2015 Ford F-150 Engine Problems

The vehicle’s original engine began producing excessive white smoke during startup. The vehicle was diagnosed by AutoNation Ford, and it was determined that the passenger-side cylinder head was cracked near the exhaust port. This defect allowed coolant to intrude into the passenger-side turbocharger. Due to the extent of the damage, the engine required full replacement. The engine was replaced with a used motor under a third-party warranty on August 21, 2024. The replacement engine is now experiencing the exact same failure symptoms. Specifically, the vehicle produces white smoke at startup consistent with coolant intrusion. Bozard Ford performed a diagnostic evaluation, completed on February 27, 2026. Their findings determined that the replacement engine has the identical defect: a cracked passenger-side cylinder head near the exhaust port allowing coolant intrusion into the turbocharger. This repeated failure raises significant safety concerns. Coolant intrusion into the turbocharger and combustion chamber may lead to engine misfire, loss of power, potential engine damage while driving, and possible sudden engine failure. Additionally, burning coolant may damage emissions components and create hazardous driving conditions due to reduced visibility from exhaust smoke. The fact that two separate engines in the same vehicle have experienced the exact same cylinder head failure suggests a potential design or manufacturing defect specific to the 2.7L EcoBoost engine. I respectfully request that NHTSA investigate this issue to determine whether this is a broader safety-related defect affecting other 2015 Ford F-150 vehicles equipped with the 2.7L EcoBoost engine. Please let me know if additional documentation, repair records, or diagnostic reports are required.

Was driving at 50mph on hiway, all the sudden truck has loss of power and engine shut off, coasted down to stop, put truck in par, stared the car and drove another 5 miles and same thing happened again. No warning lite, no error messages was present when shut off happened nor during OBS scan at later time was. When second shut off happened there was a shift down happened. Not sure if the transmission speed sensor has something to do with engine shut off.

The contact owns a 2015 Ford F-150. The contact stated that while driving, there was an abnormally loud tapping noise coming from the vehicle. The engine warning light was illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling). The vehicle was taken to an independent mechanic, who determined the intake valve was bent. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was notified of the failure, but no additional assistance was provided. The approximate failure mileage was 201,456.

The transmission failed prematurely without warning. We were without power to move onto the shoulder of a 2 lane road.

Car randomly downshifting at freeway speeds. Mechanic is not sure what is wrong or how to fix. When Google, it seems to be a common issue with this year and I clearly very unsafe with people in the car on the freeway

Truck started making a loud sound from engine compartment on startup after towing camper 150 miles. The sound started to get louder and started to notice exhaust smells in the cabin. I took the truck into dealer to find out that the exhaust manifolds were warped leaking on both sides of engine due to a stud being broken that holds the manifold in place the tech said it sounds like a diesel. The service advisor at the dealership said that it is a "common problem" on the 3.5L twin turbo engine. The cab of the truck fills with the exhaust fumes to the point where the driver gets headaches unless the windows are open. I asked if there was a recall on this problem and they said NO. The same manifolds was used for years on that motor, since then Ford redesigned the manifolds to use extra studs into the heads that are already there but now want the consumers to pay to install the new design to keep the fumes out of the cab. Looking online it seems to be a problem that the turbos are heating the manifolds to the point that they warp and snap the only stud used on the rear portion of manifolds for owners that tow with the truck (that has a tow package and rated at 12500 capacity) FYI I'm only towing 5000 pounds. My concerns are that the exhaust fumes can overcome the driver an cause them to pass out or become impaired by the carbon dioxide poisoning.

Problem: Engine unexpectedly goes to idle speed after accelerating up to highway speeds. Cruise control was not engaged at time of failure. This has happened three times, all after a cold start up, and all within 2 miles of home. The most recent occurrence being 6-19-25. At time of failure, multiple warning screens come up on the dash, including "Hill Start Assist Not Available", "Service Advance Trac", "See Manual" (with a picture of a wrench). No check engine light comes on, and no error codes are set. Engine does not respond to accelerator pedal, engine will only idle roughly. When this occurs, the only remedy is to pull over to the side of the road, shut off the engine, then restart the vehicle. Each time this has happened, the engine starts and runs normally with all warning messages cleared from dash. Safety Concern: Unexpected loss of power can increase the likelihood of an accident, especially in heavy traffic. This truck is used frequently for towing, and an unexpected loss of power can create a loss of trailer control. Dealer Contact: Last September when this issue initially cropped up, the truck was taken to our Ford dealer for diagnosis. They kept the truck for approximately two weeks, driving it daily without having the issue reoccur. They performed diagnostics on electronic modules but found no concrete issue. Inspection: Truck has not been inspected by the manufacturer, only the dealer. Warning Lamps and Messages: "Hill Start Assist Not Available", "Service Advance Trac", "See Manual" (with a picture of a wrench)

The contact owns a 2015 Ford F-150. The contact stated that while driving 75 MPH, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. In addition, the check engine warning light illuminated, and the vehicle stalled. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The dealer was made aware of the failure; however, the contact was requested to pay a diagnostic fee. The contact stated that due to the persistent failure, the contact was fearful of driving the vehicle. The contact stated that the failure had occurred four times. The manufacturer was made aware of the failure, and a case was filed. The contact referenced an unknown recall; however, the VIN was not included in the recall. The contact was advised to contact the NNHTSA Hotline to report the failure. The failure mileage was approximately 80,000.

Truck is at 135,000 miles and needs its 3rd oil pan due to faulty engineering. Ford is not covering repairs or offering assistance for previously repaired products. I bought truck certified pre-owned with extended warranty. The oil pan was cracked at that time and needed to be replaced at first service. On average oil pans are lasting less then 70,000 miles. How is this allowed to continue to occur.

Intake manifold actuator fails prematurely. Code P2007 and P2005

The contact owns a 2015 Ford F-150. The contact stated that while driving in cold weather and attempting to depress the brake pedal, there was a rattling sound coming from the engine. The contact stated that the check engine warning light was illuminated. A dealer was contacted. The vehicle was taken to a dealer where it was diagnosed and determined that the rattling sound was coming from the cam phasers and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but offered no assistance. The contact was transferred to NHTSA Hotline to report the failure. The approximate failure mileage was 116,000.

Pulled into traffic and car had sudden loss of power, several alerts showed up and car could not move and just idled.

Transmission abruptly shifted down from high gear to low gear causing it to lock up at a fast speed. My son hit his chest on steering wheel bc it was so abrupt

I was driving at around 45mph and my truck suddenly downshifted automatically and almost brought me to a complete stop. It finally shifted back up and I was able to return to the proper speed. If this would have happened at higher speeds I could have been in an accident. Event at 45mph, had I not had my seatbelt on it would have thrown me into the steering wheel.

I have had the gasket for the oil pan fix two times. It is leaking again and told by ford that it will happen again. It is 1200 to have it fixed plus they have to keep it for a few days to make sure the seal is dry. If you do not check the oil all the time it could be low and lock up. I know other people that have had this problem. It is on the 2.7 Eco boost.

The contact owns a 2015 Ford F-150. The contact stated while driving at an undisclosed speed, the vehicle made an abnormal screeching sound while accelerating. There was smoke coming from the passenger's side engine. No warning light was illuminated. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic. The contact related the failure to the exhaust manifold; however, the vehicle had not been diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 121,000.

Broken exhaust bolt on passenger manifold. Exhaust leak... Felt as though Carbon monoxide gas was entering cabin portion of truck. Smelling of exhaust in cabin of vehicle. Made wife and kids nauseated and lightheaded. Did research and found out that ford had a poorly designed manifolds and didn't utilize all exhaust bolts. In turn caused the #8 bolt to snap and manifold to warp and release exhaust fumes

Truck will on occasion downshift into a low gear out of nowhere and feels like the rear axle is going to rip out of the truck.

The contact owns a 2015 Ford F-150. The contact stated that while the vehicle was in for a routine oil change, the mechanic discovered that engine oil was leaking from the oil pan. The contact was informed that the oil pan needed to be replaced. The vehicle was not repaired. The local dealer was notified of the failure, but no assistance was offered. The manufacturer was not notified of the failure. The failure mileage was 102,000.

The engine while operating at normal speed loses power to a rough idle and is remedied by putting the vehicle in park and restarting the engine. The engine never fails to start after restarting, but could fail at any moment, short or long term.