUT AND CRACKED EXTENSIVELY. IT IS CRACKED BEYOND REPAIR AND NO LONGER SAFE TO DRIVE. THIS VEHICLE IS ONLY 12 YEARS OLD AND SHOULD NOT BE EXPERIENCING EXTENSIVE PREMATURE RUST IN THIS WAY. THERE ARE ALOT OF THESE TRUCKS ON THE ROAD AND IT'S ONLY A MATTER OF TIME BEFORE SOMEONE GETS HURT.

NHTSA ID

11219176

Incident

Jun 9, 2019

Mileage

115,000 mi

TL* THE CONTACT OWNS A 2007 FORD F-150. THE CONTACT STATED THAT THE VEHICLE'S FRAME WAS RUSTED. THE VEHICLE WAS TAKEN TO AN UNKNOWN DEALER WHO DIAGNOSED THAT THE FRAME WAS FRACTURED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS 119,000. *TT VEHICLE PURCHASE DATE SHOULD BE ON OR BEFORE INCIDENT DATE *JB

NHTSA ID

11164525

Incident

Dec 3, 2018

Mileage

119,000 mi

O/D OFF LIGHT , TRANSMISSION FAULT ON INFORMATION DISPLAY INTERMITTENT LIGHT AND TONE! TRUCK WOULD NOT START, PCM FAILURE $3500 DOLLARS IN REPAIR, AT FORD DEALER STILL NOT FIXED!

NHTSA ID

11024747

Incident

Sep 11, 2017

Mileage

150,000 mi

I BOUGHT THIS TRUCK JUNE 28 2010. ON 2-11-14 I TOOK IT TO FORD DEALER BECAUSE OF FRAME ROT AND WAS TOLD THEY COULD NOT COVER THE REPAIR. I HAD IT REPAIRED AT A WELDING SHOP. THE TRUCK FRAME IS NOW SO BAD THAT IT IS UNSAFE AND WILL NOT PASS INSPECTION. IT HAS SEPARATED AT FACTORY WELD. OBVIOUS MANUFACTURING DEFECT.

NHTSA ID

11010312

Incident

Jul 24, 2017

Mileage

98,000 mi

FRAME IS COMPLETELY RUSTED THROUGH TO THE POINT THAT IT CANNOT BE REPAIRED AND IS UNSAFE. IT CANNOT PASS A STATE SAFETY INSPECTION AND HAS DETERIORATED TO THE POINT WHERE IT CANNOT EVEN BE PUT ON A LIFT BECAUSE IT HAS NO STRUCTURAL INTEGRITY. THERE ARE LARGE HOLES RUSTED THROUGH AND WHERE IT HASN'T ENTIRELY RUSTED THROUGH, THE METAL HAS DETERIORATED TO BEING LESS THAN HALF OF ITS ORIGINAL THICKNESS. THE PROBLEM WENT UNNOTICED BECAUSE THE REST OF THE TRUCK SHOWED NO SIGNS OF ANY ADVANCED DETERIORATION.

NHTSA ID

10985516

Incident

May 1, 2017

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2007 FORD F-150. AFTER THE CONTACT GRABBED THE SAFETY HANDLE ON THE DRIVER'S SIDE DOOR, IT DETACHED FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS CONFIRMED THAT THE HANDLE DETACHED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 70,000.

NHTSA ID

10946476

Incident

Nov 19, 2016

Mileage

70,000 mi

2007 FORD F-150 XLT WITH 5.4L TRITON V8,ENGINE BEGAN SHAKING VIOLENTLY WHILE AT STOP LIGHT, THEN HESITATED CONSISTENTLY WHILE ACCELERATING 40-50MPH, NO WARNING LIGHTS OR INDICATORS ON IN TRUCK. FORD DEALERSHIP REPLACED COIL I BELIEVE, JUST PURCHASED THE TRUCK USED AND DIDN'T GET ANY DOCUMENTATION WHEN THEY FIXED IT.

NHTSA ID

10876604

Incident

Dec 23, 2015

Mileage

98,000 mi

2007 FORD F-150. CONSUMER WRITES IN REGARDS TO VEHICLE PASSENGER ASSIST HANDLE BROKE OFF. *SMD THE CONSUMER STATED HIS WIFE FELL WHILE ATTEMPTING TO ENTER THE FRONT PASSENGER SIDE OF THE VEHICLE. SHE WAS USING THE PASSENGER ASSIST HANDLE LOCATED AT THE POST BETWEEN THE DOOR AND THE WINDSHIELD. SHE HAD ONE FOOT ON THE RUNNING BOARD AND HAD JUST STARTED USING THE ASSIST HANDLE TO ENTER THE VEHICLE WHEN THE ASSIST HANDLE BROKE OFF AND SENT HER BACK FROM THE VEHICLE. FORTUNATELY, SHE STILL HAD ONE FOOT ON THE GROUND AND WAS ABLE TO CATCH HERSELF AND WAS NOT HURT. THE PART WAS REPLACED AT A COST OF $ 213.86. *JB

NHTSA ID

10838386

Incident

Aug 29, 2015

TL* THE CONTACT OWNS A 2007 FORD F-150. WHILE PARKED, THE VEHICLE FAILED TO START. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE TECHNICIAN STATED THAT THE FUEL DRIVER MODULE WAS CORRODED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000. MA 08/14/15 UPDATED 10/19/2017*CN

NHTSA ID

10723977

Incident

May 30, 2015

Mileage

100,000 mi

CAB CORNER RUST OUT ROCK PALL RUST OUT WHEN I PAY 38000 GRAND FOR A TRUCK NEW OFF THE LOT NOW WITH 30000 MILES SHOULD NOT BE THAT MUCH RUST COME TO FIND OUT ON THE BACK OF THE CAB CORNER THERE A GAP WHERE WATER LEAK IN TO THE ROCKER AND THE WATER LAYS IN THERE AND RUST OUT THE BOTTOM OF THE DOOR AND HOW HARD WOULD OF BEEN TO RUN A BEAD OF SEAM SEALER FOR WATER COULD OF GOT DOWN IN THERE. *TR

NHTSA ID

10680369

Incident

Apr 4, 2012

Mileage

30,000 mi

WATER LEAKING FROM INTAKE MANIFOLD COOLANT CROSSOVER LINE. CROSSOVER IS AN ALUMINUM PIPE THAT CONNECTS TO THE PLASTIC INTAKE MANIFOLD. WHEN MANIFOLD STARTED LEAKING COOLANT, 1 & 2 SPARK PLUG HOLES FILLED WITH WATER CAUSING SPARK PLUGS TO SHORT OUT AND STALL THE ENGINE AT LOW SPEED. PER FORD THE ONLY REPAIR IS REPLACEMENT OF THE COMPLETE INTAKE MANIFOLD AT A COST OF OVER $1200.00. THIS IS A COMMON PROBLEM WITH THIS ENGINE. I HAVE SEEN MANY COMPLAINTS ON F-150 FORUMS VIA THE INTERNET OF PEOPLE HAVING THE SAME PROBLEM. MY TRUCK HAS ONLY 105000 MILES ON IT. *TR

NHTSA ID

10652546

Incident

Oct 27, 2014

Mileage

105,000 mi

TL* THE CONTACT OWNS A 2007 FORD F-150. WHEN THE VEHICLE ACCELERATED FROM A STOP, THE CONTACT HEARD A LOUD EXPLOSION NEAR THE REAR OF THE VEHICLE. THE VEHICLE STALLED IN THE MIDDLE OF THE INTERSECTION AND WAS TOWED TO A DEALER. THE DEALER STATED THAT ONE OF THE BOLTS THAT SECURED THE REAR END BECAME DETACHED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 74,000.

NHTSA ID

10628104

Incident

May 3, 2014

Mileage

74,000 mi

I WAS DRIVING DOWN THE ROAD AND I HEARD A LOUD POPPING NOISE SO I PULLED OFF ON THE SIDE OF THE ROAD AND TURNED THE TRUCK OFF. I THEN SAW SMOKE LIKE THE ENGINE HAD OVERHEATED BUT IN A MATTER OF SECONDS FLAMES IGNITED AND I QUICKLY GOT OUT OF THE VEHICLE AND CALLED 911. AS I WAS SPEAKING TO THE DISPATCHER THERE WAS A LOUD EXPLOSION AND THE WHOLE FRONT OF MY TRUCK WAS ENGULFED IN FLAMES. BY THE TIME THE FIRE DEPARTMENT ARRIVED AND PUT OUT THE FIRE MY HOOD WAS TOTALLY BURNED UP THE ENGINE IS BURNED UP AND MELTED AND THE WINDSHIELD AND DRIVER'S SIDE WINDOW BLEW OUT AND THE DASH AND FRONT INTERIOR IS BURNED AND MELTED. I AM LUCKY THAT I WAS ABLE TO GET OUT IN TIME BECAUSE IT HAPPENED SO QUICKLY. I AM ALSO GLAD MY 10 MONTH OLD SON WAS NOT WITH ME ON THIS DAY. *TR

NHTSA ID

10627389

Incident

Aug 21, 2014

Mileage

93,300 mi

TL* THE CONTACT OWNS A 2007 FORD F-150. THE CONTACT STATED THAT THE SIDE SUPPORT HANDLES USED TO LIFT ONESELF INTO THE VEHICLE BECAME FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER BUT WAS NOT REPAIRED. THE CONTACT STATED THAT IT WAS THE SECOND OCCURRENCE OF THE FAILURE. THE FAILURE MILEAGE WAS 48,000. *TR

NHTSA ID

10525716

Incident

Jul 18, 2013

Mileage

48,000 mi

I WAS STOPPING AND ABOUT TO PARK INTO A PARKING STALL. AS I WAS APPLYING MY BRAKE, THE VEHICLE SUDDENLY ACCELERATED. IT JUMPED A CURB, CROSSED A LANDSCAPE ISLAND, TOOK DOWN SHRUBS, THEN STOPPED ON THE OTHER SIDE. IT HAPPENED FEW OTHER TIMES, BUT NOT TO THIS EXTEND. OTHER TIMES I THOUGHT I MAY HAVE ACCIDENTALLY PRESSED ON THE GAS PEDAL, AND DID NOT PAY TOO MUCH ATTENTION. ONE OTHER TIME IT HAPPENED, IT WAS RAINING WHEN I THOUGHT PERHAPS IT WAS THE RAIN THAT CAUSED IT. *TR

NHTSA ID

10487725

Incident

Dec 7, 2012

Mileage

109,900 mi

THE MOLDING WITH BUILT IN HANDLE BROKE WHILE I WAS GETTING INTO MY TRUCK. I FELL BACKWARD AND CAUGHT MYSELF ON THE TRUCK DOOR SO THAT I WOULD NOT FALL ONTO THE PARKING LOT. THE PART NUMBER IS 4L3Z-1503599-AAA. I REPAIRED THE TRUCK PUT IN NEW MOLDING. *TR

NHTSA ID

10470868

Incident

Aug 8, 2012

Mileage

32,120 mi

TL* THE CONTACT OWNS A 2007 FORD F-150. THE CONTACT WAS ENTERING THE VEHICLE AND GRABBED THE PULL UP HANDLE LOCATED ON THE DRIVER'S SIDE FRONT DOOR. AS THE CONTACT GRABBED THE HANDLE, THE HANDLE DETACHED FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER AND THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 68,000.

NHTSA ID

10440949

Incident

Jun 5, 2011

Mileage

60,000 mi