2022 Ford F-150 Hybrid

The contact owns a 2022 Ford F-150. The contact received notification of NHTSA Campaign Number: 23V896000 (Power Train) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2022 Ford F-150. The contact received notification of NHTSA Campaign Number: 23V896000 (Power Train) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while her husband was driving at an undisclosed speed and towing a camper, the vehicle made a shuddering sound and failed to accelerate while depressing the accelerator pedal. The contact was unsure what warning lights were illuminated. The vehicle was towed to the dealer and the contact was informed that there was a recall related to the failure. The dealer replaced the rear axle hub and seals. The contact stated on another occasion while driving at an undisclosed speed, unknown warning lights illuminated, and the vehicle was taken to the dealer for diagnostic testing. The dealer replaced the rear wheel speed sensor. The vehicle was returned to the contact, and the contact stated that the vehicle failed to drive or reverse as needed. The vehicle was taken to another dealer to be diagnosed. The contact was informed that the failure was related to the recall. The vehicle was not repaired, and the contact stated that the warranty was used to repair the vehicle two times to repair the rear axle; however, the failure persisted. The manufacturer was made aware of the issue. The failure mileage was approximately 35,000. VIN tool confirms parts not available.

Vehicle's engine will not start. When attempting to start, it will turn on all usual electrical components, but will immediately show an warning message to "Stop Safely Now" along with an engine light of a red outlined truck with exclamation mark. Followed by a message of accessory mode on, however the engine will not start with no access to power steering or shifting gears. Normal attempts to jump start or charge the battery will not work. All fuses and harness connections appear to be normal. After researching Ford community forums, this appears to be a common complaint in the Powerboost Hybrid 2021-2022 Ford F-150s. Extremely inconvenient as this situation has left us stranded several hours from home with no reasonable solution other than to tow to a dealership. We hope our message helps encourage Ford Motor to continue researching the issue and come with a reasonable solution for all effected.

My 2022 Ford F150 Powerboost Hybrid has the Max Tow Axle option. A known defect is that the LH and RH Axle bolts break early in the life of the vehicle. The failure is a tensile failure in the bolt causing the head to essentially pop off, rendering the vehicle unsafe to drive. I have had (1) of these failures so far. I expect more failures to come and do not accept that Ford has fixed this issue with the Max Tow option utilizing the 3/4 float axle design that they have had since 2021. For 2024 Ford is now disallowing the Max Tow option with the Hybrid Powerboost model, leading me to believe there is an incompatablity between the Hybrid drive system in the Powerboost model and the Max Tow axle design. Possibly certain dynamic forces are inherent in the combination to cause this failure. It is speculated it could be the regenerative braking that is part of the Hybrid system. Other scenarios are possible as well. Aside from the ridiculously small 12 mm single bolt in this design, I believe this change with the 2024 model year is indicative that they have presented an inadequate fix for us current 2021-2023 model year owners since they have discontinued this combination. Ford is repairing under CSP [XXX]. I request NHTSA investigate this issue thoroughly and force Ford to recall all Powerboost Hybrid F150 trucks with this design and present a proper / robust solution that will not fail when out of warranty which is very likely to occur in my opinion. Ford's actions are inadequate regarding this issue in my opinion. Thank you. [XXX] Greensboro, NC [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While in 4A, at a stop the vehicle lurched forward. This repeated 5 times having come to a stop with brake pedal depressed or not (autohold). Check engine light came on at some point for auxiliary transmission pump motor did not come on. Started after having truck serviced and pcm reprogrammed. Back at dealership claims issue due to HEV battery dropping below 285V and going in to fail safe due to usage in stop and go traffic. Truck was not in stop and go traffic during drive in which incidents occurred.

1) The rear axle bolt failed on my Max Tow equipped truck, the bolt head and washer broke off and were rattling around in the wheel. 2) The rear axle bolt secures the axle to the knuckle/hub and transmit power from the differential to the wheels. Without this bolt the axle could fall away from the hub and the vehicle would loose the ability to drive. 3) Yes the problem has been reproduced, Ford has CSP 22B34 for this same issue. That CSP is incomplete, it does not cover all of the date ranges that this issue can happen on. 4) No, there were no warning lights or messages while the issue was present.