2021 Ford F-150 Hybrid

3.6.2021 - Ford F150 purchased at Battlefield Ford (Ourisman Ford), Manassus VA / registered in CT 7.27.21 – inspected by Torrington Ford, Torrington CT for rubbing sound front left side, nothing found / 6,325 miles 2.10.22 – inspected for same issue / nothing found / 16,000 miles 7.27.22 – inspected for same issue / nothing found / 24,000 miles 12.24.2022 – “Catastrophic failure” of front differential / 34,369 miles. On Christmas Eve 2022 myself, husband and son were driving to family in NY when the truck very quickly started to make a severe grinding sound, became unable to steer, loss of control, and started to produce smoke & fire under the hood. We immediately stopped and got out unharmed. Fire was dripping out of the bottom of the truck and smoke/fire under the hood. We were lucky. Firetrucks came but were unable to do anything. The truck's wheels completely seized up - the tow truck had to skid it onto the flatbed. Repaired at Simmons-Rockwell Ford, Hallstead, PA. Complete new front differential and damaged parts in proximity to the failure (pinion gear, axle shaft, etc). 12.16.2023 – Again hearing a sound in front left side while driving; bring to the shop for inspection. Shop confirms front differential is failing again, per Torrington Ford, (where all maintenance and repairs were completed, except for the first failed front differential in PA). Advise not to drive for safety reasons. 52,922 miles. With both front differential failures - no warning lights or messages. Symptoms - a slight rubbing/grinding noise in the front left side of vehicle; “rough” sound while driving. 1st front differential – inspected at 6,000 miles, 16,000 miles, and 24,000 miles. Failed at 34,369 miles. 2nd front differential – inspected at 52,922 miles, failing differential, advised not to drive. Dec 2023 – Buy-back claim filed with Ford Motor Co. Denied - "outside of the 18-month warranty period for VA Lemon Law". Clearly, safety is not a guiding tenet for Ford Motor Co.

Radio started blasting a boom/ static sound from the rear speakers and subwoofer; extremely loud and has occurred multiple times. It had previously made a similiar sound occasionally at start up which when under warranty was always diagnosed as unable to duplicate but is now occuring while driving and I am out of warranty. Very startling and distracting when it occurs. Has occured multiple times and lasts upto an hour before I gave up an parked my vehicle. Have a special needs minimally verbal disabled child who is very sensitive to noise (rear speakers are always turned off via fade to front) who was very impacted by this loud explosion of chaos/ noise when it occured with him in the car. Ford response: since out of warranty can pay for diagnostic and repairs. Don't expect NHTSA to care as they weren't concerned with my complaint regarding complete loss of brakes (incomplete or bad programming) with this truck but maybe this will let others know they arent alone if they have this issue.

Console lid with integrated work table. Will not stay open and will slam shut because the springs are not strong enough to hold lid open. This has been present since the vehicle was purchased new. Several members of my family including me have had the lid slam on my fingers. The lid is heavy and it hurts. Local ford dealer said that the console in all the F150 do it and there is no fix from ford. I’m concerned that a grand child may open the lid and it slam down on their fingers and cause serious injury. Ive read multiply f150 complaints about this issue, and even a possible fix. the truck is still under warranty . Ive been dealing with issue from a month after the purchase. It’s a virtual mouse or rat trap to who ever opens the lid! I know this is not your typical safety issue, but it is a safety issue! Thank you

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.

Audio/speaker system made extremely loud and surprising pop when vehicle on but audio system off. This could very easily startle the driver causing him to take an unsafe maneuver. The problem has not been reproduced by a dealer nor been inspected by anyone, but I have seen other reports of this problem for this model via an internet search. I saw no warning lights prior or after this occurred. Subsequent to this pop, the speakers crackled even when the vehicle was off, but this crackling stopped over the night.

Deafening pulsing noise coming from all speakers , volume button did not turn it off. Shut truck and locked it and did not stop the noise. Unplugged battery and did not stop noise. After about 15 minutes it stopped. Got into truck and there was an electrical burning smell. I have recorded the noise on video. Big safety concern, if the noise happened while I was moving I might have crashed. My ears were ringing for awhile after the incident.

I heard a very loud screeching noise around 4K miles and took it to the dealership, they said my axle nut on the driver side of the truck was sheared off. They said it was covered under warranty and repaired the issue. 8k miles after repair it is doing the exact same thing. No check engine lights for this issue ever appeared on the dash. Ford spend about 3 weeks or longer fixing this the first time. They promised when I purchased the truck if there where any issues I would get a loaner vehicle, nothing available to loan on the first time. Now that it’s happened again I called to scheduled a time to repair and they say I can’t even get seen until January 20th. So this truck has costed me a lot of out of pocket money for rentals.