NHTSA Complaint #11489467 — 2016 FORD F-150

The exhaust manifold system on my F-150 failed and the Ford Motor Company is making me pay for repairs that costed approximately $4,000.00. At the time of repairs my truck had around 78,000 miles and yet the Federal Emissions Warranty is supposed to cover my vehicle for 80,000 ,miles or less for components that could adversely effect the vehicle's emissions status while in the continental United States. I have been bringing my vehicle to Ford-Service for it's regularly scheduled maintenance intervals. I have been maintaining my vehicle in accordance with the Ford Vehicle's manual for 2016 F-150. Failure of the F-150 exhaust manifold system is common on Ford Vehicles with the 3.5L Eco Boost Engine. This is due to the metallic warping of the cast iron manifold system over time. To address this issue, Ford has issues a 2021 Special Service Message Sep 1 2021 2979 - 2015-2021 Transit - 3.5L EcoBoost - New Exhaust Manifold Part Numbers - Built On Or Before 01-Dec-2020. The proper repair and replacement parts calls for stainless steel parts that will not warp over time. Failure of the existing manifold parts on these engines could result in the unplanned loss of these critical emission components directly onto the road and into the path of other drivers while operating the vehicle. Ford should be issuing a recall in addition to it's already published Special Service Message for these components so that the safer components can be installed on all affected vehicles. If Ford does not feel any pressure from the NHTSA or any other federal agency in regards to vehicle safety, then it will take a series of tragic accidents involving emission component failures and personnel death/injuries to get the proper amount of attention to force a recall. This is my attempt to notify the NHTSA of a possible critical safety flaw in their 3.5L Ecoboost designs and to get Ford to issue a recall as soon as possible, before getting into extremis.