Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
I purchased a 2006 f-150 on July 6, 2006 with 9,177 miles on it. On July 10, 2006 I allowed my 24-year-old son to take the truck 700 feet to his mobile home to take a washer and dryer from my home to his. He was within 3 feet of the porch of the mobile home with the truck in four wheel drive in reverse when the gas pedal stuck and knocked his mobile home about 3 feet off the foundation. He had just let off the brake a little to ease back. The truck and mobile home seem to be totaled. My husband and I went to the dealership on 7/12/2006 and he said he was not going to do a d*** thing about it and threatened to call the police. I told him the manual said to go to the dealership. Asked if I should call Ford motor company. He stated that he did not make the vehicle and he didn't know what to tell me. We paid cash for the vehicle and had it towed to a secure lot until further investigation. …
Spark plugs on the 5.3 liter engine when replaced break--in return the book said pull engine and pull heads to replace spark plugs. The law suit filled Ford admits to bad decision on spark plugs and will reimburse some of the cost. The cost is very high--the book and Ford's shop said the engine needs to be pulled to pull the heads to replace the spark plugs. There was never any software updates, and now the vehicle requires them. The error in the cluster software recall was suppose to be repaired and I read from the experts all software should have been upgraded with the cluster error. There are 42 p.m. Ford and nhsta knew or knows about on my vehicle and nothing has been done, I am a 100% dav and my vehicle has been broken down. The 2006 harley davidson f-150 that cost so much with it's on board computer system does not work. …
El dia 27 de septiembre del ao 2007 ,circulaba en mi camioneta Ford lobo o f 150 cuando sin causa aparente,se empezo a incendiar por defectos que fueron detectados en la agencia pero que nunca fueron corregidos ,como son los varios casos de los que ustedes tienen conocimiento ,cuando dicha unidad se incendio yo me encontraba en su interior poniendo en riesgo mi vida ,sin que hasta el momento Ford motor company de Mexico haga valida la garantia ,sera muy interesante para los usuarios Ford tener en cuenta en manos de quien ponen sus vidas,como es el caso de la familia denika washington quien perdio a su hija por los mismos motivos sin causa alguna se incendio su unidad Ford f 150 en mayo del 2004 este caso les sera de bastante interes para sacar a la luz publica el gran peligro que representa este tipo de unidades ,y la omision que hace Ford motor company en referencia a este problema
2006 f-150 lost all power function while traveling down the interstate. I lost power steering and brakes. The cause is a corrosive fuel pump control module. After taking with my local Ford dealer I was made aware that this is major safety issue and one that fmc refuses to recognize. This incident could have resulted in a major accident. I was lucky enough to be able to signal to the cars around me that I was having trouble - however I was still almost rear ended twice before being able to pull off to the side of the road.
The engine bucks,misses and doesn't come up to speed. There is no advanced warning as when this will happen, thus making pulling out into traffic a hazard! The garage where I had the problem fixed was surprised to hear my description of my trouble. They had a f150 in the week before with the same issue!! This gentleman's truck actually shut off in traffic,so I consider myself lucky!
While in passing lane of three lane west bound route 3 engine shut down, had to negotiate two lanes of highway traffic to get to shoulder while coasting. Vehicle towed to repair shop. Fuel pump control module failure. Module corroded, holes thru back of module where it mounts to frame.
The vehicle was being driven at 35 MPH and simply stopped running. Vehicle could not be re-started. Towed to repair shop. The mechanic tested the fuel system and determined the fuel pump had burned out. The fuel pump was replaced at a cost of $552.05. One day after repairs were completed the check engine warning light was activated and the code revealed a fuel system issue. The vehicle was immediately taken back to the same repair shop. The fuel pressure was operating at 90 psi. After several unsuccessful visits, it was eventually determined that the fuel pump control module was severely corroded and malfunctioning. The "pot" metal has been completely corroded and there is an approximate 1 inch diameter hole leading directly to the electric panel. The control module was replaced for an additional $399.89. …
Went to start truck and engine would crank but would not fire. I tried the starting fluid test to see if it was an ignition problem or fuel problem. Gave a little shot of starting fluid into the intake and then tried to start. Motor acted like it was going to start but never started beings I didn't give it enough starting fluid to start because I'm not a fan of using it. With that I eliminated the ignition had to be fuel. I got on the internet and searched no start problem for 2006 f-150 and found a you tube video of the fuel pump control module rusting out. Went out and dropped spare tire and took the control module off the cross member and noticed the hole corroded through the housing just like the video. I got the upgraded part from a Ford dealer for $163 and installed. Runs fine now. …
Ford f150 xlt 2006 should have a mandatory safety recall for the fuel control module. This is clearly a design defect and a major safety concern. I was driving down vt116 (a hilly, winding 2 lane country highway with no shoulder) in the rain at about 40mph when my truck started to buck and lose power. There was no place to pull over, so I put my hazards on and tried to limp it to a safe place to pull over. The engine stalled and I lost steering and braking power on a curve. I applied the brakes manually and wrestled the steering wheel (which no longer had any power assist). With major difficulty, I was able to bring the truck to a controlled stop. I was then able to restart the engine, limped along at 15mph, bucking and stalling 3 more times before getting to a safe place to pull over. …
I recently purchased this vehicle used but the body was in great condition and it ran good on the test drive. After three days I noticed a fuel smell in the cab and when overtaking a vehicle it started miss fire. Fortunately the dealer I bought it from had me take it to the mechanic here in town who said that it was the number five ignition coil which he replaced. The next day the problem continued so I took it back and it was the spark plugs which he replaced (400.00) but it ran well. I drove it to pa. And back with no problem but yesterday the same problem happened and now it is coil number 2 (73.00). The mechanic who has been in business for 28 years in our farm town in which he services numerous Ford trucks said that this is a serious problem with fords from the coils to the ill designed spark plugs. …
Fuel System complaints in other F-150 years
Frequently asked questions
How common are fuel system problems on the 2006 Ford F-150?
NHTSA has 59 complaints about the fuel & propulsion system of the 2006 Ford F-150, 10% of the model year's 585 complaints. The component named most often is fuel injection system › injectors (2 mentions).
Is there a recall for 2006 Ford F-150 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Ford F-150, though it has 4 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 2006 Ford F-150 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 77,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 2 fires and 2 injuries to fuel & propulsion system 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.