Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine and 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable to enter electric-only drive modes as expected during normal drive cycles. This may be due to the software within the belt integrated starter generator (BISG). For vehicles with this condition, follow Pinpoint Test I: Battery Isolation/Voltage Stabilization Control Circuit Carry Outance located in the Workshop Manual (WSM), Section 303-06D and repair the vehicle as necessary. No
full bulletin at NHTSA ↗2021 Ford F-150 engine problems
moderate 57 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
57
Recalls
0
Avg fix
$3,100
1fire
What stands out
Owners have filed 57 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.
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 2021-2026 F-150 vehicles equipped with a 5.0L/5.2L engine, 2021-2025 F-Super Duty/F-53 Motorhome/F59 Commercial Stripped Chassis vehicles equipped with a 6.8L/7.3L engine and 2021-2025 E-Series/F-650/F-750 vehicles equipped with a 7.3L engine may exhibit a rattle/scraping noise upon startup that may remain after the engine is running. Workshop Manual (WSM),
full bulletin at NHTSA ↗Some 2021-2025 F-150/Expedition/Navigator vehicles equipped with a 3.5L EcoBoost engine may exhibit diagnostic trouble code (DTC) P0299 stored in the powertrain control module (PCM) and may also exhibit a rattle noise from the turbocharger. This may be due to the wastegate actuator rod being disconnected. Workshop Manual (WSM), Section 303-04 Fuel Charging and Controls > Turbocharger has been added to address this condition to allow servicing of the turbocharger actuator rod. In addition, the wastegate actuator rod and associated retention springs and clips have been released as lower level components to complete the repair without replacing the entire turbocharger actuator assembly.
full bulletin at NHTSA ↗Some of the vehicles listed in the Model statement above may exhibit an illuminated malfunction indicator lamp (MIL) with DTCs P0301-P0306, P0201-P0206 and/or various other powertrain DTCs stored in the PCM. This may be due to the engine harness contacting the hose crimp end or spring clamp tangs on the exhaust heat exchanger heater hose assembly.
full bulletin at NHTSA ↗Some 2021-2025 Expedition/Navigator/F-150/F-Super Duty/F-53 Motorhome/F59 Commercial Stripped Chassis/F-650/F-750/Transit vehicles equipped with a 2.7L/3.5L (non hybrid)/6.8L/7.3L engine and 2021-2026 E-Series may exhibit a rattle/scraping noise from the bellhousing area on start-up. Workshop Manual (WSM), Section 303-00 Engine System - General Information > Diagnosis and Testing and 303-06 > Starting System has been updated to address this condition. Additionally, WSM, Section 303-01 > Removal and Installation > Engine to Transmission Spacer Plate has been added to address this condition. Refer to the revised WSM sections for normal diagnosis.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2021 F-150 engine failures cluster around two dominant patterns: uncontrolled oil burn and sudden mechanical collapse.
Owners report the engine losing 1–2 quarts every 1,200–1,500 miles with no visible external leak—a condition appearing as early as 6,500 miles or as late as 56,000. Dipstick readings drop below safe operating level within weeks of purchase in some cases. Ford's TSB 19-2365 for 5.0L excessive oil consumption did not resolve the issue when applied; dealerships have opened cases with Ford corporate, but owners cite no permanent fix and repeated denials of warranty coverage.
Catastrophic engine failures—connecting rod fracture, bearing collapse, piston crown damage, valve failure—strike across mileage ranges: 2,300 miles, 2,966 miles, 4,000 miles, and up to 134,000 miles. Most occur with either no prior warning or only brief misfire codes. Owners report loud knocking, grinding, or banging immediately before stall; the engine will not restart, and towing becomes necessary. Internal inspection reveals piston fragments in the oil pan and bearing wear. Repair requires complete engine replacement at $12,000+ out-of-pocket in many cases, even within warranty mileage, because Ford denies coverage if the failure is not explicitly listed under an active recall.
Fuel pump failures cause sudden stalls in traffic or at highway speed. NHTSA Recall 24V635 addresses the issue, but remedy parts remain unavailable as of May 2025 despite the August 2024 recall notice. Dealerships offer no loaner vehicles during diagnostic holds, leaving owners without transportation for work or family needs. One owner reported being told to continue driving a vehicle with a known defect because no remedy exists yet.
Owners experiencing engine seizure, stall events, or recall waits have little recourse: warranty coverage is inconsistently applied, parts backlogs persist, and dealership service timelines stretch beyond five weeks in some cases.
Same Ford F-150 engine reports on nearby years: 2018 · 2019 · 2020
Failure modes owners describe
Excessive oil consumption
Engine burns or loses oil rapidly without external leak, reducing dipstick level to critically low within 1,000–1,500 miles of driving. Owners report 1–2 quarts consumed per service interval. Some instances tied to defective PCV system allowing oil bypass.
When: Onset varies: as early as 6,500 miles to 56,646 miles; may appear within weeks of purchase for early failures.
Symptoms owners cite: Oil level below safe operating line on dipstick; Check engine light for low oil pressure (when severely depleted); No external oil leaks visible; Engine running lean or noisy if oil becomes critically low
Codes mentioned: P0521 (oil pressure circuit malfunction, reported indirectly), PCV system failure (noted by technicians)
Repairs/costs cited: Ford TSB 19-2365 (5.0L Excessive Oil Consumption) attempted on at least one vehicle without resolving the issue; oil consumption test prescribed over 1,000–1,500 miles; third-party vendors unable to permanently fix; some owners out-of-pocket for repeated oil additions.
Recalls/TSBs owners mention: Dealerships opened cases with Ford corporate; communication ongoing but no consistent resolution reported; some owners told repairs cannot be covered under powertrain warranty.
Catastrophic engine failure (connecting rod/bearing/valve damage)
Engine suffers sudden mechanical failure—bearing collapse, connecting rod fracture, piston damage, or valve failure—causing immediate loss of power, often at highway speed or idle. Vehicle typically will not restart; towing required. Failures range from early onset (2,300 miles) to later in warranty period.
When: Failure mileage: 2,300 miles, 2,966 miles, 4,000 miles, 19,448 miles (knocking before failure), 61,000 miles (post-warranty), 99,000 miles, 134,000 miles. Some with no prior symptoms; some after misfire warnings.
Symptoms owners cite: Loud knocking, grinding, or banging sound from engine before failure; Abnormal rattling or ticking accelerating with throttle application; Engine shudder or vibration; Sudden loss of power/stall while driving; Engine will not restart; Burning odor from engine compartment (one case); Internal damage: piston fragments in oil pan, damaged rod bearings, piston crown damage, valve seat erosion
Codes mentioned: Cylinder misfire (e.g., Cylinder 1 or 4), Timing failure (reported indirectly via Ford App), System failure message (one case)
Repairs/costs cited: Engine replacement required in all reported cases where diagnosis confirmed; parts found in oil pan (piston, valve retainer fragments); labor and parts cost $12,000+; one replacement covered under warranty; others denied or partially covered at owner expense; dealership repair timelines 5+ weeks in one case; independent mechanics unable to repair.
Recalls/TSBs owners mention: Some related to NHTSA Recall 24V635000 (intake valve cracking on 2.7L/3.0L EcoBoost engines); however, many failures occur in non-recalled engine sizes (5.0L Coyote, 3.5L EcoBoost, 3.3L V6) or outside recall coverage; Ford refused warranty repair in several cases, citing failure not covered by recall or policy; no extended warranty offered in most instances.
Fuel pump failure and fuel system stall
Low-pressure fuel pump fails, causing vehicle to stall unexpectedly during operation—particularly in traffic or at highway speed. Some instances tied to active NHTSA Recall 24V635 but remedy not yet available. Related to high-pressure fuel injector cracking in one case.
When: Multiple owner reports; one stall cited as 'a couple of weeks ago'; one incident post-recall notification but no parts available for remedy.
Symptoms owners cite: Engine stalls abruptly while driving; Vehicle loses all power (cannot accelerate or coast to safety); Dashboard warning: 'fuel accessory' or generic malfunction light; Battery warning appears (may be secondary to stall); Fuel gauge reading incorrect or dropping rapidly; No prior warning lights in most instances
Codes mentioned: Low-pressure fuel pump fault (active recall 24V635/24S55)
Repairs/costs cited: Fuel pump replacement required; one owner paid out-of-pocket for replacement; parts/remedy unavailable for recall cases as of complaint dates; one case involved high-pressure fuel injector cracking (fuel spraying into engine); high-pressure fuel injector replacement needed (fire hazard cited).
Recalls/TSBs owners mention: NHTSA Recall 24V635/24S55 issued for low-pressure fuel pump on certain EcoBoost and 5.0L engines; however, remedy parts not available at complaint time, delaying repairs indefinitely; Ford not providing loaner vehicles during diagnostic waits (owners cite financial hardship); one owner told no remedy exists yet and to drive with known defect.
Engine misfire and ignition/compression issues
Cylinder misfire, severe power loss, or ignition faults occur during normal driving, often at idle or under load. Some linked to valve damage or piston crown degradation; others cite defective spark plugs or coils, though replacement does not always resolve.
When: Reported at various mileages; one case at approximately 58,000 miles; another 'over the last couple of months' before total engine seizure; some after cold start or hot-weather exposure.
Symptoms owners cite: Check engine light with misfire code (Cylinder 1, 4, etc.); Service engine soon warning; Rough idle; Power loss under acceleration; Hesitation or delayed throttle response; Engine shaking; Misfires worse when engine hot or during idle
Codes mentioned: P0300 (random misfire, implied), P0301, P0304, P0305 etc. (cylinder-specific misfire), P0012 or P0014 (cam/valve timing, implied)
Repairs/costs cited: Spark plugs, ignition coils, and fuel injectors replaced in multiple attempts without resolution; actual root cause in some cases determined to be piston damage or valve failure requiring full engine replacement; no cost recovery reported for owners who replaced components first.
Recalls/TSBs owners mention: Dealerships blame spark plugs/coils initially; diagnostic clarity delayed; some customers told repairs not covered under powertrain warranty if valve/piston damage confirmed; no TSB issued to address root cause in misfire cases.
Recall parts unavailability (24V635000 engine and cooling)
Owners notified of NHTSA Recall 24V635000 (Engine Intake Valve Cracking on 2.7L/3.0L EcoBoost) but remedy parts not yet in stock at dealerships. Delays exceed 6–9 months from recall notice, leaving owners unable to address safety defect and unable to drive vehicle without risk.
When: Multiple complaints spanning late 2024–early 2025; one owner reported parts promised for January 2025, still unavailable by May 2025.
Symptoms owners cite: Recall notification received via mail/NHTSA; Check engine light (may or may not be illuminated before parts availability); Anxiety over unknown timeline for repair; No actual failure (in cases where vehicles still operable)
Codes mentioned: Recall 24V635000
Repairs/costs cited: No parts in inventory; dealers unable to perform recall repair; some customers report dealer promising timeline (e.g., January 2025) that is not met; no loaner or rental vehicle offered by Ford during diagnostic hold or parts wait; vehicles remain under recall defect status indefinitely.
Recalls/TSBs owners mention: Ford issued Recall 24V635000 (24S55) in August 2024 for 2.7L/3.0L EcoBoost engines; no remedy parts available; customers told recall repair cannot proceed; Ford has not communicated revised timelines or interim safety measures; no warranty extension or loaner program offered.
Engine shutdown at idle or in traffic (unrelated to fuel pump recall)
Vehicle's engine randomly shuts off while stationary (stopped at light, in intersection, or during slow-speed operation) without fuel pump or fuel system fault codes. Vehicle becomes disabled temporarily; driver must restart to regain mobility.
When: Reported during normal traffic/stop-and-go driving; no specific mileage cited.
Symptoms owners cite: Engine stalls without warning while vehicle at stop or low speed; Pre-collision warning may appear on dashboard simultaneously; Engine restarts after shifting to park and attempting restart; No fuel system or battery warning lights in some cases
Codes mentioned: Pre-collision system warning (not a fault code)
Repairs/costs cited: No repairs reported; mechanism not diagnosed by owners.
Recalls/TSBs owners mention: No manufacturer response documented in these narratives.
Oil leak (source undetermined)
Owner discovers oil dripping underneath vehicle; mechanic and dealership unable to pinpoint leak source. Steering wheel fails to lock after engine shutdown (separate electrical symptom). No resolution achieved.
When: Approximately 60,600 miles.
Symptoms owners cite: Visible oil pooling under vehicle; Steering wheel not locking as designed after shutdown
Repairs/costs cited: Mechanic unable to locate leak; dealership unable to diagnose; vehicle not repaired.
Recalls/TSBs owners mention: Dealership could not determine cause; no manufacturer involvement reported.
Engine overheating and fluid leak
Engine overheats while fluid leaks from an undetermined location. Transmission has been serviced multiple times despite no transmission complaint from owner, suggesting possible internal circulation or cooling system issue.
When: Approximately 40,000 miles.
Symptoms owners cite: Fluid leaking from vehicle (source not identified); Engine overheating; No warning lights illuminated
Repairs/costs cited: Vehicle taken to dealer; not diagnosed or repaired.
Recalls/TSBs owners mention: No manufacturer notification or response documented.
Serpentine belt and pulley wear
Serpentine belt and pulley require replacement; described as premature wear occurring at relatively low mileage. A/C vent tab also separated.
When: Approximately 48,000 miles.
Symptoms owners cite: Abnormal ticking sound from exhaust baffles (may be unrelated); Squealing sound while driving or idling; Hesitation during acceleration from complete stop; A/C outlet vent tab separated; other tabs loose
Repairs/costs cited: Serpentine belt and one pulley replacement needed; vehicle not repaired; manufacturer informed repairs not covered under powertrain warranty.
Recalls/TSBs owners mention: Manufacturer notified; repairs ruled out of powertrain warranty coverage.
Exhaust fumes in cabin ventilation
Carbon monoxide or exhaust fumes are entering the vehicle's interior through the dashboard ventilation system, creating a health hazard for occupants.
When: No specific mileage or timeline provided.
Symptoms owners cite: Exhaust fumes/carbon monoxide odor inside cabin via dashboard vents; Health concern for driver and family
Repairs/costs cited: No repair documented; owner states dealership not equipped to address.
Recalls/TSBs owners mention: Ford/dealership described as not taking the matter seriously.
Engine shaking, white smoke, and oil head gasket failure
At very low mileage (1,200 miles), engine shakes and white smoke emerges from tailpipe; low oil pressure warning follows shortly after. Dealership initially blamed spark plug; subsequent diagnosis revealed oil passing through the cylinder heads, indicating head gasket or internal seal failure.
When: 1,200 miles (initial symptom); 150 miles later (low oil pressure light); diagnosis after extended dealership delay.
Symptoms owners cite: Engine vibration/shaking during operation; White smoke from tailpipe; Low oil pressure warning light at 75 mph; Oil internally leaking into combustion chambers
Codes mentioned: Low oil pressure (P0520 or similar, implied)
Repairs/costs cited: Dealership initially blamed spark plug; no remedy offered for weeks; second dealership identified internal oil leak (head gasket or piston rings); parts/repair details not provided.
Recalls/TSBs owners mention: No manufacturer involvement documented in this narrative.
Powertrain malfunction and reduced power mode
Vehicle enters reduced power mode with 'Powertrain Malfunction' warning, indicating a fault in engine or drivetrain system. Recurs multiple times under normal highway driving conditions.
When: Multiple instances reported on 8/25/2024 and 9/6/2024.
Symptoms owners cite: Service engine soon light; Powertrain malfunction warning via dashboard and mobile app; Reduced power mode triggered; Occurs during normal highway speeds
Codes mentioned: Powertrain malfunction (generic, pending dealer diagnosis)
Repairs/costs cited: No repair documented; owner advised to contact dealership.
Recalls/TSBs owners mention: No response documented.
Shift lock failure after engine shutdown
After catastrophic engine failure on highway, vehicle becomes locked in park; driver unable to move shift lever even with engine powered on, stranding vehicle.
When: During/after catastrophic engine failure event.
Symptoms owners cite: Shift lever stuck in park position; Unable to move to neutral despite engine on; Vehicle immobilized
Repairs/costs cited: No repair documented; occurred during towing scenario.
Recalls/TSBs owners mention: No response documented.
Synthesized from 57 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The contact owns a 2021 Ford F-150. The contact received notification of NHTSA Campaign Number: 24V635000 (ENGINE AND ENGINE COOLING) however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution…
Had engine trouble with your 2021 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 2021 Ford F-150?
It's a documented issue but not catastrophic. 57 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 11 complaints that reported odometer mileage, most engine failures cluster between 2,966 and 58,000 miles, with the median around 40,000. A quarter of owners report trouble before 2,966; a quarter make it past 58,000. 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 $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/2021/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.