2021 Ford F-150 Hybrid problems

“I picked up my F-150 Powerboost from the Ford dealership after getting and oil change. Recorded mileage was 100,385 (just 385 miles out of the 100,000 EV warranty. Just 2 hours after getting it back the check engine light came on for P0B24 for hybrid battery failure. The Ford dealership diagnosed the issue and confirmed the entire hybrid battery has to be replaced. I requested Goodwill assistance from Ford being that it was <500 miles out of warranty. Ford denied the request immediately. The Ford service department wrote them an email with official confirmation of the issue and the timing of the issue starting. Ford denied their request for Goodwill assistance/financial help within 20 minutes of the request. The repair is $5,000+ out of pocket.”

“The vehicle is currently at Kayser Automotive Group located at 2303 West Beltline Hwy Madison, WI 53713, their direct line is [XXX], since the diagnoses of the corrosion of the DCN. SYSTEMS & COMPONENTS THAT FAILED: A faulty or clogged engine bay drain plug failed to divert water, causing significant water accumulation that routed into the interior cabin. This water intrusion directly soaked interior carpeting and exposed the Data Communication Network (DCN) connector and Body Control Module (BCM) wiring harness to moisture, resulting in severe pin corrosion and electrical communication faults. The vehicle and all affected components are fully available for inspection upon request. SAFETY RISK: The DCN connector and Body Control Module control critical vehicle operations, exterior lighting, instrument clusters, and safety/driver-assistance systems. Water corrosion on these communication buses causes unpredictable, uncommanded electrical failures and module communication dropouts while operating the vehicle at speed, creating a severe crash hazard to occupants and surrounding traffic. DEALER CONFIRMATION & INSPECTIONS: The issue was physically inspected and…”

“While traveling home on a 2 lane highway 55 on a busy Sunday, the truck started misfiring and jerking, shaking then stalled. Engine light was flashing and we were able to pull off to side as it stalled. After a short time we proceeded on the highway, as we were in a precarious position, about 3 miles and it began misfiring and stalled again. This could have been a tragic situation had there not been a pullout with our travel trailer. We had to have our truck towed to the ford dealer and our RV towed home. While seeking similar cases online we believe it to be a fuel pump driver module and contamination. Our truck VIN is not currently on the national recall list and feel it should be.”

“The contact owns a 2021 Ford F-150. The contact stated while driving approximately 65-70 MPH, the contact was flagged down by a nearby driver and advised to pull the vehicle over to the shoulder of the road. The contact stated that the vehicle was driven to the shoulder of the road. The contact exited the vehicle and proceeded to inspect the vehicle. The contact noticed that the rear driver's side rim cap had detached. The contact stated that the center axle bolt was still attached to the rim cap. The vehicle was towed to the dealer where it was diagnosed with a failed rear axle half shaft and hub and the rear axle half shaft and hub needed to be replaced. The vehicle was repaired. The contact stated that the driver's side rear axle bolt had previously been replaced and was under an unknown recall. In addition, the contact stated that the failure had occurred on five occasions within two years and that the vehicle was unsafe to be driven. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 20,000.”

“Experiencing total stop of acceleration in two occasions: 1) when putting the car in reverse and pressing the accelerator and 2) when making a left or right turn after a yield or stop. And when I say loss of acceleration, I don’t mean hesitation, reduced power, or sluggish acceleration. I mean absolutely ZERO acceleration. I’ll press the accelerator and nothing happens. The engine stays basically at idle, and the truck will not accelerate for roughly 5-10 seconds, regardless of how much accelerator I’m giving it. Then suddenly power comes back and the truck drives normally again. This happens with normal operating temps while driving most of the day. It got to a point where it happened once every day. Very scary stuff when you're pulling out into traffic - major safety concerns with oncoming traffic.”

“I was driving home after dark from a work trip. I was about 15 minutes from home when I slammed on my brakes to avoid hitting a deer that ran out in front of me. I was going approximately 45 miles an hour. Then all of the brake warning lights and ABS Fault lights came on. I was able to get home with no problem and though it might have just been because of the sudden brake application and it would clear at the next drive. When I went to drive my truck next, I had no brakes and the pedal went to the floor. I started looking and found a puddle of brake fluid under my truck. I used to be a mechanic, so I started to trouble shoot the problem and found that a wire mesh covered flexible section of the brake line feeding the front passenger wheel brake caliper had a blow out and is what had failed. Although my 2021 F-150 is out of warranty, a 5 year old well maintained truck shouldn't have a brake line fail and I think I was luck to get home safe. I had my truck towed to the local Ford dealership for the repair. They did a thorough examination and could find a reason for the failure and agreed that it shouldn't have failed and that they had never seen anything like it before.”