2020 Ford F-150: broken coil spring

Filed Oct 23, 2026 · Suspension · MI

On XXX, while the vehicle was parked and not in use, the passenger-side front coil spring abruptly fractured, causing the front passenger side of the vehicle to drop onto the tire. The failure also damaged additional components. The vehicle and failed component are currently located at Hines Park Ford in [XXX], and are available for inspection upon request. This failure presented a serious safety concern. Had the spring fractured while the vehicle was traveling at highway speeds, the sudden drop in the vehicle’s front end, contact with the tire, and damage to additional components could have resulted in a sudden loss of vehicle control, potentially causing a serious crash, significant injuries, or fatalities. I am unaware whether the failure has been independently reproduced. However, the dealership inspected the vehicle and confirmed that the coil spring had broken and that additional components were damaged as a result. There were no warning signs, unusual noises, dashboard warning lights, or other noticeable symptoms before the failure. The spring fractured abruptly and without warning while the vehicle was parked. The sudden failure of a critical suspension component on a vehicle that was not in motion raises serious concerns about the component’s reliability and the potential consequences if the same failure occurs while driving. Video of event - [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Sep 7, 2026 · Suspension · VA

2020 Ford F-150 Raptor supercab with 47,500 miles. Front right coil spring broke into several pieces while sitting in the driveway. Rust on one half of the piece that fell on the driveway indicates rust coating failed and caused the initial break in the coil spring. The way the coil spring broke and the vehicle lost ride height could have killed me if I were underneath changing the oil. If it had broke while driving, it would have caused an accident from loss of control endangering vehicle passengers and others on the road.I will keep all parts and have available for inspection. In hindsight, the only sign this was a problem was noise while driving over speed bumps and it was inspected by several different shops (Ford, VA inspection, two auto body shops) over the last year while it presented the noise. The truck has not been inspected since the coil spring broke.

Filed May 28, 2025 · Suspension · MI

With 72,000 miles the driver's side spring broke just setting in our driveway. Unknown to my wife who drove it 7 miles to work with a broken suspension spring. Within 200 miles the other spring broke on the passenger front while going down the road. Didn't hit a bump and was going straight. This one also snapped with no notice and i had visually inspected it days before. We were going 15-20 mph when it broke and were able to safely pull off the road. Unheard of them breaking when the vehicle is only driven on the paved roadways and not off used off road. Cost approximately $1,200 to just repair the driver front at a shop.

Filed May 10, 2025 · Suspension · NY

After completing a 200-mile highway drive with my family in the vehicle, I performed a routine visual inspection of the undercarriage. During this inspection, I immediately noticed that one of the front coil springs appeared to be off-center in relation to the shock assembly. Upon closer examination, I discovered that both front coil springs had shifted significantly out of position. Even more alarming, the coil spring on the passenger side had a complete fracture—it was fully cracked through. In addition, the misalignment of both springs had caused visible damage to the shock bodies, suggesting metal-on-metal contact had been occurring during operation. This is not a wear-and-tear issue or a cosmetic concern—this is a catastrophic suspension failure on a relatively new and well-maintained vehicle. Coil springs are a critical structural component designed to support the weight of the vehicle, absorb shocks, and maintain proper handling and ride height. A complete failure of one coil spring, coupled with misalignment of both, indicates either a serious design flaw or material defect. Had this failure progressed during our highway drive, especially at speed or during an evasive maneuver, the consequences could have been tragic—not only for my family, but for other drivers on the road. The loss of suspension integrity at highway speeds could lead to sudden loss of vehicle control, steering instability, or even a rollover. The fact that this occurred without any warning signs (no abnormal noises, ride quality changes, or handling issues were noticed prior to inspection) makes it even more concerning. This type of failure should not be happening on a modern pickup truck, especially one marketed for its toughness and reliability. I am filing this complaint in the hope that the federal safety agency investigates whether this is an isolated incident or part of a broader issue affecting other 2020 F-150s. If other vehicles are at risk of similar suspension failures, this poses a serious publ

Filed Apr 8, 2024 · Suspension · 59,000 miles · CT

The contact owns a 2020 Ford F-150. The contact stated while driving approximately 50 MPH, he observed a loud noise emanating from the passenger side of the vehicle. The vehicle swerved violently to the right almost driving off a cliff. The vehicle was taken to a dealer where it was diagnosed that the front coil spring on the passenger’s side strut had fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 59,000.