Warped exhaust manifold. The design of the exhaust manifold where it connects to the turbo is not engineered correctly and only has 2 mounting studs. The heat generated from both the exhaust and the turbo is more than the 2 manifold studs can handle and the exhaust manifold warps causing a broken manifold stud and exhaust leak. This is clearly an engineering design fault and this part should…
2015 Ford F-150 fuel system problems
moderate 5 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Complaints
5
Recalls
0
Avg fix
$1,200
What stands out
No new NHTSA fuel system complaint has been filed on this vehicle in over 4 years — the issue may be aging out of the active population.
What owners are reporting 1 most recent
Had fuel system trouble with your 2015 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 fuel system problem on the 2015 Ford F-150?
It's a documented issue but not catastrophic. 5 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 5 complaints filed, fuel system issues most often appear around 24,600 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system 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 fuel system?
No active recalls currently cover fuel system 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/2015/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.