2015 Ford F-150 Fuel system Problems

I am reporting a potentially serious safety issue involving my 2015 Ford F-150 Lariat 2.7L EcoBoost (129,610 miles at recall service; now approximately 130,155). On XXX, Orchid Isle Ford in [XXX] performed recalls 24E03 and 26S28 (Service Order XXX). Before this recall service, I had never experienced the engine-stalling problem described below.Since the recall work, my truck has unexpectedly shut off more than six times. While slowing for a traffic light, the RPM smoothly drops and the engine quietly shuts off. I do not have to be completely stopped. I must put the transmission in Park and restart the truck, after which it generally operates normally. The truck also intermittently takes longer than normal to start. No check-engine light appears when it stalls.There was also a previous frightening incident on Saddle [XXX] before the recall service. While transporting a truck full of girls to a volleyball game, the truck unexpectedly and rapidly downshifted. A wrench warning briefly appeared. We turned the truck off and restarted it, and the warning disappeared. Recall 26S28 is relevant because it addresses an intermittent Transmission Range Sensor signal to the PCM that can cause unintended downshifting. I returned the truck to Orchid Isle Ford on XXX. They could not reproduce the stall during an 8-mile test drive and found no active codes. Their testing found fuel-pump pressure/injector readings, battery, and compression were normal. The vehicle continues to stall.The battery was recently replaced and the fuel pump was replaced XXX.I cannot establish that the recall programming caused the stalling, but the timing is concerning. I have also found reports from other 2.7L EcoBoost owners describing low idle/near-stalling after PCM updates, including reports associated with 24E03.I request that NHTSA investigate whether PCM programming, 24E03/26S28, Transmission Range Sensor/PCM communication, or related powertrain issues could cause shut INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.

NHTSA ID

11764512

Incident

Aug 31, 2026

While driving on the [XXX], close to [XXX], throttle response was lost on the vehicle. Immediately put the hazards on, turned them off momentarily to indicate a turn off to the shoulder, traffic was right behind me, with some fast movers. “Hill start assist not available” was displayed on the main panel and “trac off”/ traction control. Below approx 10 mph the vehicle started shaking violently and we came to a stop. Turned the vehicle off and started looking in the manual and online for associated issues. Was able to restart the vehicle with no annunciated issues and continued driving at a cautious speed. A few minutes later the same issue arose. Had to pull over and reset the vehicle. By this time we had committed to taking the vehicle to the Ford service center on the interstate and made it there after occurring 4-5 more times where we had to pull over during the worst time of day, avoiding traffic on the on/off ramps. We had to use heavy braking once as we were disabled and there was another disabled vehicle also pulled over and we had to stop before them with enough safety clearance. We made it to Ford. According to SB 16B32B, our truck qualifies for an expired recall based on the [XXX] plant and the production date. Ford produced P2112 code for throttle body issues. We paid for the repairs. Requesting a re-inquiry of SB 16B32B. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11763952

Incident

Sep 9, 2026

mY TRUCK HAS TWO ISSUES . BACK UP CAMERA IS FAULTY AND THE DEALER REFUSED TO REPAIR. iT WAS GOING ON AND OFF AT TIMES WHICH IS A PROBLEM WHEN YOU ARE TRYING TO BACK UP AND NOT HAVE AN ACCIDENT. THE TRUCK BRAKE PEDAL GOT STUCK AND IT WAS CAUSING MY TRUCK TO REV UP AND DOWN I WAS ABLE TO GET IT HOME AND IT COST ME THOUSANDS TO FIX AT THE DEALER. RED MCCOMBS DEALERSHIP ON I 10 IN SA TEXAS IS WHERE I GO THEY DONT WANT TO FIX ANYTHING ON A RECALL AND YOU HAVE TO PAY EACH TIME AND THEN THEY DONT FIX. I COULD HAVE HAD A SERIOUS ACCIDENT EACH TIME BUT I FEEL BLESSED THAT I DIDNT

NHTSA ID

11693786

Incident

Dec 31, 1969

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

While parked and shut off at a gas station in Lakeside, CA, my 2015 Ford F‑150 XLT spontaneously caught fire under the hood. The fire appeared to originate in the fuse box area, specifically where the fuel pump relay is integrated. The incident posed significant risk, occurring near a fuel pump while my child was in the vehicle. A gas station employee assisted with extinguishing the fire. The cause is believed to be an electrical short. There were no modifications or recent repairs.

NHTSA ID

11672103

Incident

Jun 28, 2025

It's the same issue as Recall Notice 22S02/NHTSA Recall 22v011. The replacement part is MR3Z-7583-A 1X ($2-$5 part with 30 second install), but they do not show it under parts for my truck, they would prefer to sell me the whole brake pedal assembly ($50+ part and labor probably diagnosis charge in addition to part replacement). The part becomes brittle and breaks. This caused dead battery, 5 hours from home, due to lights staying on, allowed me to start and put truck into gear without touching the brake, lost acceleration between 45 & 50 mph, cruise control would not turn on and message presents that hill assist is not available.

NHTSA ID

11638308

Incident

Jan 17, 2025

Fuel inlet light on

NHTSA ID

11633723

Incident

Jun 28, 2024

What component or system failed or malfunctioned, and is it available for inspection upon request? Transmission lead frame - error P072 - traveling on the interstate at 65mph and transmission downshifted in 1st gear nearly causing the car behind me to rear-end me. Lucky i wasnt killed or serioiusly hurt. How was your safety or the safety of others put at risk? yes Has the problem been reproduced or confirmed by a dealer or independent service center? yes Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others?yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? no

NHTSA ID

11605199

Incident

Jul 8, 2024

STARTED TRUCK AND DROVE ABOUT 1/4 MILE WHEN IT LOST ALL POWER AND NUMEROUS MESSAGES STARTED FLASHING ON THE SCREEN. TRUCK HAD NO POWER AND I HAD TO PULL TO THE SIDE OF THE BLVD TO LET OTHER TRAFFIC PASS. SHUT ENGINE OFF AND RESTARTED. STARTED OKSY BUT RETURNED HOME. LEARNED FROM MY MECHANIC 180 MILES AWAY THAT IT IS THE THROTTLE BODY, A COMMON PROBLEM TO WHICH THERE IS NO RECALL BUT POSSIBLY AND EXTENDED WARRANTY. TRUCK HAS 49,253 MILES ON IT.

NHTSA ID

11604687

Incident

Jul 22, 2024

Throttle body failure approx every 45,000 miles. Bought F-150 new, now driven it approx 135,000 miles. Failure occurs when driving a various speeds, incl 75 mph. Engine shuts down, complete loss of power. DANGEROUS situation; safety at risk! Unexpected & random loss of power - w/ passengers aboard - in various traffic situations. After engine shuts down, restarts, then randomly shuts down until a new throttle body is installed. First throttle body failure repaired (=throttle body replaced) @ Ford Dealership in Price, UT. 2nd failure repaired @ Ford dealership in Hamilton, MT. Both covered by extended warranty. 3rd failure repaired [XXX] @ Hamilton, MT @ $324.55 personal expense. Check engine light warning occurs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11591358

Incident

May 21, 2024

Chech engine light keeps coming on. Dealer said it was an evap canister issue, I told them warning had come on prior for check fuel fill cap. (Capless). Said they needed to replace purge cylinoid. So as I'm paying $500 for the repair, I'm told this might not fix the issue. What? Started with small evap leak. And fuel door codes. That only came on at 1/4 tank used. Now it's a large leak that comes on every time I start the engine. And I got the check fuel fill door warning again. I've done every trick listed on forums to clean and lubricate the fuel fill door, it did help for a while but as stated above problem is now much worse. Dealer should know how to fix this issue once and for all. Forums note that this is a common problem with no quick solution.

NHTSA ID

11587912

Incident

May 9, 2023

The throttle body will randomly get stuck either shut or open and when this happens the truck goes into a “limp” mode that makes the truck lose all power. There is no warning of when it will happen or to get your vehicle checked. If this were to happen pulling into traffic it could cause a serious wreck since you cannot get the truck to accelerate in any way. This problem has been reproduced numerous times.

NHTSA ID

11540814

Incident

Aug 25, 2023

My 2015 3.5l ecoboost had the Exhaust manifolds replaced back in 2018 when my truck had 51,909 miles on it and now at 90,000 miles the new manifolds warped and snapped off a stud bolt to which the American Fork Utah Ford Dealership said that since it was over a year ago even though it was a known issue that was covered under warranty I will have to pay out of pocket over $2,000 per manifold... this is a known issue with the manifold warping and causing exhaust leaks when the stud bolts snap off. Ford needs to recall this design flaw and pay for the fix.

NHTSA ID

11530489

Incident

Jun 29, 2023

at 63000 miles in June 2021, randomly while driving, it presented warning "Hill Start Assist unavailable" and other traction control warnings,, throttle goes to idle in traffic, vehicle coasts and dies. Key off & on restarts it. Code P2112. Ford dealer replaced throttle body motor under extended warranty on June 3, 2021. MotorCraft Part has 2 year warranty. On June 17, 2023 (14 days out of part warranty), at 93,000 miles truck does identical behavior. Starts & runs fine, presents warning with random frequency (4 times this morning) at various speeds from 30 mph up to 75 mph in freeway traffic. Throttle goes to idle, truck coasts at 3-5 mph until ignition key recycled. happened this morning at 65 mph on freeway in construction zone with no safety shoulders. VERY dangerous!!!

NHTSA ID

11527678

Incident

Jun 19, 2023

While driving with my family the truck gave several error messages and a check engine light. I pulled over immediately because the truck lost power and the stability control started shaking violently. I was able to safely maneuver out of traffic, but I cannot imagine what would have happened if I was on a busy highway instead of a small side street. Apparently this is an issue that has been fairly common with Ford from what I have seen online. The vehicle is at the mechanic now for repairs. He has determined that the Throttle body needs to be replaced.

NHTSA ID

11522045

Incident

May 13, 2023

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.

NHTSA ID

11508555

Incident

Feb 21, 2023

Failing Exhaust manifold and studs

NHTSA ID

11502073

Incident

Aug 20, 2020

Throttle Actuator control system error (Hill Start Assist Not Available/Service AdvanceTrac). Vehicle lost accelerator power at highway speed in traffic. Traveling at highway speed without the ability to accelerate resulted is difficulty exiting to the shoulder when vehicle lost acceleration. Computer code error P2112 was later diagnosed with subsequent check engine light. This is a known problem. As such, Ford had issued a temporary Service Bulletin 16B32B for this issue on various models. However this narrow window for repair is not adequate for the issue at hand.

NHTSA ID

11478073

Incident

Aug 7, 2022

Warped exaust manifolds due to broken bolts. Both sides. Result in bad emmisons and possibly of carbon monoxide entering occupied cabin and poisoning passengers. Glazing/ warped rotors. Unknown cause.

NHTSA ID

11462790

Incident

Mar 1, 2022

The fuel economy for my truck is not working at the best I’ve have gone from medium gas mileage to poor (at its best) 18-20 mpg - 10 or less

NHTSA ID

11459614

Incident

Oct 15, 2021

Unknown: On 1/2/2021 at approximately 11:30pm, we were awakened by neighbors to warn us that our home was on fire. Neighbors witnesses an explosion from our truck, that blew up most of the Ford F-150 and cause major damage to my van next to it. The fire department has investigated the explosion and listed cause of fire to Be electrical issues from the Ford F-150. Thankfully no lives were lost, but would like to see that This be investigated to avoid loss of life as a preventative measure.

NHTSA ID

11446254

Incident

Jan 2, 2022

Warped exhaust manifold. The design of the exhaust manifold where it connects to the turbo is not engineered correctly and only has 2 mounting studs. The heat generated from both the exhaust and the turbo is more than the 2 manifold studs can handle and the exhaust manifold warps causing a broken manifold stud and exhaust leak. This is clearly an engineering design fault and this part should be recalled. Loss of performance, and fuel economy. No warning signals in the vehicle. This is the second time that the exhaust manifolds have warped. The first time was covered under the powertrain warranty and replaced by the dealer at +/-60,000 miles. This problem has now occurred again and is no longer covered under warranty at 86,000 miles

NHTSA ID

11445638

Incident

Oct 14, 2021

While driving at 70 mph in heavy traffic the vehicle experienced a complete loss of power narrowly avoiding an accident. Suspect failed throttle body was the cause for loss of power.

NHTSA ID

11440166

Incident

Nov 11, 2021

Manifold leak.

NHTSA ID

11431485

Incident

Jul 30, 2021

Went into 'limp mode'. Advance track, hill descent warnings. Wouldn't throttle. stopped going downhill. Known Throttle Block problem.

NHTSA ID

11430914

Incident

Aug 28, 2021