2022 Ford F-150 Hybrid

The contact owns a 2022 Ford F-150. The contact stated while operating the vehicle, the air conditioner blower intermittently malfunctioned and would not blow air through the air vents. During the failure the front windshield could not be defogged or defrosted, creating a visibility hazard for the driver. The vehicle was taken to the local dealer on several occasions, but no failure was found. The vehicle was not repaired. The contact stated that a TSB was issued for the failure. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 3,000.

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.