Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how
full bulletin at NHTSA ↗2016 Ford Transit body problems
severe 10 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Complaints
10
Recalls
0
Avg fix
$1,500
1injury
When does it fail?
Of the 10 body complaints filed for the 2016 Ford Transit, 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
Of the 6 model years of Ford Transit we track for body problems, this one carries the most owner complaints on file — 10.
No new NHTSA body 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 body 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 2015-2022 Transit vehicles may experience a snap, click and/or pop noise from the door check when opening/closing the front door(s). This may be due to a cracked/broken door check and/or fastener. To correct the condition, follow the Service Procedure to inspect/replace the front door check and/or fastener.
full bulletin at NHTSA ↗Some 2015-2021 Transit vehicles may experience difficulty opening and/or closing the manual sliding door that will require sliding door adjustment. When performing the sliding door adjustment procedure in Workshop Manual (WSM), Section 501-03, use the following updated torque specs. Step 12 = 70 Nm (52 ft-lb). Step 27 = 40 Nm (30 ft-lb). In step 18, apply Motorcraft Threadlock 262 (TA-26) to the nut before torqueing. The WSM is in the process of being updated to include these revisions.
full bulletin at NHTSA ↗Some 2015-2020 Transit high roof bus/passenger wagon vehicles may experience a loose or unseated headliner at the C and/or C 1/2 pillar(s) causing visible gaps. This may be due to a lack of retention capability of the headliner locator tabs to the pillar block pins. To correct the condition, install repair coupons to the headliner and replace the headliner air conditioning (A/C) vent foam gaskets.
full bulletin at NHTSA ↗Some 2015-2019 Transit High-Roof Bus/Passenger Wagon vehicles may experience a loose or unseated headliner at the C and/or C 1/2 pillar(s) causing visible gaps. This may be due to a lack of retention capability of the headliner locator tabs to the pillar block pins. To correct the condition, install repair coupons to the headliner and replace the headliner A/C vent foam gaskets.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2016 Transit has multiple structural and closure problems that vary widely in severity. The most serious is a missing floor plug positioned directly above the exhaust system, allowing hot exhaust gases into the cabin when windows are open. One owner reported family members experiencing headaches, nausea, and vomiting after a 12-hour drive with windows closed and AC running, suggesting possible carbon monoxide exposure even with the AC on.
Sliding door issues dominate the complaints: hinges break repeatedly, latches fail to secure properly, and doors open during highway driving when passengers lean against them or over bumps. One owner reported the door won't close at all, making the van undriveable. Ford refuses to repair these issues on at least one vehicle despite complaints made at purchase.
Water intrusion enters from roof rack seals and deteriorates floor insulation, which then spews into the cabin vents at highway speed, causing respiratory issues and skin irritation. The backup camera provides inadequate visibility, leading to collision damage. An interior door handle detached and trapped an occupant inside. A fuel door hinge fractures, and Ford won't acknowledge it as a defect.
Dealers have confirmed some problems exist but declined to repair them, claiming they are normal. The sliding door failures appear systemic given multiple reports.
Failure modes owners describe
Missing floor plug over exhaust
Factory assembly omitted a ~3"×4" oval floor plug positioned directly above the heat shield and exhaust pipe. Hot exhaust air and potentially exhaust fumes enter the cabin through the open hole when windows are down, causing respiratory distress and potential carbon monoxide exposure.
When: Present from delivery
Symptoms owners cite: Hot air blowing from under front passenger seat onto legs when windows open while driving; Headaches and nausea reported after 12-hour drive with windows closed and AC on; Vomiting during extended driving
Repairs/costs cited: Dealer confirmed plug was supposed to be installed and ordered replacement part(s)
Backup camera insufficient visibility
Backup camera does not provide adequate visibility clearance, leading to collision damage. Owner contacted dealer (Tasca Automotive Group) with no resolution offered.
When: 0 miles (early vehicle life)
Symptoms owners cite: Camera did not provide adequate visibility; Vehicle struck overhead obstruction, damaging roof near camera
Recalls/TSBs owners mention: Manufacturer notified; no recall or resolution documented
Insulation debris in cabin air vents
Insulation material spewed through air vents into the cabin while driving. Flooring compartment contained mud and water, indicating water intrusion and subsequent deterioration of insulation material.
When: 59,000 miles
Symptoms owners cite: Insulation particles ejected from air vents at highway speed; Skin irritation from insulation contact; Respiratory issues following exposure
Repairs/costs cited: New floorboard installed; floor compartment had contained mud and water
Interior door handle detachment
Interior door handle assembly detached from bracket while vehicle was parked, trapping occupant inside. Failure traced to door handle bracket and switch.
When: 145,561 miles
Symptoms owners cite: Door handle detached, preventing exit; No warning light illuminated prior to failure
Repairs/costs cited: Door handle replaced by independent mechanic
Recalls/TSBs owners mention: Manufacturer determined VIN not included in recall
Water intrusion from roof rack seal
Water leaks into driver and passenger sides of cabin during rain. Dealer (Keller Ford) identified roof rack plug as the source and recommended replacement, but repair was not completed.
When: 29,000 miles
Symptoms owners cite: Water leaking into vehicle from driver and passenger sides during rain
Repairs/costs cited: Roof rack plug replacement recommended but not performed
Recalls/TSBs owners mention: Manufacturer notified
Sliding door hinge failures
Side sliding door hinges repeatedly break and require replacement. Door fails to close or latch properly, making the vehicle unsafe to drive as the door slides open during motion.
When: Multiple occurrences; timing not specified
Symptoms owners cite: Hinges broken requiring multiple replacements; Door does not close or latch properly; Door will not latch and slides open when attempting to drive
Repairs/costs cited: Hinges replaced multiple times
Sliding door inadequate latch
Passenger-side sliding door opens during highway driving due to inadequate latch system. Door opens when passenger leans against it or when vehicle encounters road bumps. Adjustments do not resolve the issue.
When: Not specified
Symptoms owners cite: Door opens while driving at highway speed; Door opens when passenger leans against it; Door opens when hitting road bumps; Door difficult to close and open; No amount of adjustment resolves problem
Passenger sliding door latch failure
Passenger sliding door does not securely latch or close. Reported to Ford shortly after purchase but manufacturer refuses to repair. Owner continues to drive with unsecured door.
When: Shortly after vehicle purchase
Symptoms owners cite: Door does not securely latch or close
Recalls/TSBs owners mention: Ford refuses to repair
Sliding door track derailment
Sliding door jumps its track during operation, preventing proper opening and closing. Owner has driven home with door in open position because door would not shut.
When: Not specified
Symptoms owners cite: Door jumps track while opening or closing; Door cannot be closed and gets stuck open
Fuel door hinge fracture
Fuel door upper hinge breaks. Owner reports this is a common part failure that Ford refuses to acknowledge or address.
When: Not specified
Symptoms owners cite: Upper hinge on fuel door broken
Recalls/TSBs owners mention: Ford refuses to acknowledge defect
Synthesized from 10 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Fuel door broken at upper hinge. Common part failure Ford refuses to acknowledge.
Had body trouble with your 2016 Ford Transit?
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 body problem on the 2016 Ford Transit?
It's a meaningful issue. 10 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Based on the 10 complaints filed, body issues most often appear around 68,356 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 $1,500 for body 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 body?
No active recalls currently cover body 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/2016/Ford/Transit.
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.