This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD 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 to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.
full bulletin at NHTSA ↗2015 Ford F-150 wheels problems
moderate Owners of the 2015 Ford F-150 have filed 31 NHTSA complaints about the wheels, typically surfacing around 60,000 miles at roughly $400 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See wheels across all vehicles →
Failure mileage
Complaints
31
Recalls
0
Avg fix
$400
| Model year | wheels complaints |
|---|---|
| 2011 F-150 | 10 |
| 2012 F-150 | 13 |
| 2013 F-150 | 21 |
| 2014 F-150 | 18 |
| 2015 F-150 (this page) | 31 |
| 2016 F-150 | 49 |
| 2017 F-150 | 38 |
| 2018 F-150 | 37 |
| 2019 F-150 | 4 |
When does it fail?
Of the 31 wheels complaints filed for the 2015 Ford F-150, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 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 31 wheels 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 wheels complaint has been filed on this vehicle in over 5 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 wheels 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 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 ↗Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with 4-wheel drive (4WD) may exhibit an intermittent grinding noise while driving in 2-wheel drive (2WD) mode most commonly on acceleration. This may be due to a loss of vacuum to the integrated wheel end (IWE) actuators and/or wear of the IWE components. To correct the condition, follow the Service Procedure steps to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.
full bulletin at NHTSA ↗Some 2013-2018 F-150/Expedition/Navigator 4x4 vehicles may exhibit an intermittent grinding noise coming from the right front or left front wheel area while accelerating in 2WD mode. Refer to the Workshop Manual (WSM), Section 308-07, Diagnosis and Testing Symptom Chart - NVH > The front axle makes noise in 2H mode only and generally under heavy throttle.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The overwhelming majority of complaints center on defective two-piece, chrome-plated lug nuts that swell and corrode, starting around 40,000 miles. Owners describe nuts expanding to the point the factory wrench won't fit, then having to resort to hammering, power tools, or angle grinders to remove them. Once swollen, the nuts cannot be tightened to specification with a torque wrench, leaving wheels improperly secured. Multiple owners got stranded roadside when flat tires became impossible to change. One owner's front wheel detached while driving at highway speed; another's rear wheel came off at 48 mph. Dealers consistently replace lug nuts with identical OEM two-piece parts ($156–$337), causing the problem to recur within months or years. Once owners switch to aftermarket one-piece replacements ($60–$70), the swelling stops and doesn't return. Ford has issued no recall despite documentation of this defect spanning over a decade and affecting F-150 owners in multiple states. A handful of complaints also mention brake noise at the left front wheel during cold weather and wheel sticking on hubs, though the lug nut defect dominates the complaint volume.
Same Ford F-150 wheels reports on nearby years: 2014 · 2017 · 2018
Failure modes owners describe
Swollen/Distorted Lug Nuts
Two-piece chrome-plated lug nuts with dissimilar metal construction swell, corrode, and deform, preventing removal with the factory-supplied lug wrench. The chrome cap expands, making the nuts larger than original specification and incompatible with standard sockets and the vehicle's jack kit wrench.
When: Begins appearing around 40,000–60,000 miles; can recur even after replacement with OEM parts
Symptoms owners cite: Lug nuts too large for factory wrench to fit; Nuts rounded off or deformed, making removal difficult or impossible; Chrome cap swollen/distorted; Excessive force required to remove nuts (hammering, power tools, angle grinder needed); Inability to rotate tires during service; Nuts seize and cannot be removed without damage
Repairs/costs cited: Dealers replace with same OEM two-piece lug nuts ($156–$337 per complete set), causing repeated failure. Owners report aftermarket one-piece replacements ($60–$70) resolve the issue and do not re-swell. Some owners forced to purchase tools or use power equipment to remove swollen nuts.
Recalls/TSBs owners mention: Ford has not issued a recall. Multiple owners report Ford closed their NHTSA cases without explanation. Ford service advisors refer owners to aftermarket lug nuts only after OEM replacement fails multiple times. Online forums document this issue spanning 11+ years across F-150 model years.
Wheel Loose/Detached While Driving
Wheel studs bust or lug nuts fail completely, causing wheels to separate from the hub while the vehicle is moving. One owner experienced a rear wheel coming off at highway speed; another lost the front driver-side tire while driving.
When: One incident at approximately 48 mph; one at highway speed after dealership inspection missed the hazard
Symptoms owners cite: Sudden loss of wheel during driving; Tire felt like a blowout, then separated completely; No warning lights or check-engine indicators before failure
Repairs/costs cited: One owner had Ford replace all lug nuts from closed-cap to open-face design. No documented permanent fix.
Recalls/TSBs owners mention: One dealership stated no open recall exists; referred owner to dealership. Another owner reports Ford inspected the vehicle, declared it safe, but failure occurred 2,600 miles later.
Wheel Stuck on Hub
Wheels become seized or stuck to the hub, requiring excessive force to remove during tire rotation or flat-tire changes. Affects both aluminum summer and steel winter wheel sets.
When: Occurs early in vehicle ownership; escalates over time
Symptoms owners cite: Wheels require excessive force to remove from hub; Roadside manual tools (factory jack and wrench) insufficient to break wheels free; Aluminum and steel wheels equally affected; Dangerous during emergency tire changes on highway
Repairs/costs cited: No repairs described. Owners note roadside emergency procedures become impossible without power tools.
Brake Noise / Left Front Wheel Grinding
Rubbing, grinding, or whirring noise at the left front tire area during cold weather and low-speed driving (2–40 mph). Sound intensifies when braking and is felt in the brake pedal. Dealership attributed it to a tire issue despite original tires being in good condition; noise stops only after several minutes of driving.
When: Occurs on cold days (temps 40 °F and below); happens at low speeds on gravel or pavement
Symptoms owners cite: Rubbing/grinding/whirring noise at left front tire; Noise increases when braking; Vibration felt in brake pedal; Noise does not change pitch with speed changes; Occurs only at low speeds (2–40 mph) in cold weather; Noise ceases after a few minutes of driving
Repairs/costs cited: Dealership initially suspected suspension issue; spent 2 hours investigating but found and repaired nothing. Dealership ultimately attributed it to tires, but owner disputes this diagnosis.
Recalls/TSBs owners mention: Dealership asserted noise was tire-related and that no further repairs were needed while under warranty.
Synthesized from 31 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
When turning onto a road and starting to accelerate, the truck suddenly lost all power and the traction control, advance traction control, hill descent control, maintenance required light all came on and the truck went into limp mode. Luckily I was able to pull off the road and avoid being hit.
Had wheels 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 wheels problem on the 2015 Ford F-150?
It's a documented issue but not catastrophic. 31 complaints have been filed. Repairs average $400 and most owners catch it before it causes a breakdown.
At what mileage does the wheels typically fail?
Across the 16 complaints that reported odometer mileage, most wheels failures cluster between 44,000 and 90,000 miles, with the median around 60,000. A quarter of owners report trouble before 44,000; a quarter make it past 90,000. 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 $400 for wheels 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 wheels?
No active recalls currently cover wheels 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.