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full bulletin at NHTSA ↗2009 Ford F-150 engine problems
severe 40 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
40
Recalls
0
Avg fix
$3,100
1crash
2fires
When does it fail?
Of the 40 engine complaints filed for the 2009 Ford F-150, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 40 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.
Of the 17 model years of Ford F-150 we track for engine problems, this one has the fewest owner complaints on file (40).
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.
Some 2009-2017 Expedition/Navigator, 2009-2014 F-150/Mustang, 2008-2009 Sable, 2008-2019 Taurus/Flex/MKT, 2013-2019 Police Interceptor Sedan/Utility, and 2011-2019 Explorer vehicles may exhibit inoperative or intermittent HVAC blower motor function at various fan speed settings. This may be due to a poor electrical connection at the blower motor speed control. If the blower motor speed control is determined to be the causal part, replacement of the electrical connector pigtail harness (14S411) to the blower motor speed control is also recommended to avoid repeat repairs. Refer to Wiring Diagram, Cell 5 for recommended splicing procedures. Refer to Wiring Diagram, Cells 54/55 to obtain the se
full bulletin at NHTSA ↗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 ↗SUMMARY TO BE PROVIDED ON A FUTURE DATE.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2009 F-150 engine complaints cluster around several repeating failures, none of which Ford has recalled despite their prevalence across owners and documented technical service bulletins.
Cam phaser failure dominates the 5.4L modular V8 complaints. Owners report severe engine knock, rattling at idle and low speeds, shaking that causes stalling at traffic lights and turns, and sudden loss of power. The symptom shows up between 30,000 and 185,000 miles. Dealers confirm the diagnosis but cannot repair it affordably—cam phaser replacement runs $4,000+, and many vehicles need full engine replacement ($8,000+). Owners note this is a known, documented issue that Ford discontinued the 5.4L to avoid addressing.
Exhaust manifold fastener deterioration affects both 4.6L and 5.4L engines. Studs break after normal heat cycling, releasing unburned emissions and leaking fumes into the cabin. Repair requires removing the exhaust system, often necessitating engine removal for access. Costs escalate quickly, and owners report Ford has known about this for nearly a decade via service bulletin SB-17320 without issuing a recall.
Unintended acceleration episodes occur during light throttle input or low-speed maneuvers, with RPMs climbing to 4,000–6,000+ and staying high despite the driver's foot off the accelerator. Braking does not stop the high RPMs; neutral engagement is required. Dealerships consistently report finding no fault codes and cannot replicate it.
Engine stalling without warning happens at idle, during turns, and at highway speeds with no check engine light or diagnostic code. Vehicles restart after variable delays. Multiple stalling episodes can occur on the same vehicle. Dealers cannot diagnose, and one case referenced TSB-15-0137.
Spark plug ejection occurs during acceleration, especially from a stop at traffic lights, damaging cylinder head threads. Heli-coil repair is used, though some heads require replacement.
Owners report Ford's responses consistently avoid remedy: dealerships say they cannot replicate the problem, Ford does not issue recalls, and repairs remain the owner's responsibility even when technical service bulletins exist.
Same Ford F-150 engine reports on nearby years: 2006 · 2007 · 2008 · 2010 · 2011
Failure modes owners describe
Cam phaser failure with severe engine knock/rattle
Cam phaser malfunction causes loud engine knock, rattling, or shaking, especially at idle or low speeds. Engine loses power or stalls. Occurs typically after 30k–185k miles. Multiple owners report this as a known, documented issue with 5.4L modular V8s that Ford has not recalled despite widespread complaints.
When: 30,000–185,000 miles; at idle, low speeds, or during turns
Symptoms owners cite: Severe engine knock or knocking noise; Loud rattling at idle or low RPM; Engine shaking and jerking badly; Engine stalling at traffic lights or during turns; Loss of power during driving; Check engine light flashing (in some cases)
Codes mentioned: P0016 (implied from timing chain/gear failures), Check engine light (intermittent or flashing)
Repairs/costs cited: Cam phaser replacement ($4,000+ reported). Many cases require full engine replacement ($8,000+) due to internal damage. Some repairs ineffective. Timing chain and engine replacement often necessary.
Recalls/TSBs owners mention: Ford service bulletin SB-17320; TSB referenced in narratives. Ford has not issued a recall. Service departments often cannot replicate the issue. Extended warranty may cover repair.
Exhaust manifold fastener (stud) failure
Exhaust manifold studs deteriorate and break after thermal cycling, causing exhaust leak. Reported as a well-documented, longstanding issue affecting 4.6L and 5.4L modular V8 F-150s across many model years and documented in Ford service bulletins.
When: Occurs after normal heat cycles; mileage ranges from 50k to 125k+ miles
Symptoms owners cite: Exhaust leak noise; Loud exhaust sound on cold start that diminishes as engine warms; Exhaust fumes entering passenger cabin; Cracked or cracked manifold (secondary to stud failure)
Repairs/costs cited: Requires removal of exhaust system and manifolds to extract broken studs and replace with improved parts. In many cases, entire engine must be removed due to clearance. Expensive and labor-intensive repair. Owners cite costs in thousands of dollars.
Recalls/TSBs owners mention: Service Bulletin SB-17320 documents the issue. No recall issued. Ford aware of the problem but has not addressed it via recall.
Unintended acceleration / stuck throttle
Engine RPMs spike unexpectedly and remain high (4000–6000+ RPM), often after light throttle input or during low-speed maneuvers. Foot remains off accelerator. Braking does not stop the high RPMs; neutral must be engaged to regain control. Issue intermittent and difficult to reproduce.
When: Various speeds (45 MPH, highway, city, backing up); 2011–2017 model years in complaint cluster
Symptoms owners cite: Sudden RPM spike to 4000–6000+ RPM; RPMs sustained despite brake application; Foot off accelerator but engine holds high RPM; Loss of deceleration when throttle released; Anti-lock brakes engage to assist stopping
Codes mentioned: No fault codes detected (in most cases)
Repairs/costs cited: No repair identified in narratives. Dealership inspections found no mechanical or electronic faults. Adjustment of power adjustable foot pedals sometimes coincided with normal restart. Floor mat checked as potential cause but ruled out.
Recalls/TSBs owners mention: Dealerships unable to replicate the issue or find root cause. Some cases reference floor mat recall guidance (not specific to this vehicle model). No technical service bulletin cited for this failure mode.
Engine stalling without warning
Engine suddenly stalls or shuts down during driving at various speeds and conditions—idle, turns, highway speeds—without warning light or check engine code. Vehicle restarts after delay (sometimes 30 minutes) or immediately. Recurs multiple times with same or different trigger conditions. Dealers cannot replicate or diagnose.
When: Occurs at 50k–218k miles; at idle, slow speeds, turns, and highway speeds (40–70 MPH)
Symptoms owners cite: Engine stalls without warning; No check engine light or code present; Stalls at traffic lights, during turns, on highway; Hard steering and brakes when power is lost; Vehicle restarts after variable delay (seconds to 30 minutes); Stalling recurs multiple times
Codes mentioned: No fault codes present (reported in multiple cases)
Repairs/costs cited: No consistent repair identified. Fuel pump replacement performed in at least one case ($700) but problem persisted. Dealers unable to diagnose. One case referenced TSB-15-0137 (Crank No-Start, Stalling).
Recalls/TSBs owners mention: TSB-15-0137 and NHTSA Campaign 10074713 (Engine) noted in at least one narrative. Dealers cannot duplicate or provide solution. Ford customer service instructed one owner to continue driving and report next incident.
Spark plug ejection from cylinder head
Spark plugs eject from cylinder head during acceleration or normal operation, damaging threads and cylinder head. Occurs in multiple cylinders on same vehicle over time. Root cause is insufficient thread engagement in head design.
When: Occurs at 71k–80k+ miles, often during acceleration from stop (traffic light acceleration)
Symptoms owners cite: Spark plug ejects from cylinder head; Tinking or rattling noise from engine; Damage to cylinder head threads; Multiple ejections in same vehicle
Repairs/costs cited: Heli-coil repair used to restore thread integrity. Damaged cylinder head may require replacement. One owner replaced multiple spark plugs. Repair costs unknown but owner noted it was at owner expense despite TSB coverage.
Recalls/TSBs owners mention: Technical Service Bulletin (TSB) exists but not cited by number in narratives. Ford dealership initially declined responsibility, stating repair was at owner's expense. One narrative notes this is a 'common problem' with 4.6L 2V Triton engines.
Check engine light illumination (computer program fault)
Check engine light goes on and off periodically with no underlying mechanical problem. Root cause diagnosed as computer program issue with main engine control module.
When: Intermittent, occurring over multiple visits to dealer
Symptoms owners cite: Check engine light illuminates and extinguishes periodically; No mechanical or sensor fault detected after three dealer visits
Codes mentioned: Check engine light (no specific code provided)
Repairs/costs cited: Computer program update required to resolve. Owner charged $200+ for software update despite Ford acknowledging the program defect.
Recalls/TSBs owners mention: Ford aware of computer program issue but charges owners for software update to fix it.
Engine fire (post-collision / high-mileage)
Engine catches fire during or shortly after low-speed collision impact, or during normal operation at high mileage (201k miles). Fire is severe and vehicle is totaled.
When: At low-speed collision impact and at 201,000 miles during normal operation
Symptoms owners cite: Smoke from glove box area; Flames from engine compartment; Fire spreads rapidly
Repairs/costs cited: Vehicles totaled; no repair attempted.
Recalls/TSBs owners mention: No manufacturer notification or response recorded in narratives.
No-start / hard-start condition with electrical involvement
Engine fails to start, cranks but does not fire, or requires multiple restart attempts. Clicking noise may occur. Sometimes related to fuel pump relay or fuse failure. Occasionally resolves after reset or foot pedal adjustment.
When: At 71k–218k miles; can occur after unintended acceleration episode
Symptoms owners cite: Engine will not crank or start; Clicking noise during start attempt; Engine cranks but does not fire; Multiple restart attempts needed; Sometimes resolves after delay or adjustment
Repairs/costs cited: Fuel pump replacement ($700 in one case); #27 fuse and relay replacement attempted; fuel module replacement; 20 AMP fuse replacement. No consistent root cause identified.
Recalls/TSBs owners mention: TSB-15-0137 and NHTSA Campaign 10074713 referenced in one case. No manufacturer support documented in most cases.
Broken exhaust manifold bolts with exhaust leak
Exhaust manifold bolts or studs fracture, allowing exhaust leak. Similar to cam phaser-related issues but distinct from fastener deterioration failure mode. Can occur 24 hours after purchase.
When: At 125k miles; can occur very early in ownership if vehicle purchased used
Symptoms owners cite: Exhaust leak; Fractured manifold bolts; Engine stalling (in at least one case)
Repairs/costs cited: Diagnosis indicated cam, timing sensors, and gears also failed in one case, requiring complete engine replacement. No repair completed in reported case.
Recalls/TSBs owners mention: None documented.
Synthesized from 40 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
On december 15, 2017, while driving on i35 in heavy traffic in fort worth, texas, the f150 autonomously accelerated to maximum RPM and would not slow down. The cruise control was not on. We were forced to ride the breaks hard until we were able to exit the freeway, put the vehicle in neutral and break to a stop. We turned the vehicle off and restarted. The vehicle still went to maximum…
Tl* the contact owns a 2009 Ford f-150. The contact stated that he heard an abnormal noise from the vehicle and noticed that the exhaust manifold was cracked and was leaking. The contact was an independent mechanic and diagnosed that the manifold needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was 77,000. Updated 02/04/16*lj updated…
Engine began to shake at 65mph. Pulled over and engine was shot. Possible cam phasers. *tr
Had engine trouble with your 2009 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 2009 Ford F-150?
It's a meaningful issue. 40 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 38 complaints that reported odometer mileage, most engine failures cluster between 59,000 and 125,136 miles, with the median around 81,000. A quarter of owners report trouble before 59,000; a quarter make it past 125,136. 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/2009/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.