F-150 years to avoid—and the years we refuse to over-rank

The official record describes a potential crash, fire, injury, or loss-of-control consequence.

“Unintended Transmission Downshift and Rear Wheel Lock-up On March 21, 2025, NHTSA’s Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE25002) to investigate instances of unexpected transmission downshifting without driver input in model year (MY) 2015-2017 Ford F-150 vehicles (subject vehicles) manufactured by Ford Motor Company (Ford). The complaints allege that, without warning or driver input, the subject vehicles experienced a sudden and rapid deceleration often accompanied by temporary rear wheel lockup, seizure, or skidding, resulting in a loss of vehicle control that increases the risk of crash and injury to all motorists, including those not within the subject vehicles. The MY 2015 and MY 2016 F-150 vehicles were equipped with the “6R80” transmission, while the MY 2017 vehicles were equipped with either the “6R80” transmission or the “10R80” transmission. This investigation was limited to MY 2015-2017 Ford F-150 with the “6R80” transmission. ODI identified 329 Vehicle Owners Questionnaires (VOQs) related to this investigation and sixty percent of these consumers were interviewed to confirm the details of their allegations. Consumers reported that their vehicles’ transmission suddenly downshifted to a lower gear, often to 1st or 2nd gear, without driver input or advance warning. Consumers described the downshift events to be regular and repeated occurrences, with some consumers stating that they no longer drive the vehicle due to safety concerns. Forty-three percent of consumers reported experiencing at least one wheel lockup event, during which the rear tires locked, screeched, or skidded during the transmission downshift.  ODI also found that 114 of the 329 consumers reported having their vehicle’s molded lead frame or valve body assembly (which comes with a molded lead frame) replaced, 80 of which were confirmed through consumer submitted repair invoices. In its response to ODI’s Information Request, Ford provided an assessment of potential root cause of failure for the subject vehicles and how this failure is different from the failure associated with MY 2011-2014 Ford F-150 vehicles that was addressed by four safety recalls (16V-248, 19V-075, 19V-433, and 24V-444). Ford has identified that the defect in the recalled vehicle population involved lead frame supplier production issues resulting in signal loss from the Output Shaft Speed (OSS) sensor. Ford has identified that the alleged defect in the subject vehicle population involved degradation of electrical connections within the lead frame due to thermal cycling and vibration over extended time in service resulting in signal loss from the Transmission Range Sensor (TRS). Signal loss from the TRS can result in an unintended shift to neutral, unintended upshift, or unintended downshift which are regulated by a gear “shift map” based on the vehicle’s speed at the time of signal loss. According to Ford’s “shift map”, at speeds between 35-64 mph, the maximum allowable downshift would be to 2nd gear (i.e. a 6th to 2nd gear downshift event) which Ford has designated to represent the worst-case scenario for subject vehicles. Ford has also acknowledged that the worst-case scenario may also involve temporary wheel lockup. However, Ford has stated that the failure mechanism in the MY 2011-2014 F-150 vehicles—previously addressed through recalls—primarily involved OSS sensor signal loss that could result in 6th to 1st gear downshift events. This OSS-related failure mode is distinct from the TRS-related signal loss identified in the subject vehicle population. ODI has identified an additional potential safety defect associated with the alleged defect in the subject vehicles. Preliminary testing performed by NHTSA’s Vehicle Research Test Center (VRTC) showed that when the TRS experiences an intermittent signal loss, one possible outcome is a change in vehicle direction. Specifically, if a vehicle is operating in reverse up an incline when the TRS signal loss occurs, then the vehicle may shift into neutral causing the vehicle to change directions and roll forward. ODI is opening this Engineering Analysis (EA) to, among other things, perform component-level testing and vehicle testing, as well as review additional technical information to better understand the alleged defect that has been identified. To review the reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.”

The official record describes a potential crash, fire, injury, or loss-of-control consequence.

“Seatbelt Pretensioner Fire On June 18, 2018, the Office of Defects Investigations (ODI) opened a Preliminary Evaluation (PE18-008) to investigate complaints alleging post-crash fires at the B pillar in the area of the seat belt pretensioners on MY 2014-2018 Ford F-150 Regular Cab, and Super Crew Cab Vehicles. On August 24, 2018, Ford Motor Company recalled (FSA 18S27 - NHTSA #18V568) the affected population. Ford's investigation found that some front seat belt pretensioners may generate sparks during deployment in excess of Ford's specification. Sparks in the pretensioner exhaust gases inside the lower portion of the B-pillar may subsequently ignite combustible components contained in the B-pillar, such as insulation or carpet, and may cause a subsequent vehicle fire. ODI also requested relevant information from other manufacturers to assess the potential scope of post-crash pretensioner fires. Ford will notify owners and require dealers to remove B-pillar insulation material and wiring harness tape, and install heat resistant tape, free of charge. The recall notification began September 28, 2018.Owners may contact Ford customer service at 1-866-436-7332.The VOQs associated with the closing of this investigation are: 11143035, 11130056, 11129828, 11128761, 11127993, 11127880, 11124717, 11123419, 11119651, 11119626, 11114065, 11113160, 11111822, 11097937, 11078447, 11014688”

The official record describes a potential crash, fire, injury, or loss-of-control consequence.

“Windshield trim molding Item detachment On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this failure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injuries. Some consumers have reported that the failure occurred while they were driving at highway speeds, with the detached trim panel entering the path of travel of the vehicle behind them, requiring the driver of the following vehicle to take evasive action. It is noteworthy that motorists who experience this type of road hazard are less likely to accurately identify the subject vehicle the item detached from and report the event to the NHTSA. In its April 17, 2023 response to ODI’s information request, Ford provided 175 consumer complaints (including field reports) and 14,162 warranty claims related to A-pillar trim panel detachment. Ford relayed that the subject vehicles utilize a plastic A-pillar bracket, which is bolted to the vehicle structure during assembly. The A-pillar trim panel is attached to the bracket utilizing 7 plastic clips. Contributory factors which have been identified by Ford as leading to the subject defect include incomplete installation at the assembly plant, inadequate part stack up, damage to fasteners during installation, and failure to follow proper repair procedure during windshield replacements or other services. On January 19, 2024, Ford filed safety recall 24V-031 for MY 2011-2019 Ford Explorer vehicles to address the subject defect. In the Part 573 Safety Recall Report, Ford identified that a detached A-pillar trim panel can create a road hazard for other road users, increasing the risk of a crash. The recall remedy includes an inspection of the existing A-pillar trim panel and, if necessary, the replacement of the component. The remedy A-pillar trim panels will be installed with an additional adhesive for robustness and utilize an inspection procedure to ensure full engagement of all the retention clips during installation. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.”

The official record identifies a condition that deserves candidate-specific inspection and record verification.

“Rearview Camera FMVSS 111 Noncompliance On September 23, 2020, Ford Motor Company (Ford) filed a noncompliance recall report under 49 CFR Part 573 (NHTSA Recall No. 20V-575), recalling 620,246 Model Year (MY) 2020 Ford F-150, F-250, F-350, F-450, F-550, Explorer, Mustang, Transit, Expedition, Escape, Ranger and Edge, and Lincoln Nautilus and Corsair vehicles for a noncompliance with Federal Motor Vehicle Safety Standard (FMVSS) 111, Rear Visibility. Ford's recall described the noncompliance as insufficient electrical conductivity within the printed circuit board (PCB) internal to the camera leading to intermittent rearview camera operation. The supplier of the cameras was Magna Electronics.According to Ford's chronology in the Part 573, during the period February-April 2020, Ford identified and monitored warranty claims pertaining to intermittent or inoperative rearview cameras. Ford reviewed supplier product changes, focusing on changes introduced by the supplier in the October-November 2019 time frame. The Part 573 stated that the issue was brought to Ford's Critical Concerns Review Group (CCRG) for review on May 12, 2020.On July 7, 2020, NHTSA's Vehicle Research and Testing Center (VRTC) informed the Office of Defects Investigation (ODI) of a trend of MY 2020 Escape vehicles with rearview camera malfunctions. ODI contacted Ford the next day, providing five Vehicle Owner Questionnaires (VOQs) alleging inoperative rearview cameras. On July 15, 2020, Ford met with NHTSA to discuss the rearview camera issue. In a subsequent August 24, 2020 meeting, ODI and NHTSA's Office of Vehicle Safety Compliance (OVSC) met with Ford to discuss the recall status and additional VOQs. Ford presented rate and scope data for many of its MY 2020 products during the August 2020 meeting indicating high failure rates for certain models.This RQ is being opened to investigate both the timeliness and scope of Ford's rearview camera recall (20V-575), and Ford's compliance with reporting requirements.The subject reports referenced in the opening resume are identified by the following ODI reference numbers which can be reviewed at NHTSA.gov: 11349813, 11344126, 11342696, 11341486, 11340254, 11337274, 11331444, 11330875, 11329235, 11316960, 11343521, 11341884, 11337226, 11344018, and 11339573.”