For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using
full bulletin at NHTSA ↗2006 Ford F-150 body problems
severe 33 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Failure mileage
Complaints
33
Recalls
0
Avg fix
$1,500
2crashes
6injuries
What stands out
Owners have filed 33 body complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA body complaint has been filed on this vehicle in over 7 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.
full bulletin at NHTSA ↗Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
full bulletin at NHTSA ↗Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
full bulletin at NHTSA ↗FORD: SOME 2006-2008 F-150 LARIAT, XLT, AND FX4 VEHICLES (EXCLUDING HARLEY DAVIDSON AND XL) MAY EXHIBIT A WHISTLE NOISE FROM THE GRILLE AREA WHEN TRAVELING AT HIGHWAY SPEEDS OF 65MPH AND GREATER. THIS MAY BE THE RESULT OF A POSSIBLE GAP BETWEEN THE TOP OF THE GRILLE SURROUND TRIM AND THE FRONT EDGE OF THE HOOD.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The narratives describe persistent frame corrosion and structural failures in 2006 F-150s. Multiple owners report severe rusting of frame rails, subframes, and areas near the rear doors at mileages as low as 50,000 miles, with some trucks described as unsafe to drive or totaled due to rust-through cracks on both sides. Owners note the corrosion occurs despite light use and garage storage, with some believing inadequate frame design—specifically lack of weep holes—traps moisture inside the frame. Two owners mention earlier model years (2001–2004) were recalled for similar issues but believe 2006 models should be included.
Body hardware failures include three documented instances of assist handles failing at attachment points—one causing a fall against a curb—and repeated rear door opening mechanism failures leading to finger injuries, including one partial amputation. Owners also report doors that won't open due to cable assembly failure, sharp unfinished door edges, and a tailgate that detached while driving and fell while unloading.
Pedal design complaints cite the gas and brake pedals as too close together, allowing simultaneous depression and causing unintended acceleration incidents. One owner reported a work boot's lace peg getting trapped behind the brake pedal, mechanically preventing safe stopping. Roof design concerns involve grooves that could collect water and ice.
Paint failures and fastener corrosion on electrical modules are documented as well.
Same Ford F-150 body reports on nearby years: 2005 · 2007 · 2008 · 2009
Failure modes owners describe
Frame and subframe corrosion
Severe rusting of frame rails, subframes, and structural components leading to cracks, rust-through holes, and complete structural failure
When: 50,000–232,000 miles; some within 5–11 years of ownership
Symptoms owners cite: Visible rust holes and rot spreading along driver-side frame rail; Cracks on both frame rails detected during safety inspections; Rust-through on both sides where cab meets bed; Subframe corrosion and bending near rear doors; Frame described as unsafe to drive; one crumpled under hand pressure
Repairs/costs cited: One owner cited $12,000 estimate for frame fabrication; another local shop performed welding repairs
Recalls/TSBs owners mention: Ford refused to take responsibility; one owner learned earlier F-150s (2001–2004) were recalled for bad frame coating but 2006 not included
Assist handle separation at A-pillar
Passenger assist handle failing at both connection points to the A-pillar, completely separating from vehicle
When: Within first 12 months, then at 36 months, then later; three failures documented on same vehicle
Symptoms owners cite: Handle completely separated and fell from vehicle; Caused passenger to fall off running board onto back against curb
Repairs/costs cited: Ford replaced the defective part with identical part after first two failures
Recalls/TSBs owners mention: Ford replaced part three times with same component; no redesign or permanent fix offered
Rear door opening mechanism failure and entrapment hazard
Interior rear passenger door handles and latches malfunction, with design that can trap fingers and cause amputation injuries
When: Multiple incidents at various mileages; one incident involved fingers pinched during opening attempt
Symptoms owners cite: Doors fail to open; cable assembly requires replacement; Handle design with thick rubber pad and ridge traps boot laces and fingers; One incident resulted in partial amputation of index finger phalange; Owner reports niece and nephew also had fingers pinched in same mechanism
Repairs/costs cited: Cable assembly replacement cited; one incident required surgery to save remaining finger portion
Recalls/TSBs owners mention: No correction offered; manufacturer unaware of some reports
Tailgate detachment and latch failure
Tailgate cover fell off while driving and tailgate latch failed during unloading
When: One incident at 62,000 miles; another during unloading operation
Symptoms owners cite: Tailgate cover fell and detached from vehicle at 15 mph; Plastic hinge part failed, allowing tailgate to fall and severely injure three fingers; Entire cover missing after recurrence
Repairs/costs cited: One owner replaced plastic part in hinge; other vehicle not repaired despite manufacturer awareness
Recalls/TSBs owners mention: Manufacturer made aware but provided no assistance in one case
Gas and brake pedal positioning hazard
Pedals positioned too close together, allowing simultaneous depression and unintended acceleration
When: Incidents during normal driving operations
Symptoms owners cite: Half of foot on gas while pushing brake, causing unintended acceleration; Owner jumped curb and crashed into wall while parking; Work boot lace peg trapped behind brake pedal ridge held foot on gas; Pedal spacing caused incident where braking increased gas input proportionally
Repairs/costs cited: One owner required vehicle repair after impact with building
Truck bed vibration and groaning
Excessive vibration of truck bed when traveling above 45 mph with accompanying rear groaning
When: Occurred during normal highway driving above 45 mph
Symptoms owners cite: Bed vibrates excessively, almost as if loose; Noticeable groaning from rear when truck goes in and out of gear
Repairs/costs cited: Service manager verified problem but was unable to fix it
Front differential bracket weld failure
Front differential bracket broke away from frame due to inadequate welding, pushing up into steering shaft knuckle
When: Occurred during 4-wheel drive operation
Symptoms owners cite: Power steering felt like going out when placed in 4-wheel drive; Bracket prevented smooth turning; Bracket had only two 1-inch spot welds instead of proper 8-inch weld
Repairs/costs cited: Mechanic repaired by properly welding existing bracket; Ford repair kit cost $600 plus unknown labor
Recalls/TSBs owners mention: Ford aware of defect and supplies $600 repair kit; refused to take responsibility or disclose labor cost
Door edge sharpness and assembly defect
Door bottom edge extremely sharp and not properly assembled, with unsealed edges
When: Occurred when wind caught front door and slammed it shut
Symptoms owners cite: Sharp bottom edge stuck into owner's leg; Injury deep enough to require staples instead of stitches; Door not put together properly with unfinished edges
Repairs/costs cited: Owner required staples for laceration repair
Paint peeling on front cap
Paint peeling off front cap below grille on multiple 2004–2006 model year vehicles
When: Owner observed on single vehicle; widespread issue noted across fleet
Symptoms owners cite: Paint peeling below grille on front cap; Owner reports most 2004, 2005, and 2006 F-150s in large company fleet exhibit same peeling
Fuel pump control module corrosion
Fuel pump control module corroded with holes through back where it mounts to frame, causing engine shutdown
When: Failure occurred while vehicle in passing lane during highway driving
Symptoms owners cite: Engine shut down suddenly on three-lane highway; Module corroded with holes through back plate at frame mounting point
Codes mentioned: Fuel pump control module failure
Repairs/costs cited: Vehicle required towing to repair shop
Roof groove ice hazard
Ten grooves in roof cab design could collect water and ice, creating projectile hazard
When: Concern raised regarding winter operation
Symptoms owners cite: Grooves in roof potentially fill with water during winter; Ice accumulation could dislodge and become projectile toward vehicles behind
Door cable assembly failure
Door cable assembly failure preventing rear doors from opening
When: At approximately 66,670 miles
Symptoms owners cite: Both rear doors failed to open; Diagnosis indicated door cable assembly needed replacement
Repairs/costs cited: Cable assembly replacement required
Decal fading and delamination
Vehicle decals faded and delaminated
When: Observed during vehicle ownership
Symptoms owners cite: Decals faded; Decals delaminated from vehicle
Truck bed structural damage from rust
Truck bed rusted through at bottom with audible noise and front tilted downward
When: At 140,000 miles
Symptoms owners cite: Abnormal sound coming from truck bed while driving 55 mph; Front of truck bed tilted downwards; Both sides of bed near leaf springs rusted; Truck bed rusted in bottom and all over
Recalls/TSBs owners mention: Manufacturer stated no recalls related to the failure
Unintended acceleration and throttle response failure
Multiple incidents of unintended acceleration where vehicle revved to 5000–6000 rpm without driver pedal input, particularly when shifting from Park to Drive
When: June 2007 through February 2008 in one case; multiple incidents documented
Symptoms owners cite: Engine failed to decelerate 2–3 seconds after removing foot from accelerator; Vehicle revved to 5000–6000 rpm without driver input; Incidents occurred when shifting into Drive; Tire squealing and vehicle drifting; one incident nearly caused rear-end collision
Repairs/costs cited: Dealership replaced throttle body; engineer allegedly accused driver of standing on accelerator instead of brake despite multiple witnesses and recorded incidents
Recalls/TSBs owners mention: Dealership installed 'black box flight recorder' to capture data; claimed recorded data was lost; engineer accused driver of pedal confusion despite driver's account and evidence
Synthesized from 33 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
'takata recall' the frame is rusted really bad and almost rusted into. The truck bed is rusted in bottom and rusted all over. I bought this truck thinking Ford didn't rust like this. Please help me. Truck is too dangerous to drive but I can't afford to get a new frame and truck bed.
Had body trouble with your 2006 Ford F-150?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the body problem on the 2006 Ford F-150?
It's a meaningful issue. 33 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Across the 25 complaints that reported odometer mileage, most body failures cluster between 50,000 and 138,000 miles, with the median around 85,000. A quarter of owners report trouble before 50,000; a quarter make it past 138,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,500 for body repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to body?
No active recalls currently cover body issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Ford/F-150.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.