2023 Ford Maverick Hybrid

The welds broke on the front driver side door. Door has a creaking sound and the door has visibly growing stress crack near the door check arm. I took it to the dealer and here' s their repair comments. "B. CUSTOMER STATES DRIVERS SIDE DOOR CREAKS WHEN OPENING AND CLOSING. X MUST GO TO BODY SHOP DOOR WELDS ARE BROKEN (DOOR)" It seems to be the same issue as Ford's customer satisfaction program 23B56 "inspect front door check-arm reinforcement spot welds", for the Ford Excape, coming from the same factory as the Maverick, but the Maverick didn't get a customer satisfaction program for this issue.

The contact owns a 2023 Ford Maverick. The contact stated that the interior passenger’s side floorboard was wet. The vehicle was taken to a local dealer, where it was diagnosed; however, the cause of the failure was not determined. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 40,000.

My driver side door hinge has a broken spot weld and has come unattached from the door and it goes inside and blocks the power window from coming down when the door is closed. Ford has had these breaking hinge problems since 2019. I took it to the Ford dealership for them to look at the problem and they want me to pay for it. I have attached pictures. As of October 2023, the National Highway Traffic Safety Administration (NHTSA) is investigating a potential defect in the front door weld of the 2020 and 2021 Ford Escape and its hybrid variant. This defect could cause the door to open unexpectedly while the vehicle is moving, which is a significant safety risk. Some owners have reported a popping noise followed by the door opening, while others have reported their doors not opening at all after a creaking noise. Some owners have also reported being unable to close the vehicle after the door opens. If the issue requires a recall, it could affect up to 346,071 vehicles.

The contact owns a 2023 Ford Maverick. The contact there was a leak on the floor of the vehicle from underneath the windshield on the passenger’s side. The contact stated that there was mold forming underneath the floor mats. The vehicle was taken to the dealer where it was diagnosed that the cabin air filter was fractured and caused a leak. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the failure was a known issue; however, the repair was not covered under warranty or a recall. The contact was referred to the NHTSA Hotline to file a complaint. The failure mileage was 37,000.