2016 Ford F-150 Body & Structure Problems

Door latches seize in cold temperatures. If you can get the door open, it won't latch when you close the door. I must hold the door shut and lock the door for it to latch. Then, the handle becomes incredibly difficult to pull and open the door. I have pulled out only to be alerted that my door was open, but I have also exited the vehicle, closing the door behind me, not realizing that the door did not latch and was open and unlatched the entire time. The inability to secure my vehicle and the risk of entrapment is concerning. A door should work. This has been happening the entire time I've owned the vehicle but I typically make do and get through the winter but I recently saw this had a recall once upon a time though I show no record of that for my vehicle.

Frame is rusted through along the bottom weld. Most likely water, sand and debris entered the frame from side openings and this corrosive mixture sat in the bottom of the frame as there were no drain holes nearby. The problem was discovered by a Ford mechanic and the dealership said they could not repair it, and to try a collision center. An auto body said they could not strengthen the frame as Ford does not allow welding but they could replace the frame for $9,179 plus other cost for draining fluids, etc.

The Hood is peeling the clear coat. The upper cab on both drivers side and passengers side from front to back is down to bare metal. Top of the pickup box is down to the bare metal along both sides. Tailgate top is down to bare metal. These spots are clearly do to the prep and paint work.

The frame is rotting through. It was on a lift for a new starter; this resulted in the frame bending. It will not pass inspection. Ford refuses to repair /replace the frame as it is past their 5 year rust warranty. The vehicle has only 15000 miles. It has never been immersed in fresh or saltwater. The undercarriage has been sprayed off regularly when driven in the winter.

The contact owns a 2016 Ford F-150. The contact stated that the subframe was severely rusted. The vehicle was taken to the local dealer for a routine oil change and was determined that the subframe was severely rusted. The dealer was unable to be raise the vehicle up on the hydraulic lift. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 120,076.

The contact owns a 2016 Ford F-150. The contact stated that while undergoing a routine inspection at an independent mechanic, the contact was informed that the vehicle failed the inspection due to a rusted subframe. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted, opened a case, and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 40,000.

The contact owns a 2016 Ford F-150. The contact stated that upon opening the front passenger's side door, the contact noticed that water had leaked into the interior of the door panel through the rubber seal. There was no warning light illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 128,000.

The contact owns a 2016 Ford F-150. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact noticed an abnormal sound coming from the vehicle. The contact who is an independent mechanic had the vehicle with a fractured sub frame and bracket. The contact stated that the sub frame had a 6-inch hole. The contact stated that the sub frame and the bracket needed to be cleaned and re-welded. The vehicle was repaired. In addition, the contact stated that the metal showed stress cracks. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 91,000.

The door latches on some of the f150s, including mine, freeze under certain weather conditions. This presents the latches from opening. This can trap an individual inside in an emergency situation, or prevent someone from opening the door external to remove or address babies and children, which is an issue I experienced. Ford is aware of the problem, but will not repair unless the issue is replicated in an unrealistic environment. This leaves many owners at risk of a dangerous situation should the issue occur in a non-controlled environment. The inverse issue can also occur, where the door latches does not close properly and can cause the door to open during driving, and this has also been experienced. There are no warnings of the problem ahead of time.

Front passenger door failed to latch properly. The door will not close when pushed shut. Door is available for inspection upon request. Multiple family members ride in the front passenger seat and this door failing to close and latch properly does cause a serious concern for their safety. I avoid putting any passenger in the front passenger seat because it's is completely random if the door will latch and shut or if it will pop open while driving. Problem was reproduced and confirmed by local dealership but disputed by them. Vehicle has not be inspected by manufacturer, police or insurance. There was no warning lamps or messages of the problem prior to the failure. The only message is that the passenger door is open which is a typical message when any door is opened when entering and exiting the vehicle. It is not a warning. Just a reminder. Doors shutting, latching and locking properly are a major safety concern that no vehicle owner should have to stress over. I cannot safely put my family in this truck knowing that at any moment the door will not latch or that it will open as we drive down the road.

The contact owns a 2016 Ford F-150. The contact stated that while in reverse (R), he observed a loud snapping noise. The contact stated that he exited the vehicle and observed the driver's front tire was turned oddly in the right direction. The vehicle was towed to a dealer where it was diagnosed that the frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 90,000.

The contact owns a 2016 Ford F-150. The contact stated that while the vehicle was parked, the contact became aware that the chassis frame underneath the vehicle was fractured and had started to crack. There was no warning light illuminated. The vehicle was able to restart; however, the failure recurred. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 90,000.

Tailgate is corroding at the hinge assembly, due to aluminum body panel and steel hinges causing galvanic corrosion. Possible that the tailgate could fall off on the road from accidentally pressing automatic tailgate release on key fob if the hinge fails and/or in addition to a person getting hurt when opening the tailgate, or climbing in the truck bed, whie loading or unloading a heavy object should hinges fail. Ford engineering basically told me "oh well" and offered no help. I live in the rust belt. This has taken 7 years to show up.

Driver side door would not close after opening assuming due to frigid temperatures. Had to hold door closed in transit.

On 2/18/2019 took the F-150 to Mathews Ford Marion Ohio service to address several issues. First, the tailgate had unexpectedly opened striking a trailer jack and damaging the tailgate. Tailgate opening while driving with cargo could result in cargo falling onto roadway. Damaged tailgate remains on the truck and is available for further inspection. Second, the owner heard rubbing/grinding noises when switching in and out of 4 wheel drive. The service technician could not replicate either issue. On 11/29/2023 took the F-150 to Leroy's Service Center in Delaware Ohio as the dashboard indicated several messages including required oil change (although odometer showed an oil change was not needed for another 3,000 miles compared to oil change sticker on windshield), a large yellow wrench adjacent to required oil change message, a small yellow wrench below required oil change message, and a yellow check engine light. Twice there was sensation of slipping (applying gas but no movement). Once parked in Leroy's lot the truck could not be started. Service technicians suspected LEAD frame failure. Service technician replaced the original LEAD frame with Ford Part numbers 2592734 and aL3z-7g276-d 1x (off replacement part box). I retained malfunctioning part for inspection if desired. Numbers off the malfunctioning part include aL3p-7g276-ak a9-21416-0998 c108p; Ford b556d; 3264 487 321 09 330743; Continental 3a8214160008 a2c53308751. Malfunctioning transmission while driving could cause unexpected vehicle slowing or stoppage. In summary, experienced unexpected tailgate opening, History of transmission issues (unexpected sounds when switching into or out of 4 wheel drive), and failure of the LEAD frame with slipping and inability to start vehicle after it was parked.

Doors do not latch/stay latched when temperatures have dropped to freezing and below.

Driver side door will not close or unlocked by fob or door lock button

Rear window cracked for unknown reason, searched only and serveral trucks has same known issue

I've noticed on 2 separate occasions my tailgate opening while driving. I see I separate recall but it doesn't include my vehicle year.

I'm writing in concern about my 2016 F150 brake lights. This concern is due to the rear break light assembly is breaking for no reason. I am on my third set of break light assembly. The driver and passenger side rear break light assembly keeps breaking on its own. There have been no accidents involving the rear end of the truck . It's becoming a safety concern . Looking to see if any other incidents have been reported. Please see attached photos of the most recent break light assembly and take note when the break light assembly clips into the truck the mounts are completely broken . The plastic where the screws would be going from the bed of the truck are severely cracked.