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.

2021 Ford F-150 PowerBoost Hybrid, VIN [XXX]. At 112,000 miles — just 1,000 miles outside of warranty — the vehicle experienced catastrophic failure of the hybrid battery system. Ford's own technician diagnosed a short in the high voltage battery system that caused damage to the hybrid electric drive unit. Repair estimate is $19,000. Ford declined goodwill warranty coverage despite the vehicle being only 1,000 miles outside warranty and the failure occurring on a known problematic system. This is a $72,000 vehicle purchased new in 2021 that has suffered a catastrophic drivetrain failure at only 3 years old. The high voltage battery short and hybrid drive unit failure represent a potential safety hazard to drivers and other motorists. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Transmission kept slipping out on the freeway. Led to a near accident. Then ended up broken down on a highway while towing a trailer. Transmission couldn’t find gear for the next serval times we tried to place in gear. Then on the third time it went into gear and started driving again only to slip out and lead to another breakdown on the highway. Still had to drive it into dealership in its unsafe condition.

At a stoplight the truck began running rough. When the light turned green, the truck failed in just 3 blocks (approximately 1 minute). Power was greatly reduced. Check engine illuminated on dashboard, then another red icon, followed by a stop safely now message. Immediately I attempted to pull over from the left lane to the right lane but the truxk Immediately stalled across both lanes, blocking all traffic. Ford dealer has ordered a new fuel pump and the repair is pending.

When starting from a stop or rolling slowly under 15 mph, pressing the accelerator pedal — even flooring it — produces no engine or motor response for 1–3 seconds. The vehicle then suddenly accelerates. This occurs intermittently on both electric and gas power. Safety concern because it delays merging or pulling out into traffic.

Several times, the vehicle has failed to accelerate or respond to accellerator pedal input for several seconds. It seems to happen when switching from electric to hybrid modes, and when shifting between lower gears simultaneously. Once the switch to hybrid occurs the engine will rev high with some acceleration even if the accelerator pedal is no longer being pressed. This acceleration has happened when I had my foot over the brake pedal in anticipation of pulling over to stop since the truck would not accelerate. There are no warning lights or messages that appear on the vehicle. It is dangerous because it seems to happen when trying to accelerate from a lower speed. If it happens when trying to change lanes in stop and go traffic or while pulling into traffic other cars would have to brake hard to avoid hitting our vehicle that has experienced stalled acceleration. It is also dangerous because once the transition happens there is brief uncommanded acceleration.

My truck because of the transmission and it's "powertrain" faults; puts itself in low power mode. I can be driving fine, stop for a red light, to turn a corner or before pulling into oncoming traffic leaving a parking lot etc and without warning, no power. It won't go over 5-10 miles an hour. You have to let off the gas and give gas sometimes more than once to get the truck to finally pick up and go. I have almost been hit countless times because I suddenly couldn't get out of the way of oncoming traffic. The dealer has confirmd to me a few times that this is a transmission issue that is sending my powerboost into low power mode. I believe he said the tech that drove it said it was dangerous; but a known issue. Started a few years ago and doesn't happen all the time. Occurs sporadically and lately more and more frequently.

Vehicle Information 2021 Ford F-150 PowerBoost VIN: [XXX] Complaint Description While driving approximately 70 mph on a highway, my 2021 Ford F-150 PowerBoost suddenly displayed a “Stop Safely Now” message and immediately lost propulsion. The engine shut down without warning while I was in active traffic. After the shutdown, the vehicle automatically shifted into park and would not allow me to shift into neutral. This left me unable to move the vehicle out of a live traffic lane. I was forced to shut the vehicle off while still in a dangerous roadway position. This incident created a serious safety hazard, as I was traveling at highway speed and could have been rear-ended due to the sudden loss of power and inability to move the vehicle. This issue appears to match Ford Technical Service Bulletin (TSB) 23-2317, which describes “Stop Safely Now” warnings, no-start conditions, and gateway module (GWM) software faults. This indicates a known defect that can cause sudden loss of propulsion. A claim has already been opened with Ford Motor Company under case number [XXX], and the vehicle is currently at a Ford dealership for diagnosis. At this time, the issue has not been resolved. This failure occurred without warning and presents a significant risk to driver safety and others on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

2021 ford f150 PowerBoost hybrid. There is a LOT of internet chatter and forum chatter about KNOWN issues with the following, and it recently almost led to a major and likely serious injury accident. Specific Parameters: Low speed (~5 mph) slow roll Under internal combustion power, not battery In 2nd gear only When gas pedal is pressed vehicle does nothing. Does not respond. Two choices are to hammer the gas, or hit the breaks. Does two things, slams forward eventually after 3-4 second delay if gas pedal depressed OR shifts down or into electric mode (internal combustion off) and then will once again go from first to third in normal acceleration progression and pace They must have an issue with the standard 1-3 skip programming with ICE power and 2nd gear being a hang-up I almost got T boned by a semi truck due to this with family in car. This could have been deadly. It happens as an annoyance at least once per day but this one was scary. Online, and based on what I can find - Ford is aware of this issue as they have the 1-3-5 programming in the transmission but when it finds itself (due to real world driving conditions) in 2nd gear under Internal combustion, it does not know what to do. I brought it to Ford last year in Anchorage and they are attempting to blame it on normal hybrid system operation. That is NOT the case. It would be something that could be duplicated but with effort. A basic, simple test drive is NOT going to find this. They are aware of this being an issue. If you have any situation where you are rolling through, merging into traffic, or other scenario where you end up in 2 under ICE you are in TROUBLE. Dangerous, scary, and totally a manufacturer issue that is known and needs to be taken VERY seriously.

My Ford F150 was traveling on I95 North in Maryland when an emergency notice on the dashboard told be to pull over. The truck would not restart and had to be towed to a Ford dealer. I have since been told a controller module caught fire and damaged the hybrid battery and both would need to be replaced at a cost of over $10,000. This is a know issue and other Ford F150 Hybrid trucks as well as other Ford cars have already been recalled. Ford claims that my VIN was not included in the recall even though I experienced exactly what the recall was suppose to prevent. My wife and I could have been killed while traveling on the highway at 70 MPH and the vehicle was on fire without our knowledge.