1996 Ford F Super Duty recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-18. Recalls apply to specific VINs — run your VIN to confirm.
2 safety recalls, most serious first
1. Body / structure
What's wrong, in plain English: Body panels, frame, doors, hood, trunk or latches. THE CROSSMEMBER FRAME GUSSETS WERE INSTALLED WITH UNDERSIZED THREADED FASTENERS FOLLOWING A BREAKDOWN OF THE PRODUCTION RIVET GUN THAT IS GENERALLY USED. THIS GUSSET IS THE ATTACHMENT POINT FOR THE REAR STRAP OF THE MID-SHIP FUEL TANK.
What could happen: THE SUBJECT FASTENERS CAN SEPARATE CAUSING IN THE REAR STRAP OF THE AFFECTED FUEL TANK TO BECOME DISCONNECTED. A LOOSE OR DISCONNECTED REAR STRAP ALLOWS THE FUEL TANK TO POSSIBLY CONTACT THE ROAD SURFACE INCREASING THE RISK OF A VEHICLE FIRE.
The fix: DEALERS WILL REPLACE THE CROSSMEMBER GUSSET FASTENERS WITH THE SPECIFIED ALTERNATIVE FASTENERS (BOLTS).
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1996 F SUPER DUTY.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 96V146000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: STRUCTURE:FRAME AND MEMBERS
Summary: THE CROSSMEMBER FRAME GUSSETS WERE INSTALLED WITH UNDERSIZED THREADED FASTENERS FOLLOWING A BREAKDOWN OF THE PRODUCTION RIVET GUN THAT IS GENERALLY USED. THIS GUSSET IS THE ATTACHMENT POINT FOR THE REAR STRAP OF THE MID-SHIP FUEL TANK.
Consequence: THE SUBJECT FASTENERS CAN SEPARATE CAUSING IN THE REAR STRAP OF THE AFFECTED FUEL TANK TO BECOME DISCONNECTED. A LOOSE OR DISCONNECTED REAR STRAP ALLOWS THE FUEL TANK TO POSSIBLY CONTACT THE ROAD SURFACE INCREASING THE RISK OF A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE CROSSMEMBER GUSSET FASTENERS WITH THE SPECIFIED ALTERNATIVE FASTENERS (BOLTS).
Notes: OWNER NOTIFICATION: OWNER NOTIFICATION IS EXPECTED TO BEGIN AUGUST 26, 1996. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
2. Engine
What's wrong, in plain English: Engine problems range from stalling to fire. VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. HOT EXHAUST GASSES CAN LEAK FROM THE EXHAUST GAS RETURN (EGR) TUBE ON THE ENGINE. A HOLE CAN DEVELOP IN THE FLEXIBLE SECTION OF THE TUBE. HEAT DAMAGE TO THE PASSENGER COMPARTMENT FLOOR AND FLOOR COVERING CAN OCCUR.
What could happen: DEPENDING ON THE MATERIALS USED IN THE CONSTRUCTION OF THE COMPLETED VEHICLE, IGNITION OF THESE MATERIALS COULD OCCUR RESULTING IN A VEHICLE FIRE.
The fix: DEALERS WILL REPLACE THE EGR TUBE.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1996 F SUPER DUTY.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 97V209000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
Summary: VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. HOT EXHAUST GASSES CAN LEAK FROM THE EXHAUST GAS RETURN (EGR) TUBE ON THE ENGINE. A HOLE CAN DEVELOP IN THE FLEXIBLE SECTION OF THE TUBE. HEAT DAMAGE TO THE PASSENGER COMPARTMENT FLOOR AND FLOOR COVERING CAN OCCUR.
Consequence: DEPENDING ON THE MATERIALS USED IN THE CONSTRUCTION OF THE COMPLETED VEHICLE, IGNITION OF THESE MATERIALS COULD OCCUR RESULTING IN A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE EGR TUBE.
Notes: OWNER NOTIFICATION BEGAN JANUARY 19, 1998. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD MOTORHOME CUSTOMER SERVICE AT 1-800-444-3311. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- 1996 Ford F Super Duty owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Vehicle Speed Control (3), Fuel system (3), Other (2), Engine (2), Transmission / drivetrain (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
02/13/2008 · Vehicle Speed Control · fire
SPEED CONTROL DEACTIVATION SWITCH FAILURE THAT RESULTED IN AN ENGINE COMPARTMENT FIRE WHILE THE VEHICLE WAS BEING DRIVEN. THIS VEHICLE IS EQUIPPED WITH A DIESEL ENGINE AND HAS NOT BEEN INCLUDED IN THE RECALL TO DATE. *TR
02/01/2008 · Vehicle Speed Control
TL*THE CONTACT OWNS A 1996 FORD F SUPER DUTY. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 07V336000 (VEHICLE SPEED CONTROL) AND FORD RECALL NUMBER 05S28 IN AUGUST OF 2007. HE CALLED FORD SEVERAL TIMES AND THEY STATED THAT THE PARTS WOULD BE AVAILABLE IN MID'DECEMBER OF 2007 AND THEN IN JANUARY OF 2008. THE DEACTIVATION SWITCH WAS DI…
07/24/2003 · Transmission / drivetrain
WHILE DRIVING TRANSMISSION QUIT RUNNING, UNABLE TO ACCELERATE. DEALERSHIP REPLACED THE TRANSMISSION, BUT THE PROBLEM RECURRED.*AK
03/19/2002 · Fuel system
WE WERE TRAVELING FROM LIVINGSTON TEXAS BEFORE LEAVING LIVINGSTON WE GASED OUR MOTOR HOME UP AND WE BEGIN TO SMELL GAS WE TRAVELED TO SAN ANTONIO TEXAS AND NOTICED WHEN WE FILLED THE TANK THAT WE COULD SMELL GAS LOOKING AROUND THE MOTOR HOME WE SAW NOTHING SO WE TRAVELED ON TO EL PASO TEXAS. UPON ARRIVING IN EL PASO WE DECIDED TO FILL UP AND THEN PARK FOR…
03/30/2000 · Engine
THE PASSENGER'S SIDE EXHAUST MANIFOLD ON MY 1997 MOTORHOME HAS WARPED, WHICH SUBSEQUENTLY CAUSED A BOLT HOLDING THE MANIFOLD IN PLACE TO BREAK OFF. THE FORD DEALER NOW REPAIRING THE VEHICLE SAID THAT FORD HAS HAD MANY PROBLEMS WITH EXHASUT MANIFOLDS ON THE 460 CID ENGINE IN MOTORHOMES...WHY NO RECALL, WHY NO ACTION ON THIS? THE RESULTING EXHAUST LEAK CLEA…
10/15/1999 · Fuel system
FAILURE OF THE FUEL PUMP, FUEL FILTER AND SENDING UNIT CAUSED THE MOTOR HOME TO STALL OVER AND OVER AGAIN. YH
10/15/1999 · Electrical system
WIRING ASSEMBLY FAILED. YH
10/15/1999 · Vehicle Speed Control
IDLE AIR VALVE ASSEMBLY REPLACED DUE TO STALLING. YH