NHTSA Complaint #11613945 — 2015 FORD F-150

The exhaust manifold on the 2015 Ford F-150 EcoBoost engine is designed with only eight securing bolts. Owners have reported that this number of bolts is insufficient to adequately secure the manifold, leading to heat-induced warping and subsequent exhaust leaks. The leaks cause an audible whistling noise when the engine is under acceleration, which not only affects vehicle performance but may also lead to more severe engine issues if left unaddressed. Many owners of the 2015 Ford F-150 EcoBoost engine have experienced similar issues, indicating a widespread design flaw. While the immediate issue is the noise and potential performance degradation, prolonged exhaust leaks can lead to more serious problems, including increased emissions and possible engine damage. The warping of the manifold could also lead to more severe mechanical failures if not properly addressed. Detailed Description: The exhaust manifold on the 2015 Ford F-150 EcoBoost engine is designed with only eight securing bolts. Owners have reported that this number of bolts is insufficient to adequately secure the manifold, leading to heat-induced warping and subsequent exhaust leaks. The leaks cause an audible whistling noise when the engine is under acceleration, which not only affects vehicle performance but may also lead to more severe engine issues if left unaddressed. Affected Population: Many owners of the 2015 Ford F-150 EcoBoost engine have experienced similar issues, indicating a widespread design flaw. The problem typically arises in vehicles with relatively low mileage, highlighting a critical manufacturing oversight. The design of the exhaust manifold should be revised to include additional securing bolts to prevent future occurrences of warping and leaks.