2021 Ford F-150 Hybrid

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.

On November 29, 2023 I took my 2021 F150 to Larry Miller Ford for servicing and repairs related to Recalls 22S71 and 23S35. When the tech was rotating the wheels he discovered that the axle shaft bolts were sheered off on both the left and right rear wheels. The service manager called to tell me that this was a serious safety issue and that only the brake rotors were preventing the wheels from falling off the truck. The service manager told me there was a "Customer Satisfaction Program 22B34" issued by Ford, but no Ford Recall relating to the problem. Larry Miller Ford has replaced both axles and axle bolts. I am waiting to find out if there is damage to the rotors, calipers or brake pads, a concern since the sheered off bolts were rattling around within that area since breaking off apparently between service visits. I strongly believe Ford should be required to issue a recall on this problem. I never received a notification on CSP 22B34. Had it not been for my tire rotation, the wheels could have fallen off at highway speed.

My truck has the Maximun payload axle upgrade. The axle bolts on the end of the shaft have broken. I first notice squealing sound of metal from rear of truck. I searched on line for the symptom and found the problem. I then removed passenger rear wheel to verify broken bolt. I took my truck for service to Morries Grand Ledge Ford in Michigan. They verified the problem, told me it was not safe to drive and have ordered parts. They also informed me that the defective axle is not covered by recall on my vehicle. The service representative did confirm that there are recalls for the same axle but not my vehicle.

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.

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.

Planned one week, 1,400 miles roadtrip along pacific coast during memorial day weekend. Before starting our trip I went to rotate the tires and upon removing the rear passenger side wheel a bolt and metal gasket fell out. Issue: Center bolt that locks the brake assembly to the rear axle shaft was sheared off with remaining half stuck in the axle shaft. How was your safety or the safety of others put at risk?: The truck would have been loaded for our week long roadtrip up North. On the way back we were going to tow our 5000lbs trailer. This bolt would have impacted the braking ability, cause damage to the rear axle assembly possibly resulting in an accident. If I didn't rotate the tires before leaving who knows what could have happened especially if I was towing. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes. Vehicle is currently at a Ford dealer for axle shaft replacement. The service manager had a broken bolt from another vehicle and asked me is this what happened? There are hundreds of F150 owners complaining about the same thing on various forums. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Not yet. I'm glad it didn't get to that point. But from all users that had this problem and got replacement axle for what seems like defective bolts I would hope Ford would voluntarily inspect and issue a recall. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No fault lights but I did hear faint grinding sound when the windows are rolled down. I guess the bolt was spinning around in the wheel.