2015 Ford F-150 Body & structure Problems

I can have the vehicle available for inspection. I have to hold the truck door shut while driving it when the issue happens. There has been no confirmation of the issue by a dealer or independent service center. There has been no inspection of the problem by the insurance company, manufacture, police or others. This year during cold weather the issue started. I bought the vehicle used. -------------------------------------------------------------------------------------------------------------------------------------------- I have a 2015 f150 and when it gets cold i can open my driver's side door, but when i go to close the door, it won't latch.   The inside door handle is really loose, like it's not attached to anything.  Once the vehicle heats up, the door handle gets stiffer, like it is connected and I'm able to close the truck door.  This only happens when it's extremely cold outside.  I was told by a ford dealer that this is not a recall door actuator problem.  They think it may be the door cable that connects to the inside door handle.  They stated it may or may not be a warranty replacement and not a recall.  They say it would be around $149 to diagnose the door problem, and if it's not a warranty replacement, I will have to pay the diagnosis cost and repair cost.  They say the only way to know if the door repair is under warranty is for them to go inside the door and diagnose.   So this is my concern.  I have an extended warranty on the truck and it runs out at 147,000 miles.  I'm at 144,000 miles.  If I take the vehicle to them and they take the door apart and then say it's not a warranty or recall issue, this could cost a lot of money.  With all the problems that the F150 has with the door lock problems when the temperature gets cold, it seems to me that Ford should know right away that my truck door problem is a common problem and it should be covered immediately under a recall or warranty.  I bought the truck used.  Let me know your thoughts on this.

NHTSA ID

11715238

Incident

Jan 1, 2026

Ford F150 1FTEW1CPXFFC58647, caught fire while parked and unoccupied. PRINCETON, TX Fire Dept was not able to identify cause and origin of ignition / fire. Vehicle is available for inspection. Vehicle caught firer while we where asleep. Vehicle was looked at by fire dept and origin of fire was undetermined.

NHTSA ID

11689552

Incident

Sep 7, 2025

Track of rear cabin sliding door came unglued and popped off track while driving down highway in rain. Water entered vehicle. Looked online and found numerous complaints for 2015-2020 Ford F-150. Why is there no repair for this? [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11681955

Incident

Aug 20, 2025

The contact owns a 2015 Ford F-150. The contact stated that while an independent mechanic was servicing the vehicle, the mechanic informed the contact that the frame was severely rusted, and the contact then noticed the failure. The mechanic informed the contact that water had intruded into the frame and had become stagnant at the lower point of the frame, causing the severe rust. The vehicle was taken to several auto body repair shops, where the contact was informed that the vehicle could not be repaired, and the failure could be related to a recall. The contact stated that CT Frameworks was contacted, and an appointment was scheduled for the frame repair. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 60,000.

NHTSA ID

11680715

Incident

Aug 13, 2025

Mileage

60,000 mi

The contact owns a 2015 Ford F-150. The contact stated that upon taking the vehicle for State Inspection, the contact was informed that the frame was severely rusted and that the vehicle would fail inspection. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 110,000.

NHTSA ID

11675903

Incident

Jul 10, 2025

Driver side Door latch won’t latch when cold- below freezing temperatures. The door stays frozen in the open position and is unable to latch closed Stays open when driving

NHTSA ID

11640113

Incident

Jan 27, 2025

The contact owns a 2015 Ford F-150. The contact stated while driving approximately 70 MPH, there was an abnormal sound coming from the rear window. No warning light was illuminated. The vehicle was taken to a dealer where it was diagnosed that the rear window assembly needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 90,000.

NHTSA ID

11625471

Incident

Nov 4, 2024

Mileage

90,000 mi

The contact owns a 2015 Ford F-150. The contact stated that while an independent mechanic was performing an oil change on the vehicle, the contact was informed that there was a hole in the passenger's side subframe, at the cross member and transmission connecting point. The dealer was notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 39,970.

NHTSA ID

11585824

Incident

Apr 27, 2024

Mileage

39,970 mi

The contact owns a 2015 Ford F-150. The contact stated that while the vehicle was at the dealer for a scheduled oil change, the contact was informed that two bolts were fractured on the exhaust manifold. The contact was informed that the exhaust manifold and assembly needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 100,358.

NHTSA ID

11563837

Incident

Dec 20, 2023

Mileage

100,358 mi

Panoramic roof leaks water which can cause water to drain into vehicle. Causing mold to accumulate (black mold) which is hazardous to a person’s health.

NHTSA ID

11529737

Incident

Jun 1, 2023

The doors won't latch properly in subfreezing temperature causing the door to pop loose during driving. They haven't opened completely yet but they could.

NHTSA ID

11504383

Incident

Jan 30, 2023

The contact owns a 2015 Ford F-150. The contact stated that while driving approximately 70 MPH a loud wind noise was suddenly present inside the vehicle. Upon inspection it was discovered that the front driver side door had come unsecured and was not completely closed. The local dealer was contacted and informed that the failure was due to a front driver side door actuator malfunction. The vehicle was not repaired. The manufacturer was also contacted but no assistance was offered. The contact indicated that the manufacturer extended warranty coverage addressing the issue had expired. The failure mileage was 151,000.

NHTSA ID

11487290

Incident

Sep 28, 2022

Mileage

151,000 mi

The mounting bracket on the frame for the lower control arm on the front passenger side of the vehicle cracked and broke away from the frame thus leaving the control arm unattached to the vehicle which caused the tire/wheel to be uncontrollable. At highway speeds, the vehicle would roll.

NHTSA ID

11479536

Incident

Aug 13, 2022

The contact owns a 2015 Ford F-150. The contact stated that while closing the rear door he heard an abnormal rattling noise. The smaller rear window was hanging down. The top railing glue had detached from the rod. The window hit the rear occupant on the head. There were no reported injuries, The vehicle was taken to the local dealer but was not diagnosed or repaired. The manufacturer was contact The failure mileage was approximately 52, 500.

NHTSA ID

11458703

Incident

Mar 25, 2022

Mileage

52,500 mi

Despite several recalls dealing the the doors freezing open due to water intrusion in the door latch cables, my left rear door froze open (again) last year the right rear door froze open. At both times the door had to be secured with a ratchet strap to take for repairs. Ford is unwilling this time to repair this defect at no cost. I can't be the only person with this safety issue. It gets cold in Montana, I shudder to think what would happen if a passenger fell out because the door won't latch or suddenly opened in the winter.

NHTSA ID

11451226

Incident

Dec 20, 2021

Rear power windshield shattered while it was parked in the sun. We were on a hike and came back and the window was shattered. Temp was approximately 85 degrees. Rear bed cover was on and metal button was touching the window. Not sure what caused it to shatter

NHTSA ID

11423808

Incident

Jul 7, 2021

TL* THE CONTACT OWNS A 2015 FORD F-150. THE CONTACT STATED WHILE DRIVING IN INCLEMENT WEATHER, HE BECAME AWARE THAT THE WINDSHIELD WAS LEAKING AND CAUSING THE CARPET TO CONSTANTLY BE WET. THE CONTACT STATED THAT THE CARPET BECAME MOLDY DUE TO THE LEAK. THE VEHICLE WAS TAKEN TO REINEKE FORD LINCOLN, INC. (12000 COUNTY RD 99, FINDLAY, OH 45840) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE WELDS BEHIND THE WINDSHIELD NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 71,000.

NHTSA ID

11415083

Incident

Mar 15, 2021

Mileage

71,000 mi

AS IT RAIN OR DURING VEHICLE WASHINGS, NOTICE THAT WATER WAS LEAKING FROM THE A-FRAME TRIM ON THE DRIVER SIDE OF THE VEHICLE. ALSO FOUND THAT WATER WAS COLLECTING INSIDE OF THE DRIVERSIDE REAR DOOR BETWEEN THE SHEET METAL. UNSURE OF HOW THE WATER MANAGE TO GET INSIDE AND COLLECT BETWEEN THE SHEET METAL. I REMOVED THE DOOR GASKET AND THE WATER DRAINED FROM THE BOTTOM HOLES THAT HOLDS THE DOOR GASKET ANCHORS AT THE BOTTOM OF THE DOOR. COLLECTED CLOSE TO A HALF GALLON OF RAIN WATER. AS I WAS DRIVING I COULD HEAR THE WATER MOVING AROUND IN THE DOOR PANEL AND ORIGINALLY ASSUMED THAT IT WAS THE GAS IN THE GAS TANK, HOWEVER, AFTER I OPENED THE REAR DRIVERSIDE DOOR, I HEARD THE WATER MOVING AROUND INSIDE THE DOOR PANEL. WATER COLLECTS WHEN DRIVING AND WHEN VEHICLE IS STATIONARY.

NHTSA ID

11397520

Incident

Feb 17, 2021

Mileage

75,000 mi

SUNROOF STICKS ,BINDS AND MAKES CRACKING POPPING SOUND

NHTSA ID

11378419

Incident

Dec 1, 2020

Mileage

46,000 mi

DRIVER SIDE DOOR WILL NOT LATCH AT TIMES. THIS HAS HAPPENED 3 TIMES ALREADY AND I HAVE ONLY HAD THE VEHICLE 2 MONTHS. THE FIRST TIME I HAD TO UNLOCK AND LOCK IT MULTIPLE TIMES OT GET IT TO OPEN THE NEXT I HAD TO SHUT OFF THE ENGINE AND THE THIRD TIME I HAD TO PRESS IN THE MAUAL LOCK FOR IT TO LATCH. IT DID NOT LATCH WHEN STATIONARY OR WHEN IN MOTION.

NHTSA ID

11377825

Incident

Dec 3, 2020

Mileage

52,000 mi

THE REAR DOORS ON MY TRUCK EITHER FREEZE SHUT, FREEZE OPEN OR OPEN WHILE I AM DRIVING. I HAVE DONE THE RECALL WORK FROM FORD AND THEY TOLD ME THEY CAN'T CONTINUE TO DO RECALL WORK THAT HAS ALREADY BEEN DONE.

NHTSA ID

11375572

Incident

Nov 1, 2020

Mileage

24,000 mi

OIL PAN REPAIR WAS UNSUCCESSFUL. BEGAN LEAKING 17,000 MILES AFTER INITIAL WARRANTY REPAIR. TRUCK CURRENTLY HAS 71,000 MILES. 2ND ISSUE IS PAINT OVER WINDSHIELD IS PEELING. IT APPEARS TAPE WAS NOT REMOVED AND PRIMER DID NOT ADHERE.

NHTSA ID

11365140

Incident

Oct 13, 2020

Mileage

71,000 mi

WAS DRIVING ON HIGHWAY, CRUISE SET AT 55MPH, CAME OVER A HILL TO A CAR STALLED IN THE ROAD. I COULDN'T STOP, BOTH VEHICLES DECLARED TOTAL LOSS. DIRECT HIT, FRONT OF MY 2105 F150 TO THE REAR END OF A FORD FOCUS, APPROXIMATELY 40MPH. SEATBELT TIGHTENED AND LOCKED UP, LEFT BRUISES ACROSS MY HIPS, AIRBAGS DID NOT DEPLOY. HIT MY FACE IN THE STEERING WHEEL, BRUISED KNEES ON DASH.

NHTSA ID

11364735

Incident

Sep 18, 2020

Mileage

84,000 mi

REAR GLASS ON ON F150 SIMPLY SHATTERED THIS MORNING WHILE CLOSING DOOR. IT WAS 45 DEGREES WITH NO WEATHER. IT JUST SHATTERED, NO IMPACTS, NO OBJECTS.

NHTSA ID

11362992

Incident

Oct 6, 2020

Mileage

45,000 mi

THE "MOON ROOF" ON THE TRUCK WHEN I WENT TO OPEN IT BECAME "JAMMED" AND WOULD NOT GO BACK TO CLOSED POSITION NOR WOULD IT OPEN THEREFORE IT WAS (THE PASSENGER SIDE) NOT AN AIR/WATER TIGHT SEAL. I HAD TO TAKE IT TO THE DEALER FOR A $2300 REPAIR. THE REPAIR, TO THIS DAY IS STILL NOT 100% CORRECT. IN LOOKING ON LINE MINE IS NOT THE ONLY TRUCK THIS HAS HAPPENED TO. SOMETHING IS NOT RIGHT WITH THE MECHANICS OF IT AS I HAVE OPEN AND CLOSED THE MOON ROOF, AT THE MAXIMUM OF, 12 TIMES SINCE I PURCHASED IN 2016, SOMETHING IS JUST NOT RIGHT WITH THAT FEATURE TO BE USED SO SELDOM AND WHEN IT BREAKS DOWN THE COST BEING SO EXTREME.

NHTSA ID

11344127

Incident

Apr 3, 2020

Mileage

41,300 mi