2020 Ford F-150 Suspension Problems

The contact owns a 2020 Ford F-150. The contact stated while driving at various speeds, there was a rattling sound coming from the front-end of the vehicle. Upon inspection, it was discovered that the front driver’s and passenger’s side shock absorber springs were cracked and fractured, causing damages to several suspension components on the vehicle. The vehicle was taken to the local dealer who informed the contact that the shock absorbers and springs needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 34,000.

NHTSA ID

11675580

Incident

Jul 17, 2025

Mileage

34,000 mi

With 72,000 miles the driver's side spring broke just setting in our driveway. Unknown to my wife who drove it 7 miles to work with a broken suspension spring. Within 200 miles the other spring broke on the passenger front while going down the road. Didn't hit a bump and was going straight. This one also snapped with no notice and i had visually inspected it days before. We were going 15-20 mph when it broke and were able to safely pull off the road. Unheard of them breaking when the vehicle is only driven on the paved roadways and not off used off road. Cost approximately $1,200 to just repair the driver front at a shop.

NHTSA ID

11663357

Incident

May 25, 2025

After completing a 200-mile highway drive with my family in the vehicle, I performed a routine visual inspection of the undercarriage. During this inspection, I immediately noticed that one of the front coil springs appeared to be off-center in relation to the shock assembly. Upon closer examination, I discovered that both front coil springs had shifted significantly out of position. Even more alarming, the coil spring on the passenger side had a complete fracture—it was fully cracked through. In addition, the misalignment of both springs had caused visible damage to the shock bodies, suggesting metal-on-metal contact had been occurring during operation. This is not a wear-and-tear issue or a cosmetic concern—this is a catastrophic suspension failure on a relatively new and well-maintained vehicle. Coil springs are a critical structural component designed to support the weight of the vehicle, absorb shocks, and maintain proper handling and ride height. A complete failure of one coil spring, coupled with misalignment of both, indicates either a serious design flaw or material defect. Had this failure progressed during our highway drive, especially at speed or during an evasive maneuver, the consequences could have been tragic—not only for my family, but for other drivers on the road. The loss of suspension integrity at highway speeds could lead to sudden loss of vehicle control, steering instability, or even a rollover. The fact that this occurred without any warning signs (no abnormal noises, ride quality changes, or handling issues were noticed prior to inspection) makes it even more concerning. This type of failure should not be happening on a modern pickup truck, especially one marketed for its toughness and reliability. I am filing this complaint in the hope that NHTSA investigates whether this is an isolated incident or part of a broader issue affecting other 2020 F-150s. If other vehicles are at risk of similar suspension failures, this poses a serious publ

NHTSA ID

11660141

Incident

May 9, 2025

The contact owns a 2020 Ford F-150. The contact stated while driving approximately 50 MPH, he observed a loud noise emanating from the passenger side of the vehicle. The vehicle swerved violently to the right almost driving off a cliff. The vehicle was taken to a dealer where it was diagnosed that the front coil spring on the passenger’s side strut had fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 59,000.

NHTSA ID

11581648

Incident

Apr 7, 2024

Mileage

59,000 mi

At 20,000 mile my 2020 f150 has a horrific freaking noise coming from the passenger side lower control arm. It was aligned at ford dealership 10,000 miles ago. I did check the nut and bolt to confirm they were tight. It is obvious via witness marks that the bolt is moving and removing the frame powder coating. This noise is ridiculous and I’m concerned it causing further damage.

NHTSA ID

11490503

Incident

Oct 12, 2022

While backing out of a residential driveway, While turning the steering wheel the Right front wheel caught the edge of the curb and had a catastrophic failure of the right front upper ball joint. Wheel and knuckle collapsed under the wheel well. The vehicle is new with 8600 miles on it. While removing the wheel in order to tow it, found there was no torque nut on the balljoint stud. It was transported to a certified Ford dealership where it is being evaluated for repairs. Suspension, steering, alignment, sensors are non operational and damaged. The nut was either never put on, or was never tightened. No prior warnings were given. Had we been driving at speed I have no doubt we would have sustaine major injury or worse. Dealership has reported documentation of the aformentioned problem, and pictures sent to Ford administration with no response yet.

NHTSA ID

11420468

Incident

Jun 5, 2021

Mileage

8,600 mi

RATTLE IN LEFT FRONT SUSPENSION

NHTSA ID

11375783

Incident

Nov 18, 2020

DRIVE MODE MALFUNCTION MESSAGE APPEARS IN MESSAGE CENTER. VEHICLE CANNOT CHANCE DRIVE MODES, SUSPENSION STIFFENS UP, AND ENGINE WILL GO INTO LOW POWER MODE OR COMPLETELY STALLS. MESSAGE HAS RANDOMLY APPEARED ABOUT 6 TIMES NOW. FIRST ERROR MESSAGE APPEARED ON FIRST DAY OF OWNERSHIP AT 118 MILES. VEHICLE CURRENTLY HAS 1600 MILES. 6TH INCIDENT HAPPENED 2 DAYS AGO. *TR

NHTSA ID

11327860

Incident

Feb 24, 2020

Mileage

118 mi