Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
1996 Ford f150 4 x 4-both rear brackets connecting the leaf springs (rear of vehicle) to the frame were terrible corroded and cracked. Mechanic was fearful of failure within a month or two. Replacement parts are only available from a Ford dealership. Called local dealership and was assured parts available. Upon arrival at the dealership, not all parts available as demand had been so great they kept running out of the parts. I had to go to a different dealership to obtain the rest of the parts. The replacement parts were of significantly heavier build than original parts. Have since been informed by my mechanic and others that mid 90s Ford 150s and explorers are losing the brackets en masse. I consider this a significant safety issue as an important chasis component is more than likely to fail. These older trucks are now being handed down to high school kids. …
Oct 4, 2005-during annual state safety inspection, the inspector discoverewd that both front coil springs were broken. The breaks were aproximately 90 from the top end of each coil, leaving them unattached. The broken ends were rusty, so they had beejn in this condition for some time. The springs were replaced with new ones.
Majority of problems have been with front and rear suspension in addition to the following: cambers, slugs, toes, rotors, gear box, springs, drag links, tie rods, bushings, trans cross members, stabilizer barrs, bushings, electrical, computer, transmission, oil leaks, ignition cylinder, and replacement of four wheel drive components. Dealership tells me their hands are tied. Ford motor company only "documents" difficulties and I can't get past a customer service representative who can do nothing but put my complaints into a database. Repeated letters and phone calls have gone unresolved and Ford motor company has made no attempt at customer service! I was told today that notice would be sent to the local field office where they would contact the dealer service manager and most likely not me directly although I asked that they do so. …
Loud popping noise. Dealer was no help. Independant repair shop found and replaced control arm bushings. Originals had chemically deteriorated from application of slovents at some point at assembly. Repairs cost me $400. Attachment points were worn to the point of being oblong.
Rear leaf spring appears improperly installed. Bracket replacement was done to 1997-1998 vehicles , would like further information concerning this problem. Dealer notified and informed consumer that 1997-1998 vehicles were recalled only.
Power steering hose rusted and developed a massive leak which caused no power steering ability. Wire harness for air bag sensor not operational. Both rear springs broke under light load resulting in steering and brake failure.
Front left spring coil broke, causeing excessive tire wear, brake/rotor failure, and diminished vehicle control at highway speeds. Expenses to repair defective spring and subsequent damage to brakes/rotors in excess of $500.00.
Noticed rear of truck was not level-noticed control difference on curves in road. Inspected truck and found right rear spring shackle rusted away. Parked truck until repairs are made. The old part is still on truck.
Put in new shock absorbers but brake lining rested against the shock absorbers which rubbed a hole through the metal, causing brake failure. Contacted dealer and manufacturer, but were not able to help.
Driving at any speed the front right wheel makes a loud noise while driving, in for repair, replaced the wheel bearning, but vehicle continues have a problem.
Suspension complaints in other F-150 years
Frequently asked questions
How common are suspension problems on the 1996 Ford F-150?
NHTSA has 21 complaints about the suspension of the 1996 Ford F-150, 6% of the model year's 324 complaints. The component named most often is front (8 mentions).
Is there a recall for 1996 Ford F-150 suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 178,000 miles, and 50% before 25,000 miles.
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.