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full bulletin at NHTSA ↗2007 Ford F-150 engine problems
severe 120 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
120
Recalls
0
Avg fix
$3,100
1crash
5fires
1injury
What stands out
Owners have filed 120 engine 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.
Engine accounts for 24% of all owner complaints filed against this vehicle, across 12 categories tracked.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine 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.
Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only camshaft/camshaft roller follower(s) requiring replacement, replace all of the camshaft roller followers on both banks/cylinder heads with part number 3L3Z-6564-A, not just the faulty roller follower(s). When replacing the camshaft roller followers, refer to Workshop Manual (WSM), Section 303-01.
full bulletin at NHTSA ↗The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗LINCOLN/FORD: WHEN DRIVING FROM IDLE UP TO 1200 RPM, THERE MAY BE AN INTERMITTENT RATTLE NOISE COMING FROM ENGINE. 2004-2013 F-150, F-250, F-350, EXPEDITION, MARK LT, NAVIGATOR.
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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2007 F-150 engine complaints cluster heavily around five major problems. First, factory spark plugs break or blow out of the cylinder head, often during removal but sometimes while driving. When they fail, you get violent shake, rough running, and loss of power. The worst part: broken plugs lodge in the head or strip threads, forcing you to choose between removing the head (expensive) or replacing the whole engine (very expensive). Repairs run $262 to $3,500, and many mechanics won't even attempt spark plug work because the failure rate is so high.
Second, the cam phasers and timing chain fail prematurely, causing oil pressure to drop to zero even when the pan is full. You get knock, shake at idle, and sudden stall—no warning. Engine rebuild or replacement is the only fix, costing $3,500 to $8,000. Ford admits the engine design changed after 2007, which tells you they knew.
Third, the throttle body quits repeatedly. Vehicle loses power, especially dangerous when merging. One owner had three failures by 130,000 miles.
Fourth, unintended engine surge (revving to 6,000 RPM at startup or while parked) has caused near-crashes.
Finally, owners report fuel pump module failure (sudden stall, vehicle dead), transmission cooling line corrosion (fluid leaks), and crankshaft bearing failures that seize the engine solid. Ford refuses recalls and tells owners these are not covered under warranty, even when the failures are known design flaws.
Same Ford F-150 engine reports on nearby years: 2005 · 2006 · 2008 · 2009 · 2010
Failure modes owners describe
Spark plug breakage and expulsion
Factory spark plugs break or shear off during removal or spontaneously blow out of the cylinder head during operation. When they break, the threads tear out of the head or the plug separates, leaving metal fragments stuck in the cylinder. Replacement attempts frequently result in additional plug breakage. Some owners report plugs exploding out mid-drive, causing violent shaking, rough idle, loss of power, and dangerous drivability.
When: Reported from 22,000 miles onward; some failures under 100,000 miles, recurrence common even after replacement
Symptoms owners cite: Plug blows out or shatters during removal; Violent engine shake and vibration; Rough idle and misfire; Loss of power or acceleration hesitation; Loud bang or explosion-like noise from engine; Strong fuel smell in cab
Codes mentioned: Cylinder misfire codes (variable by cylinder), Check Engine Light
Repairs/costs cited: $262–$3,500 reported. Simple replacement can cost $600 for 8 plugs; extraction of broken pieces from head requires specialty tools, head removal, or complete engine replacement ($2,000–$6,400). Mechanics reluctant to attempt due to breakage risk.
Recalls/TSBs owners mention: Ford denied warranty coverage past lapse; dealers told owners 'no recall' and that breakage is risk of removal; some dealers warned against plug changes; Ford blamed owners for design flaw, refused TSB or recall despite widespread forum complaints and awareness by dealers and Ford employees.
Cam phaser and timing system failure
Variable valve timing (cam phaser) solenoids and timing chain tensioners fail prematurely, causing oil pressure to drop to zero, rough running, engine knock, and sudden stall without warning. Failures are often intermittent. Oil is present in pan but not circulating. Design flaw in 5.4L Triton allows excessive camshaft end-play. Ford redesigned the engine after 2007 but did not issue recalls for existing vehicles. Engine rebuild or replacement is the only fix.
When: Failures reported 30,000–180,000 miles; some recurrence even after engine replacement
Symptoms owners cite: Loud ticking or knocking from engine; Engine shake and vibration during idle or low-speed driving; Sudden stall without warning; Loss of power steering and brakes (when stalled); Rough idle that improves after rev-up; Oil pressure gauge drops to zero despite full oil pan
Codes mentioned: Cam phaser sensor fault codes, Oil pressure sensor faults, Check Engine Light
Repairs/costs cited: $3,500–$8,000 for engine replacement or rebuild. Some owners report repairs at $2,000–$4,000 for cam/timing chain/solenoid work, but failures recur. Rebuilders advertise correction of Ford's design flaws.
Recalls/TSBs owners mention: Ford denies defect; tells owners engine must be replaced at owner's cost; internal memos sent to dealers but refuses recall; told some owners oil-change gaps caused failure; some Ford service staff privately acknowledged Ford's awareness of the problem; no TSB or recall issued.
Unintended high-RPM surge and throttle stall
Engine revs to 6,000+ RPM on its own at startup or while driving at low speed, without driver foot on accelerator. Occurs suddenly and intermittently. Causes vehicle to surge forward unpredictably, creating hazard in traffic or parking lots. One narrative reports near-crash into oncoming traffic. Ford dealerships attribute failures to throttle body or throttle position sensor malfunction. No recall issued despite multiple owners and forum complaints.
When: Failures reported at various mileage; one at ~100,000 miles on 2005 F-150 sibling vehicle
Symptoms owners cite: Engine revs to 3,000–6,000 RPM without throttle input; Uncontrolled vehicle surge forward; No warning light or check engine illumination; Occurs at startup or while driving at low speed
Codes mentioned: No codes reported in narratives
Repairs/costs cited: Throttle body replacement quoted but cost not specified in detail. One owner paid for replacement; another was told by dealer it 'cannot happen' and was dismissed.
Recalls/TSBs owners mention: Dealers confirm it is a reported problem on other Ford models; no recall; dealership recommended replacement; manufacturer did not address in narratives.
Fuel pump control module failure
Fuel pump control module (located in undercarriage in highly corrosive environment with no protection) fails and cuts fuel supply, causing sudden engine stall. Vehicle becomes completely inoperable once module fails. Module is nickel-coated but offers no real corrosion protection. Ford redesigned the part but service managers warn owners failure will recur because redesign is still inadequate.
When: One narrative mentions prior failure; common issue flagged by dealership service manager
Symptoms owners cite: Sudden engine stall without warning; Vehicle becomes completely non-operational
Codes mentioned: Fuel system fault codes (inferred)
Repairs/costs cited: $125 parts + $356 labor reported for one owner. Dealership service manager advised owner to plan for repeat failure soon.
Recalls/TSBs owners mention: Ford redesigned part but did not issue recall; service manager told owner it is 'common issue with all Ford trucks' and failure is inevitable.
Engine structural failure (crankshaft and internal bearing wear)
Crankshaft thrust bearing malfunctions, camshaft end-play becomes excessive, or internal engine components fail due to design flaws in the 5.4L Triton. Engine locks up or seizes mid-drive. When failures occur, oil pressure drops despite full oil pan, indicating oil starvation at critical bearings. Failures are catastrophic and require full engine replacement. Problem is concentrated in 2005–2008 model years with this engine.
When: Failures reported 22,000–180,000 miles; some at relatively low mileage
Symptoms owners cite: Engine knock and vibration; Sudden loss of all engine power; Engine locks up or seizes; Pistons found in oil pan after failure; Oil pressure drops to zero despite adequate oil level; Engine will not restart
Codes mentioned: Oil pressure sensor codes (when applicable)
Repairs/costs cited: $6,000+ for engine replacement. Two owners reported dual engine replacements under warranty, then told warranty void on third failure. Tow and rental costs add $800+.
Recalls/TSBs owners mention: Ford denied warranty on third failure; told owners engine was 'starved for oil' but refused to officially admit design flaw; some private admission by Ford employees but no recall.
Throttle body failure and repeated replacement
Throttle body (electronic throttle control) fails repeatedly across the vehicle's lifespan, causing loss of motive power, limp-home mode, and check engine light. Same vehicle experienced three throttle body failures by 130,000 miles in one case. Ford has issued extended warranties on other models for this issue but not for the 2007 F-150. Failure is dangerous when merging into traffic because vehicle loses all ability to accelerate.
When: First failure at undisclosed mileage; second failure years later; third at ~130,000 miles (9-year-old vehicle)
Symptoms owners cite: Sudden loss of motive power; Limp-home mode activation; Wrench and Check Engine Light illumination; Loss of acceleration during traffic merge or highway driving
Codes mentioned: Throttle body fault codes, Check Engine Light
Repairs/costs cited: Cost not specified; replacement required each time. Owner experienced three replacements on one truck.
Recalls/TSBs owners mention: Ford has issued extended warranties on other models for this same issue but not for 2007 F-150; manufacturer offered no assistance; issue is known but unaddressed.
Ignition coil failure
Ignition coils fail prematurely, either independently or as secondary damage from spark plug defects. Coils melt or become damaged when spark plugs blow out or leak compressed exhaust. Owners report coil costs as individual replacement parts, with some coils melting due to exposure to exhaust pressure from bad spark plugs.
When: Reported at various mileages; one at 57,532 miles, another at 125,000+ miles
Symptoms owners cite: Rough running engine; Coil burns or melts; Misfire condition
Codes mentioned: Cylinder misfire codes
Repairs/costs cited: $262+ per coil; multiple coils often fail. One owner spent $300 in December 2014 on ignition coils alone.
Recalls/TSBs owners mention: No specific manufacturer response documented.
Serpentine belt detachment and collateral damage
Power steering bearing fails, causing serpentine belt to detach and strike other engine components. Detached belt damages engine temperature sending unit, clutch fan, plug and wire harness, and exposes other engine systems to damage.
When: Reported at 57,319 miles
Symptoms owners cite: Cruise control stops functioning; Wrench warning icon illuminates; Unusual noise from engine area; Temperature gauge or check engine light illumination
Codes mentioned: Power steering pressure sensor codes, Temperature sensor codes
Repairs/costs cited: Serpentine belt, power steering pump, clutch fan, temperature sending unit, plugs and wires all replaced. Total cost not stated but multiple parts.
Recalls/TSBs owners mention: Manufacturer notified but no assistance offered.
Transmission oil cooling line corrosion
Metal transmission fluid cooling lines corrode and rupture internally. Corrosion is widespread across multiple cooling lines. Failure causes transmission fluid to leak out, forcing tow and dealer repair. Dealership confirms corrosion is a 'common problem' on F-150 but Ford does not notify owners of preventive action or use corrosion-resistant materials.
When: Reported at undisclosed mileage; corrosion found to be extensive when first line fails
Symptoms owners cite: Transmission fluid leak under vehicle (front left area); Multiple cooling lines corroded and ready to burst
Codes mentioned: No specific codes reported
Repairs/costs cited: Tow required; cooling system line replacement at dealership. Cost not specified but confirms corrosion is known issue.
Recalls/TSBs owners mention: Dealership confirmed it is 'common problem' with F-150 cooling lines; Ford did not notify owners or use corrosion-resistant materials.
Fuel rail split and leak
Fuel rail hose develops internal split underneath cloth protective covering, causing gasoline to leak from underside of fuel rail. Leak creates severe fuel smell inside and outside cab. Potential fire hazard on longer road trips.
When: Reported at undisclosed mileage
Symptoms owners cite: Severe gasoline smell in cab; Gasoline smell outside cab; Visible fuel streaming from fuel rail hose
Codes mentioned: No codes reported
Repairs/costs cited: Fuel rail removal and hose replacement required. Cost not specified.
Recalls/TSBs owners mention: No response documented in narrative; owner questioned if recall exists.
Wiring harness chafing and intermittent stall
Chafing on engine wiring harness causes intermittent electrical faults, leading to uncontrolled engine vibration and unwarned stall. RPM's drop very low after restart. Owner diagnosed via scan tool; neither dealer nor manufacturer notified.
When: Reported at 175,000 miles
Symptoms owners cite: Engine vibration and shudder without warning; Vehicle shuts off without warning; RPM's drop very low after restart; Owner must rev engine to resume normal operation
Codes mentioned: No codes reported; scan tool used for wiring diagnosis
Repairs/costs cited: Not repaired; condition diagnosed via scan tool.
Recalls/TSBs owners mention: Neither dealer nor manufacturer notified or assisted.
Synthesized from 120 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Engine was replaced in 2011 under warranty at 51,864 miles. Now at 105,662 this engine is doing the same thing. There is defiantly a problem with the engines. Ford needs to recognize and acknowledge and fix this issue with their product. If your engine does not work correctly, how can your Ford be - Ford tough!
Was experiencing a shutter similar to the feeling of a misfire when accelerating up a grade from level road conditions. This shutter was between 1250 and 1500 RPM. Took the vehicle to Ford dealership who eliminated coil pack and torque converter as the source of the problem. I had taken another vehicle I own to a repair shop I have used foe several years for an oil change and when I picked up my…
Tl* the contact owns a 2007 Ford f150. The contact stated the vehicle was taken to an independent mechanic where they discovered that all of the engine spark plugs were defective. There were six or eight spark plugs replaced. The manufacturer was notified of the problem. The failure mileage and the VIN were unavailable. ...update 01/20/12 *bf updated 01/27/12
Had engine 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 engine problem on the 2007 Ford F-150?
It's a meaningful issue. 120 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 107 complaints that reported odometer mileage, most engine failures cluster between 56,031 and 133,500 miles, with the median around 92,500. A quarter of owners report trouble before 56,031; a quarter make it past 133,500. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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.