2021 Ford F-150 Hybrid

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 confirmed by an authorized Ford dealership service department, Kayser Automotive Group located at 2303 West Beltline Hwy Madison, WI 53713. Dealership technicians verified the water accumulation path, identified the faulty/clogged drain pathway, and documented physical corrosion on the DCN wiring connector. A Technical Assistance Center (TAC) case was requested to escalate the defect to Ford Corporate. WARNING LAMPS & PRIOR SYMPTOMS: Initial symptoms appeared as heavily saturated interior floor carpets and standing water pooling near the cowl/dash area. Shortly thereafter, intermittent electrical glitches, warning lamps on the instrument cluster, and network communication Diagnostic Trouble Codes (DTCs) appeared as the corrosion worsened. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Good Afternoon. The Pro Power Onboard high-voltage electrical system has experienced a permanent malfunction, locking out with a "Ground Fault Detected" warning. The vehicle is a 2021 Ford F-150 Rocky Ridge conversion. This failure stems directly from a defective or incomplete execution of Safety Recall 23S35 (NHTSA Campaign 23V613000).The initial remedy applied by the dealership consisted only of adding protective tape to the rear wiring harness. However, due to the increased travel and ride height of the official Rocky Ridge suspension lift, the wiring harness pulled out of its factory retaining side clip. This caused excessive tension and stretching on the high-voltage lines, completely exposing the bare interior colored wires and leaving them vulnerable to road moisture and friction against the metal frame.The system now triggers a permanent short-to-ground error, creating an imminent risk of an electrical short circuit or vehicle fire under the high-voltage (120V/240V) lines. The Ford dealership and corporate customer care refuse to remedy this recurring safety hazard under the recall warranty because it was previously marked as completed, even though the applied remedy failed to safely secure the harness. The component is available for inspection.

: Driver side door latch, yes it's available for inspection and has been inspected by Tasca Ford Cranston RI 02920. : In a cold environment Driver side door can not be opened from the inside. Interior door latch freezes making it impossible to open door. Door must be opened from the outside. In some cases latch freezes and door will latch closed. You have to physically hold the door shut in order to drive! : This was inspected and issue confirmed by Ford Dealership and service advisor. Video has been taken. : First issue was in 2023 after used vehicle purchase. Issue is on going, during below freezing days.

The contact owns a 2021 Ford F-150. The contact stated while his wife was driving at an undisclosed speed and while reversing, the contact stated that his wife heard an abnormal rubbing sound. No warning lights were illuminated. The vehicle was taken to a dealer where it was diagnosed with a fractured driveshaft. The vehicle remained at the dealer awaiting the repair. The contact related the failure with NHTSA Campaign Number: 21V986000 (Power Train, Structure) however, the VIN was not included. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 86,000.

The contact owns a 2021 Ford F-150. The contact stated that while the vehicle was parked, a week after it had rained and twelve hours after it was last driven, there was an abnormal mildew odor inside the vehicle. The contact stated that there was condensation entering the vehicle from an unknown location and the carpet on the passenger’s side floor was wet. The contact stated that the sunroof was properly closed while it was raining. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 33,000.

The Axle bolts on both sides of the truck sheared off. The passenger rear axle bolt sheared at 15,000 miles into having the new truck. The driver side rear axle bolt sheared at 21,000 miles. This is a large safety concern and is not unique to just me. The first axle bolt sheared and was repaired once I figured out the problem at a Ford dealer. The second bolt is currently being repaired in the same dealer's service department. There was no warning or detection of this problem other than a rattling sound during acceleration and a wizzing sound during braking. I do not have either of the sheared axle bolts. They were kept by the dealer.

Active Air Dam: My 2021 Ford F150 XLT truck has an active air dam, (AAD), that is suppose to move downwards at speeds of 40mph or greater to help with aerodynamics. This is to help the truck hug the road better at highway speeds. When the truck slows down to under 40mph, the AAD is suppose to recess back up an be tucked away behind the stationary air dam. They started these AAD's on their trucks in the model year of 2021. It has been a widely known issue that the AAD design is flawed and they malfunction and get stuck on the front air dam. Some have came loose and flown off into other vehicles on the roadways. This presents a safety hazard to the owners and other vehicles on the road. Ford refuses to fix it stating that their extended warranty does not cover the parts. This is NOT a warranty issue, this is a poor design issue and a faulty part issue that is going to cause someone to get seriously injured or worse, killed. Some people have reported that their AAD flew off their truck and they didn't even notice until the service tech at the dealership told them during an oil change. So that means their are people out there that are driving with this hazardous part flying off their truck and where is it going? Into the traffic following behind, and what are those drivers going to do when it comes hurling at them at a high rate of speed? Most likely slam on their brakes, causing a rear end collision, or they serve to avoid it and either hit an on coming vehicle head-on or slam into the vehicle next to them on a multi lane highway or interstate. Please make Ford fix their problem before someone gets killed or seriously injured.