2022 Ford F-150 Lightning Bev

Component Failed & Inspection Status: The front-left upper and lower control arms, ball joints, wheel hub assembly, steering knuckle, and front axle shaft have failed. Severe environmental corrosion has completely seized and fused the steering knuckle inside the wheel hub. All original failed components are currently intact and are fully available for physical inspection upon request. Safety Risk: This severe structural corrosion causes the steering knuckle and axle to seize, creating an imminent risk of primary steering component separation while driving. A steering separation on a heavy electric vehicle (over 6,000 lbs curb weight) causes a sudden, complete loss of directional control, creating an immediate life-threatening hazard to the occupants and surrounding traffic. Confirmation & Testing:The failure and severe structural corrosion were officially diagnosed and confirmed by a certified technician at an authorized Ford dealership service center. Warning Signs & Symptoms: The symptom appeared as a very noisy, distinct creaking sound coming from the front-left suspension. This noise occurred specifically when turning the steering wheel and when operating the vehicle at speeds below 40 mph. The sounds may have been present but obscured by road noise at higher speeds. There were no dashboard warning lamps or error messages prior to the diagnostic inspection. Systemic Concerns: This 2022 model is experiencing a severe vulnerability to premature environmental corrosion that causes the steering knuckle, axle, and control arms to seize to the point of failure. This demonstrates a critical structural durability issue under heavy EV loads in road-salt regions that warrants federal safety tracking for the 2022 model year.

Vehicle: 2022 Ford F-150 Lightning Pro VIN: [XXX] This vehicle is subject to a fire-related battery recall issued by Ford Motor Company. The vehicle has been at an authorized Ford dealership (West Herr, New York) since December 26 for recall repair. As of today, it has been out of service for 53 days. The dealership has stated that the delay is due to EV battery lift capacity limitations and that my vehicle is waiting behind another truck because they only have one lift capable of performing the repair. No firm repair completion date has been provided. For over seven weeks, I have received no proactive communication from the dealership regarding repair status. All updates have required me to initiate contact. This complaint is being filed to document prolonged failure to complete a fire-related safety recall due to dealership capacity constraints. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The rear lightbar assembly on our 2022 Ford F-150 Lightning Lariat has developed micro-cracks in the outer lens, allowing moisture to accumulate inside. This has caused flickering or inoperative reverse lamps and now appears to be impacting the rear passenger blinker, which functions intermittently. We are concerned that the moisture has begun to corrode the rear wiring harness or electrical system, creating additional safety risks. When we reported the issue, a Kendall Ford representative told us the rear lightbar replacement was “mainly cosmetic,” but that assessment contradicts both Ford’s recall documentation and our experience. Moisture intrusion has already led to intermittent lighting failures that reduce signaling visibility to other drivers, posing a real risk of collision. The problem has been confirmed by the dealer and a Ford Field Service Engineer dispatched from Dearborn, who inspected the truck in 2025 after the same recall repair (23S30) failed. Ford has since issued a new recall (25V731 / 25S86) acknowledging improper dealer repairs as the cause. Visible condensation, flickering lights, and intermittent “charging system fault” and “sensor unavailable” messages began shortly after the 2023 recall repair and have continued to worsen. The vehicle remains in our possession and is available for inspection by NHTSA or Ford corporate upon request.

I own a 2022 Ford F-150 Lightning Lariat (VIN [XXX] ). Around June 6, 2025, I brought my truck to Apple Ford Shakopee for a scheduled appointment because I noticed moisture collecting inside the rear light bar. The service representative told me Ford considers that moisture normal, likely from a car wash, and that it would dry out on its own. At that time the truck had fewer than 36,000 miles and was still under the bumper-to-bumper warranty. The moisture never went away, and the light bar is now failing — my backup lights are dimming and flickering. I’ve since learned there was a recall (23S30) on 2022–2023 F-150 Lightning Lariat and Platinum trucks for micro-cracks in the rear light-bar lens that allow moisture in. My VIN currently shows no open recalls, but this failure appears identical to what the recall described. Additionally, owner forums are full of reports from other Lightning owners experiencing the same issue — including those who already had the recall repair completed, whose replacement light bars are now showing moisture again. This suggests the defect may persist even after recall repairs. I’m reporting this because the issue compromises the rear lighting and visibility of the vehicle. I hope Ford and NHTSA will review whether the recall scope or remedy should be expanded to include affected vehicles like mine and ensure owners aren’t left with expensive out-of-pocket repairs for a known manufacturing defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The light bar on the tailgate that is the brake lights and reverse lights is known to get moisture inside and stop working. It is a known problem with Ford as they recalled them 2 years ago and replaced it under warranty. However the replacement part suffers from the same issue. So, my replacement light bar has stopped working, and even though I have Fords Premium Care extended warranty that includes all LED lighting, they will not cover the repair. This part is a safety item (brake lights and reverse lights) that is known to fail, it should be a safety recall item covered out of warranty anyway, and SURELY covered with an extended warranty (Ford Premium Care with Lighting added) but it apparently is not .... It seems that this safety issue should be covered and replaced Thanks

The contact owns a 2022 Ford F-150. The contact stated that while reversing, the reverse lights failed to function as intended. The contact exited the vehicle, and someone pointed out that the rear passenger’s side reverse light failed to activate as designed. The contact stated that the rear light bar had failed to function as intended. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact stated that the vehicle was serviced under NHTSA Campaign Number: 23V418000 (EXTERIOR LIGHTING) two years ago. The contact stated that the failure persisted. The manufacturer was not made aware of the failure. The failure mileage was approximately 38,000.