2021 Ford F-150 Hybrid

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.

The contact owns a 2021 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle overheated, lost motive power, and stalled. While driving, there was an abnormal clucking noise detected. The check engine warning light was illuminated. The vehicle was taken to the local dealer, where it was diagnosed that the axle bolt and spacer were missing. Additionally, the exhaust system needed to be replaced. The vehicle was repaired. The manufacturer was not contacted. The failure mileage was approximately 15,500.

The driver's side rear axle bolt sheared off over the course of normal driving. Ford is aware of this problem, advises to not use/drive the vehicle, yet no recall has been issued. Without a recall, getting this issue fixed will take weeks/months and Ford should pay for a rental vehicle since this is clearly a manufacturing defect.

13800 miles, broken axle/wheel bearing retaining bolt. Screeching noise. Bad wheel bearing. Dealer will not replace wheel bearing because they do not correlate the broken bolt to a bad wheel bearing. Leaving me with a bad wheel bearing that I consider prematurely worn out and is making a clicking sound. Dealer says they cannot replicate the noise so will not investigate further

The rear right axle bolt sheared off at 12.5k miles. if you google "rear right axle bolt 2021/2022 f150" there are THOUSANDS of people with the same issue. Thank god I heard the sound as it rattled around. I can't imagine the danger of driving down the highway at speed with my children in the back and the tire ends up sliding off. Ford is pretending this does not require a recall, yet tens of thousands of people on the forums have the same issue