Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 1996 Ford F-150. The contact stated while driving 45 MPH, the vehicle started to shutoff and restart independently. The check engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic. The mechanic informed the contact that the rear tank's fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that there was no open recall associated with the VIN for the failure. The failure mileage was approximately 130,000. The contact stated there is an issue with the front fuel tank feeding fuel into the rear tank when the rear tank pump is not operational and having to switch the fuel supply over to the front tank. When the rear tank is full from the front tank feed, it spills over out of the rear tank fill spout, and runs out on the ground.
I am unsure of what happened. This truck was sitting in my driveway and caught fire. While on fire it kept trying to start even though no one was in it and the keys were no where near it. The fire truck was called out due to the trucks proximity to the home and the fire was put out. There has not been any insoection done on the vehicle since it is burnt to a crisp.
About three minutes after I parked and shut off the truck in the driveway, I heard a loud explosion, stepped outside and saw flames shooting out from under the hood accompanied by billowing smoke. The fire lasted 15-20 minutes, went through the firewall, entered and melted down the cab. During this period of time, I was attempting to put out the fire in order to prevent it from spreading to the garage and the propane tank. As a result, I had to be treated for moderate smoke inhalation by the first responders on the scene. The truck was part of the 2005 recall concerning the leaking brake fluid and its corrosion of the electrical systems. I brought this truck to copper country Ford in order for them to perform the necessary repairs to comply with the recall notice, which, to the best of my knowledge, was performed.
Tl contact owns a 1996 Ford f150. On October 4, 2007, the vehicle burst into flames while parked on the side of the house. A tree and some of the grass caught fire. A fire report was filed. The manufacturer stated that they would not be able to determine if the fire was due to recall number 05s28 because of the extensive fire damage. The current and failure mileages were 119,934. Updated 01/02/08 the consumer believed the fire was related to the recall regarding the cruise control. Ford stated they could not find any evidence that the fire was related to the recall. Updated
Tl* the contact owns a 1996 Ford f-150. She noticed that there were fire balls under the vehicle, near the front driver side wheel and floor board. The fire department was not notified. There were no injuries. Prior to the failure, the ABS light fuse was replaced continuosly. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 140000.
Dt: the consumer drove the truck for about 2 hours and parked it at the house. After about four or five hours, the neighbor came over saying that the truck was on fire. There was no prior warning. The fire occurred under the hood.
My Ford f-150 pickup truck caught fire after it had been parked for approximately two hours. The fire appears to have originated in the engine compartment near the master cylinder. The damage was severe and if not for a vigilant neighbor, would have spread to my house.
Copy of email to Ford: I wrote to you a couple of months ago regarding an extreme level of corrosion occurring on my 1996 f150 which resulted in the oil pan rusting through only to be rebuffed. Well now the level of corrosion is even worse. The brake lines are so corroded that one of them burst and nearly caused an accident. Clearly this is not normal. This vehicle is only used for personal use and is only used on the highway for transportation. I have another vehicle, a Jeep, which sits next to it that is 5 years older that is not exhibiting the corrosion found under your vehicle. As I mentioned in my previous letter, I am the original owner and the vehicle s mileage is less than 60K. Clearly this vehicle is defective but your earlierresponse to me indicates that you don t care. …
Oil pan rusted out. I complained 1 other time about this problem. Ford is very aware of this problem. I spoke to them and they deny knowing anything about it. They are liars. My dad is retired and is vacationing next to a retired Ford worker. He has told my dad that Ford did a cost reduction idea on the paint that they use on oil pans on the trucks in the 96 range. They took out an anti chip compound that was used in the paint to save money. Ford should be responsible for the repairs. It cost me $500.00 to get the repair fixed at Ford. Ford has caused the problem and know is making a small fortune by charging the people for repairs. This is morally wrong. Hopefully you can look into this matter. If you need additional information please feel free to contact me. I spoke to one of the vp's at Ford in dearborn michigan. She lied through her teeth. A lot of people are getting cheated. …
The oil pan is rusting out and the age of the truck is very young, (1996) and the mileage is moderate. My mechanic showed me the oil seeping thourgh the oil pan. A failure will cause oil to spill in the roadway hazardous to all vehicles.
Engine complaints in other F-150 years
Frequently asked questions
How common are engine problems on the 1996 Ford F-150?
NHTSA has 26 complaints about the engine & cooling of the 1996 Ford F-150, 8% of the model year's 324 complaints. The component named most often is engine (12 mentions).
Is there a recall for 1996 Ford F-150 engine problems?
No. NHTSA lists no engine & cooling recall for the 1996 Ford F-150, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Ford F-150 engine problems start?
Half of the complaints with a recorded mileage happened before about 130,000 miles.
Is it dangerous?
Owners linked 0 crashes, 8 fires and 2 injuries to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.