Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2016 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2016 Ford F-150. The contact stated while driving 20-25 MPH, he heard water sounds coming from the body of the vehicle. The vehicle was taken to the dealer, where the door drains were inspected and drained; however, the failure persisted. The vehicle was taken to a second dealer, Ford Service (1401 S Beacon Blvd, Grand Haven, MI 49417), where it was diagnosed that the sunroof rivets were installed incorrectly, causing water intrusion into the sunroof and curtain air bags. The dealer diagnosed that the sunroof, the sunroof frame and the curtain air bags needed to be replaced. The dealer forwarded the diagnostic report to the manufacturer, and the manufacturer agreed to partially cover the repair cost. However, the contact stated that the failure was due to a Manufacturer's defect; therefore, the manufacturer should completely cover the repair. …
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 contact owns a 2016 Ford F-150. The contact stated that the driver's side front door was unable to open due to being frozen shut. The contact had to aggressively pull at the door handle for an extensive amount of time for the door to open. The contact believed the failure was related to manufacturer communication with the NHTSA ID Number: 10149786 (Locks, Latches, Linkages). The dealer had been contacted but was unable to confirm if the vehicle was included in any recall campaigns. The vehicle had not been taken to the dealer. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The failure mileage was 75,000.
The contact owns a 2016 Ford F-150. The contact stated while driving at undisclosed speeds, a grinding and loud humming sound was coming from the vehicle. The vehicle was taken to the dealer where it was diagnosed with rear-end failure. The rear-end including the rear differential was replaced; however, the failure recurred. The vehicle was taken to the same dealer where it was diagnosed with the same failure. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 66,000.
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.
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 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 there was water leaking from the engine compartment into the driver's and passenger's side front floorboards. The dealer was made aware of the failure and scheduled an upcoming appointment. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 24,000.
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.
Body complaints in other F-150 years
Frequently asked questions
How common are body problems on the 2016 Ford F-150?
NHTSA has 199 complaints about the body & structure of the 2016 Ford F-150, 10% of the model year's 2,080 complaints. The component named most often is body (184 mentions).
Is there a recall for 2016 Ford F-150 body problems?
No. NHTSA lists no body & structure recall for the 2016 Ford F-150, though it has 13 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 2016 Ford F-150 body problems start?
Half of the complaints with a recorded mileage happened before about 20,000 miles, and 59% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 1 fire and 5 injuries to body & structure 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.