NHTSA widens probe into 1.27M 2015–2017 Ford F‑150s over 6R80 unexpected downshifts

Expanded probe tests safety of 6R80‑equipped F-150s

U.S. safety regulators are widening a probe into about 1.27 million Ford F-150 pickup trucks after drivers report unexpected transmission downshifts that occur without warning or driver input and are often accompanied by temporary rear‑wheel lockup or skidding. The National Highway Traffic Safety Administration (NHTSA) says the investigation covers 2015–2017 model year F‑150s equipped with the 6R80 automatic transmission and follows a preliminary evaluation opened on March 21, 2025, after consumer complaints about the 6R80 unit.

Ford tells NHTSA that the alleged defect in the 2015–2017 trucks differs from problems that prompted four earlier safety recalls covering 2011–2014 models, which were traced to a supplier manufacturing issue that caused loss of speed sensor signals. The company says the newer reports could stem from degradation of electrical connections due to thermal cycling and vibration over extended service life, which may lead to loss of signal from the transmission range sensor (TRS).

NHTSA’s Office of Defects Investigation (ODI) flags an additional potential hazard from preliminary testing: vehicles that experience TRS signal loss while backing up an incline can reportedly shift into neutral and roll forward. ODI opens an engineering analysis to perform further testing, review technical data and quantify incident counts and repair histories so regulators can determine whether remedies such as a recall, owner notification and repairs are warranted.

What regulators will examine next

The engineering analysis aims to clarify the failure mode, its frequency and the safety consequences for drivers and occupants, with investigators seeking to reproduce the signal‑loss events under a range of conditions. NHTSA says its expanded inquiry will also analyze repair records to assess whether field fixes are effective or if a broader remedy is necessary; agency officials do not provide a timetable for the review.

Broader context for Ford and the industry

The F‑150 remains the perennial best‑selling pickup in the U.S., and the probe comes as Ford is already dealing with other large safety actions, including a separate recall of about 1.4 million vehicles over a rearview camera issue. Regulators’ findings could influence repair costs, dealer workloads and industry attention on long‑term durability of transmission electrical connections in high‑use trucks.