Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line.
full bulletin at NHTSA ↗2007 Ford F-150 electrical problems
severe 32 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
32
Recalls
0
Avg fix
$850
1crash
3fires
1injury
What stands out
Owners have filed 32 electrical 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.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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.
Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go back to the system utilities page. Navigate to the toolbox tab and run the Programmable Module Insta
full bulletin at NHTSA ↗When ordering a 2005 to 2008 remanufactured 5.4L 3v or 6.8L 3v engine, spark plug boots may be provided in the packaging. Replace all black spark plug boots from the original engine with the 'brown' spark plug boots, as provided. The updated 'brown' spark plug boots are longer than the black boots to accommodate a running change in the spark plug length. The ignition coil bodies and spring/resistor are transferable and only the rubber boots require replacement. Failure to install the spark plug boots provided with the replacement engine could lead to drivability concerns.
full bulletin at NHTSA ↗FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD, 05-06 MUSTANG, 06-08 FUSION, 04-05 EXPLORER, 05-06 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN.
full bulletin at NHTSA ↗FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2007 F-150's electrical and ignition systems show a pattern of defects that create both annoyance and serious safety risks. Spark plugs on the 5.4L Triton V8 blow out of the cylinder head—sometimes during routine replacement, sometimes while driving. The aluminum head threading is weak; when plugs are removed, they break inside, requiring expensive extraction or helicoil repair. Dealers and owners report this as a known issue with a TSB (08-1-9) but no recall, even though one driver's engine was damaged so severely it needed complete replacement at $5,000.
Power window wiring in the door frame breaks or corrodes from vibration and moisture exposure. One owner had windows fail six times and was eventually told the replacement harness was no longer available. Multiple owners state Ford dealerships are aware of this defect but refuse to issue a recall or warranty extension.
Electronic throttle bodies fail abruptly, cutting engine power and acceleration in traffic. One owner's truck shut down on the fast lane of a freeway at 70 mph with his wife and baby aboard. Owners note the same throttle body was recalled on Ford Escape vehicles but not on F-150s—despite the identical failure pattern.
Ignition coils fail repeatedly; one owner replaced three in three years. No-start conditions strand drivers regularly. Fuel pump driver modules corrode due to galvanic corrosion (aluminum base bolted directly to steel frame), causing complete engine shutdown with loss of power steering and brakes—a life-threatening situation on the highway.
Several fires are documented: one at 1,800 miles while parked, another while driving at highway speed with flames exploding from the engine compartment. Alternator wiring is damaged by AC condensation. Dashboard and instrument panels fail entirely. Acceleration sticks, back-up sensors don't work, fuel gauges display wrong levels.
Same Ford F-150 electrical reports on nearby years: 2005 · 2006 · 2008 · 2009 · 2010
Failure modes owners describe
Spark plug ejection from cylinder head
Spark plugs blow out or eject from the cylinder head, particularly on 5.4L Triton V8 engines. The aluminum cylinder head threading is weak and thin. When plugs are removed, they frequently break, requiring expensive extraction. When they eject during operation, they can damage the engine internally—cracking the crankshaft or causing additional cylinder damage. Dealers repair failures by rethreading and installing helicoil thread repair kits, which are often temporary fixes. Some owners report the problem started in the 90s across all Triton engines.
When: Failures reported from around 84,000 miles onward; some manifest during routine spark plug replacement; one case at 140,000 miles after warranty expired
Symptoms owners cite: Spark plugs break during removal; Spark plugs eject from engine during operation; Loud popping noise from engine; Loss of power and acceleration; Check engine warning light illumination; Subsequent engine knocking after replacement; Fuel vapor escaping from plug hole (fire hazard)
Codes mentioned: P0300 (check engine light; inferred from owner narratives)
Repairs/costs cited: Broken plug extraction: $90 per plug. Helicoil thread repair kit installation: ~$800. Full engine replacement: $5,000+ if head damage is severe. One owner had spark plug replacement at 60,000 miles (recommended by dealer to prevent seizure, though owner's manual states 100,000-mile interval).
Recalls/TSBs owners mention: TSB 08-1-9 exists with procedures to address the issue. Ford stated it would not address the problem until sufficient complaints were filed and NHTSA directed intervention. No recall issued despite widespread reports.
Power window wiring harness failure
Wires in the door jam and along the frame under the driver's door break, corrode, or rub through insulation, cutting power to all power windows. The wiring harness design is improper—wires are exposed or inadequately protected from vibration and moisture. Multiple owners report this as a recurring, well-known problem at Ford dealerships.
When: Failures reported from multiple years of ownership; one case mentioned six failures total with three occurring in a single year
Symptoms owners cite: All power windows stop working entirely; No power at any window switch; Burnt smell from electrical system; Potential fire hazard from arcing wires
Codes mentioned:
Repairs/costs cited: Diagnosis and repair of broken wires: $370 reported by one owner. One owner stated the dealer knew exactly where the wires were broken before inspecting. Another owner had windows disconnected and left down because replacement wiring harnesses were no longer available.
Recalls/TSBs owners mention: No recall. Ford is reportedly aware of the issue but has not issued a recall or warranty extension.
Electronic throttle body / throttle sensor failure
The electronic throttle body or electronic throttle sensor fails without warning, causing the vehicle to lose power and enter limp-home mode (loss of acceleration, wrench symbol on dashboard). The failure can occur while driving in traffic, creating a serious safety hazard. Owners report the same throttle body is used on Ford Escape vehicles that were subject to a recall for this exact issue, but F-150 owners claim they were not included in that recall.
When: Failures reported on vehicles ranging from brand new to older models; one owner reported the issue in 2012
Symptoms owners cite: Loss of acceleration; Loss of power; Wrench symbol illuminates on dashboard; Vehicle enters limp-home mode; Dashboard lights up; vehicle shuts down while driving; Gas pedal becomes unresponsive; Engine revving without control (related failure in narrative #9)
Codes mentioned:
Repairs/costs cited: Throttle body replacement cost: over $600 (one owner's actual cost). One case also damaged the alternator.
Recalls/TSBs owners mention: Ford has not issued a recall for F-150 vehicles despite similar throttle bodies being recalled on Ford Escape. Owner stated this issue was reported to NHTSA in 2012 without response.
Ignition coil failure (repeated)
Ignition coils fail repeatedly, requiring multiple replacements over the vehicle's life. One owner replaced three ignition coil assemblies in approximately three years (2011 and 2014). Failures cause the check engine warning light to illuminate and the vehicle to lose acceleration and power while driving.
When: First failure around 2011; second and third around 2014; another case at 116,000 miles
Symptoms owners cite: Check engine warning light illumination; Loss of acceleration and power; Vehicle must be pulled over to a stop; Repeated failures after repair
Codes mentioned: P0300 (implied from check engine light)
Repairs/costs cited: $94 per ignition coil plus labor (one owner's 2014 cost). One owner waited three months to accumulate time and money for the repair.
Recalls/TSBs owners mention: No recall. Owner states Ford must know about the issue but has not fixed or recalled it.
No-start / intermittent starting condition
Vehicle fails to start or has difficulty starting. One government fleet vehicle (Charleston County Public Works) experienced 40–50 no-start events and was towed to the dealership over 20 times. After PCM replacement in one case, the vehicle ran for a few days then failed to start again, leaving the driver stranded on a remote job site. The root cause appears multi-factorial; some cases involve fuel pump driver module failure, others involve battery drain or other electrical issues.
When: Ongoing throughout ownership; one fleet vehicle experienced 4 tows in a 2-week period (6/21/11–7/5/11)
Symptoms owners cite: Vehicle will not start; Difficulty starting engine; Vehicle stranded at remote locations; Battery dies after less than 2 years (in one case); Battery dies repeatedly even after overnight charging; Multiple retries needed to complete vehicle inspection due to battery failure
Codes mentioned:
Repairs/costs cited: PCM replacement attempted in one case (cost not stated); problem recurred within days. Fuel pump driver module replacement (see separate failure mode). Battery replacement requested by owner but dealer refused, blaming aftermarket stereo (stereo was unhooked but problem persisted).
Recalls/TSBs owners mention: Ford customer service stated they would believe the dealer over the customer. No recall or warranty extension offered.
Fuel pump driver module corrosion and failure
The fuel pump driver module, bolted to the steel cross-member of the frame, corrodes due to galvanic corrosion. The module's aluminum base is bolted flush to the steel cross-member, creating an electrochemical cell that accelerates corrosion. When the module fails, the engine stops running entirely, and the vehicle loses power steering and power brakes—a safety-critical situation.
When: Failures reported with no specific mileage pattern; one case occurred while driving at highway speed
Symptoms owners cite: Engine stops running without warning; Loss of power steering; Loss of power brakes; Vehicle stops in fast lane of highway; Burning odor from electrical system (in a related case)
Codes mentioned:
Repairs/costs cited: Fuel pump driver module replacement restores function. Cost not specified by owner, but he requested Ford reimburse all owners who experienced this problem.
Recalls/TSBs owners mention: Ford denied the claim in one case. No recall issued.
Engine fire / electrical fire
The vehicle catches fire while parked or being driven, resulting in total loss or severe damage to the engine compartment and interior. Multiple owners report fires with smoke and flames. In one dramatic case, the vehicle caught fire while the owner was driving at highway speed, with the front end engulfed in flames and an explosion that blew out windows. In another case, the vehicle was parked for 15 minutes at only 1,800 miles when smoke appeared. A third case involved a dashboard fire while parked. Root causes cited include spark plug blow-out (fuel vapor ignition), electrical wiring arcing, and suspected issues with alternator wiring and AC drain.
When: Fires reported at very low mileage (1,800 miles in one case, 16,000 miles in another) and mid-life (one owner's truck was driven ~20 miles before fire)
Symptoms owners cite: Loud popping noise followed by smoke; Flames from engine compartment; Dashboard fire while parked; Smoke from interior and engine compartment; Burned hood, engine, melted dash; Blown-out windshield and windows; Burning odor from front end; Difficulty starting on a constant basis (prior to one fire)
Codes mentioned:
Repairs/costs cited: Total loss in at least one case (entire front end burned, engine melted, interior destroyed). Another owner reported needing a new hood at minimum.
Recalls/TSBs owners mention: No manufacturer response documented in narratives.
Alternator and charging system failure
The charging system fails, with the vehicle displaying a 'check charging system' warning. One owner reported that AC condensation drips water onto the alternator harness, causing wire degradation and shorting. The associated TSB exists but no recall has been issued. A separate case reported alternator damage concurrent with throttle body failure.
When: Occurs after AC operation; one case at unspecified mileage
Symptoms owners cite: Check charging system warning on dashboard; Alternator harness corrosion; Shorted wires in harness
Codes mentioned:
Repairs/costs cited: Repair requires new wiring harness and drain relocation kit. Owner stated the customer should not be responsible for the repair since it is a design defect.
Recalls/TSBs owners mention: TSB exists but no recall issued.
Instrument panel / dashboard failure
The entire instrument panel malfunctions and fails to function. One owner had to replace the entire instrument panel; repair was not completed.
When: At 86,000 miles
Symptoms owners cite: Instrument panel failed to function
Codes mentioned:
Repairs/costs cited: Full instrument panel replacement required. Vehicle was not repaired (cost not stated).
Recalls/TSBs owners mention: Manufacturer was made aware but no remedy documented.
Stuck accelerator / uncontrolled engine revving
The accelerator sticks or the engine revs uncontrollably without the driver's input. In one incident, the driver was involved in a motor vehicle accident, airbag deployed, brakes slammed, but the accelerator stuck, causing the truck to accelerate and hit another vehicle and trees. In another case, the engine revved unexpectedly at a traffic light; the driver placed both feet on the brake and shifted to neutral but the problem worsened.
When: One case after motor vehicle accident; another case at ~35 mph at a traffic light
Symptoms owners cite: Engine revs without driver input; Accelerator pedal sticks; Vehicle accelerates uncontrollably; Brake and neutral shift do not stop revving immediately; Uncontrolled acceleration after accident
Codes mentioned:
Repairs/costs cited: In one case, the driver had to pull back on the gas pedal with his foot to drop engine RPMs to normal. Floor area inspected and found no obstructions.
Recalls/TSBs owners mention: No manufacturer response documented.
Brake light indicator malfunction
The brake light indicator illuminates on the dashboard without a valid brake system fault. The root cause is improper solder connections on resistors in the brake light circuit.
When: Timing not specified
Symptoms owners cite: Brake light indicator illuminates on dashboard
Codes mentioned:
Repairs/costs cited: Cost not specified by owner.
Recalls/TSBs owners mention: Ford should be responsible per owner. No recall documented.
Fuel gauge display failure
The fuel gauge displays incorrect fuel level, providing inaccurate information to the driver about fuel remaining.
When: At approximately 36,000 miles
Symptoms owners cite: Fuel gauge displays incorrect fuel level
Codes mentioned:
Repairs/costs cited: Vehicle was not diagnosed or repaired.
Recalls/TSBs owners mention: Manufacturer was not informed of the failure.
Door wiring harness failure (driver's door)
Wires in the driver's door wiring harness break or corrode, affecting multiple door-related electrical functions. One owner reported broken wires causing power windows to not roll down, radio not turning off when key is off and door is open, keyless entry keypad failure, and folding mirrors failure.
When: Timing not specified in narratives
Symptoms owners cite: Power windows do not roll down; Radio does not turn off when key is off and door is open; Keyless entry keypad does not work; Folding mirrors do not work
Codes mentioned:
Repairs/costs cited: Cost not specified by owner.
Recalls/TSBs owners mention: No manufacturer response documented.
Backup sensor failure
Backup sensors fail to function, leaving the driver without proximity warning while reversing. One owner backed into a tree in a dark driveway due to sensor failure.
When: Timing not specified
Symptoms owners cite: Backup sensors do not work
Codes mentioned:
Repairs/costs cited: Cost not specified by owner.
Recalls/TSBs owners mention: No manufacturer response documented.
Variable speed timing solenoid failure (stalling)
The variable speed timing solenoid fails, causing the vehicle to stall on the highway at 70 mph without warning. The vehicle can be restarted after cooling but the root cause persists.
When: At approximately 134,000 miles (or possibly 1,334,000 miles—narrative unclear)
Symptoms owners cite: Vehicle stalls on highway without warning; Vehicle loses power; Vehicle restarts after cooling
Codes mentioned:
Repairs/costs cited: Variable speed timing solenoid was replaced but the repair did not remedy the vehicle.
Recalls/TSBs owners mention: No manufacturer response documented.
Ignition key stuck in ignition switch
The ignition key becomes stuck in the ignition switch after the vehicle is parked, preventing the driver from removing the key after shutting off the engine.
When: On a rebuilt vehicle at very low mileage (12 miles)
Symptoms owners cite: Ignition key stuck in ignition after engine shutdown
Codes mentioned:
Repairs/costs cited: Cost not specified; also noted brakes only operated normally after driving two miles.
Recalls/TSBs owners mention: No manufacturer response documented.
Brake system delayed operation
The brakes do not operate normally immediately after starting; they only function correctly after driving approximately two miles.
When: On rebuilt vehicle at low mileage
Symptoms owners cite: Brakes do not operate normally until after 2 miles of driving
Codes mentioned:
Repairs/costs cited: Cost not specified.
Recalls/TSBs owners mention: No manufacturer response documented.
Cam phaser failure (stalling)
The cam phasers fail, causing the vehicle to stall while driving at highway speed. One owner reported the vehicle stalled at 55 mph and was diagnosed with failed cam phasers but was not repaired.
When: At 132,000 miles
Symptoms owners cite: Vehicle stalls while driving at 55 mph
Codes mentioned:
Repairs/costs cited: Vehicle was not repaired (cost not specified).
Recalls/TSBs owners mention: Manufacturer was made aware but no remedy provided.
Synthesized from 32 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had electrical trouble with your 2007 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 electrical problem on the 2007 Ford F-150?
It's a meaningful issue. 32 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 25 complaints that reported odometer mileage, most electrical failures cluster between 36,000 and 87,759 miles, with the median around 75,000. A quarter of owners report trouble before 36,000; a quarter make it past 87,759. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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/2007/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.