What year Ford trucks have aluminum bodies?
Timeline: The F-150's Aluminum Transition
What changed in manufacturing
Ford shifted the F-150’s exterior panels to aluminum while keeping the frame built from steel. This move was intended to reduce weight, improve efficiency, and preserve strength for typical truck use. The electric version, the F-150 Lightning, follows the same aluminum-body approach.
- 2015 model year: Introduction of an aluminum body for the F-150’s exterior panels (hood, doors, bed, and body panels) with a steel frame.
- 2016–present: All F-150 models continue to use an aluminum exterior body; the Lightning also uses the same aluminum design.
The shift was marketed as a weight savings strategy aimed at improving payload, towing, and fuel economy, while maintaining durability through advanced high-strength aluminum alloys.
Other Ford Trucks and Aluminum: What to know
Beyond the F-150, Ford’s other pickup lines have not moved to a full aluminum-bodied construction as of 2024. Here’s a quick look at their material makeup.
- Ford F-Series Super Duty (F-250/350): Steel body; no full aluminum-body adoption in production as of 2024.
- Ford Ranger: Steel body in its construction; not aluminum-bodied.
- Ford Maverick: Unibody construction based on steel; not aluminum-bodied.
In practice, if you’re seeking an aluminum-bodied Ford pickup, the F-150 and its Lightning variant are the relevant options in the lineup as of 2024.
Summary
Ford’s big leap to an aluminum body began with the 2015 F-150 and has continued to the present, including the F-150 Lightning. The rest of Ford’s pickup lineup has remained steel-bodied through 2024, with no full aluminum-body adoption across those models. The shift on the F-150 represents a targeted strategy to reduce weight while preserving strength, a change that has defined Ford’s truck lineup for nearly a decade.
What year did Ford make aluminum body trucks?
Ford introduced its first aluminum-body trucks with the 2015 F-150, making it the first large-scale aluminum-intensive vehicle from an American manufacturer. The Super Duty line followed suit and adopted aluminum bodies for the 2017 model year.
- 2015 F-150: The 13th generation F-150 was the first to feature an aluminum body, which helped reduce weight, improve fuel efficiency, and increase payload capacity.
- 2017 Super Duty: For the 2017 model year, the Super Duty trucks also began using aluminum for their bodies, though they continued to have a separate, heavier-duty steel frame.
When did Ford stop making steel?
In 1989, Ford's steel mill assets were divested and became known as Rouge Industries with the steel operations trading as Rouge Steel Company in Dearborn, Michigan, outside of Detroit.
What Ford trucks are made out of aluminum?
Ford trucks with aluminum bodies include the F-150 and the F-Series Super Duty, starting with the 2015 model year for the F-150 and the 2017 model year for the Super Duty. This includes the all-electric F-150 Lightning, which also utilizes a high-strength aluminum alloy body. These trucks feature aluminum body panels but use a high-strength steel frame for structural integrity.
- Ford F-150: Switched to an aluminum-alloy body in 2015.
- Ford F-Series Super Duty: Gained aluminum bodies starting in 2017.
- F-150 Lightning: The all-electric model uses a high-strength aluminum alloy body and structural components.
What year of F-150 to stay away from?
You should stay away from Ford F-150 model years 2004–2008, which are known for severe engine and transmission issues, and model years 2011–2017, which have issues with early EcoBoost engines, transmission problems, and other defects. Specific years to avoid include the 2004, due to a widespread and expensive 5.4L Triton V8 engine, and the 2015-2017 models, which had issues with their aluminum bodies, EcoBoost engines, and transmissions.
Years to avoid
- 2004–2008: These years are notorious for problems with the 5.4L Triton V8 engine, including spark plug breakage, cam phaser failures, and timing chain issues. Transmission problems and electrical system failures were also common.
- 2011–2013: These models had significant issues with the 6-speed automatic transmission, including hard shifting and slipping.
- 2011–2014: Early EcoBoost engines in this range had problems with intercooler condensation, carbon build-up, and spark plug/ignition coil failures.
- 2015–2017: The introduction of the aluminum body brought new reliability concerns. These years are known for problems with EcoBoost engines (particularly the 2.7L), the 6-speed automatic transmission, and some door and brake issues. The 2015 model is also cited for turbocharger and timing chain problems.
How to choose the right year
- To find a reliable F-150, consider model years after 2017, such as 2018–2020, which had significantly fewer reported problems.
- Avoid the problematic years listed above, especially if you are looking for a used truck.
- The 2004-2008 models should be avoided, as they are known for the expensive 5.4L Triton V8 engine, and the 2015-2017 models had numerous problems with their new aluminum body and EcoBoost engines.
