The Ford F-150 pickup truck engine, with displacement sizes ranging from the 4.2-liter Essex V-6 to the 6.2-liter Boss V-8, has had remarkably few problems. Ford Motor Company issued no recalls for any specific internal engine problems dating to 1980. Most problems have been limited to cruise control or fuel line problems leading to the engine.
About 605,684 2005 and 2006 F-150s, along with the Lincoln Mark LT luxury car, equipped with the 5.4-liter V-8 may have a brake booster vacuum supply hose attached to the engine's intake manifold that could swell and loosen. It could cause brake failure. All 2005 F-150s with the 5.4-liter engine should be inspected for this fault and have the booster replaced.
Aftermarket Purolator fuel filters manufactured from Jan. 16 to June 22, 2006, for any F-150 engine have a faulty design and may not seat properly with the fuel tube. This could lead to a fuel leak and fire in the engine compartment. It should be replaced with a properly designed fuel filter.
Perhaps the biggest engine problem in the F-150 is a faulty speed deactivation switch affecting 5 million Ford vehicles, including the F-150, which could cause a fire. Model years 1993 through 2005 F-150s are affected. The speed control deactivation switch could overheat leading to a fire at the switch. Ford will replace the switch or disconnect it until a replacement is available.
The 1999 Ford F-150 fuel pressure regulator O-ring on F-150 engines could be damaged during initial installation in the engine's fuel rail. The damaged O-ring may cause a vapor leak leading to an engine compartment fire.
The 1997 F-150 manufactured at Ford's Kansas City or Norfolk plants may have a hole in its front fuel line assembly either below the fuel rail connection or at the rear steel tube section. The hole may have occurred when the line was secured in a bracket. This could result and leaking fuel and fire. It should be inspected and replaced if necessary.
The ignition system starting the engine in 1988 F-150s may have an internal short circuit that could cause overheating and a possible fire at the steering column. Ford dealers will replace the ignition switch if it hasn't been performed since the vehicle left the assembly plant.
Similar, but separate from the fuel pressure regulator problems in the 1999 F-150s, the 1985 Ford F-150 may have a fuel rail leading to the engine that was damaged due to sharp edges or metal burrs causing the O-ring seal to not seat properly. This could lead to fuel leakage and fire and should be inspected.
