2021 Ford F-150 structure problems

“While driving truck, it had an electrical fritz that caused the car to become undrivable, with systems not responding. when stopped to power cycle, the car would accessory on but not attempt to start. the horn would go off randomly. was able to manually put the truck into neutral and push into a safe spot, at what point a battery clear was attempted with no results, and required towing to dealership where water had intruded into the BCM”

“After a day of heavy rain, the vehicle stalled at a stop light and would not restart. The steering wheel and transmission locked, preventing the vehicle from being placed in neutral, creating a safety hazard as the vehicle was immobile in traffic. No warning lamps appeared prior to the failure. The vehicle required a tow. The dealer confirmed water had intruded through the passenger side cowl/firewall seam due to inadequate factory sealing, tracking down and pooling directly onto the Body Control Module (BCM) mounted on the passenger side firewall. The BCM failed due to water damage, causing PATS desynchronization and the no-start condition. The BCM failure subsequently shorted out the starter motor. Dealer replaced the BCM, repaired the leak, and replaced the starter. Total repair cost approximately $3,200. Failed components are available for inspection at the dealership. This identical failure; passenger side cowl water intrusion leading directly to BCM damage — is documented across numerous 2021+ F-150 owner forums, indicating a widespread factory sealing defect at the cowl/firewall/inner fender seam junction.”

“The contact owns a 2021 Ford F-150. The contact stated that while driving at 70 MPH, the contact noticed an unusual grinding sound. The vehicle was driven to the shoulder of the road. The contact noticed a lot of unusual clicking or rattling sounds. In addition, several unknown warning lights were illuminated. The contact stated that upon exiting the vehicle, the contact noticed a fire underneath the vehicle. In addition, the drive shaft was detached. The contact stated that the fire burned out independently. The vehicle was towed to the contact's residence. The contact stated that the drive shaft had scorching around it. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. In addition, the contact stated that the recall, NHTSA Campaign Number: 21V986000 (Power Train, Structure), was performed on the contact's VIN about six months ago. The dealer was not made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 111,000.”

“Astro white exterior paint is chipping on the roof of the vehicle in multiple locations. See pictures attached of sever chipping above windshield and wear the roof meets. Also chipping occurring above both rear doors on roof. This was not due to an accident or normal wear and tear.”

“My 2021 Ford F-150 Lariat has a door latch defect that occurs in freezing or near-freezing temperatures. The failure occurs without warning in cold conditions, causing the door latch to freeze and not fully engage. When this happens, the door is able to freely swing open while the vehicle is in motion and also freely open when the vehicle is parked. This creates a serious safety hazard, including the risk of occupant ejection and loss of vehicle control. The vehicle has no aftermarket modifications and is maintained per manufacturer recommendations. The issue is temperature-dependent and has occurred on multiple occasions. Ford has issued recalls for similar door latch freezing defects on multiple other Ford vehicles and model years. Despite this, my vehicle has not been included, even though it exhibits the same failure mode. This defect presents a significant safety risk and should be investigated for potential recall inclusion.”

“Please see Ford TSB SSM50543. In my case the driver's door has been freezing in the lock position. Door will not unlock and cannot be opened either from the inside or outside. The key in the outside will not unlock the door and pulling up on the knob inside cannot be done (even tried with pliers). The electric door locks for the frozen door do nothing. This made it possible for me to only get out of or into the driver's seat by climbing in/out from the passenger's side. I also tried to not lock the driver's door, and this just made the door frozen in the unlock position. Very inconvenient, but I am especially concerned if I had to exit or enter the driver's side in an emergency. Ford knows about this as can be seem from the issued TSB. This had happened more than once and goes away when the inside of the truck gets really warm, or the weather gets above sufficiently over freezing.”