2023 Ford Maverick Hybrid

Vehicle information: Ford Maverick 2023 Hybrid, with roughly 37,000 miles, observed failure on [XXX]. The failed component/system is the A/C evaporator condensation drain system. The drain line became clogged, which I believe is a critical defect in either the design, component, or construction of the drainage system. The lack of a fail-safe in this system, instead of draining water outside of the vehicle, the condensation backed up and leaked directly into the vehicle's cabin onto the driver and passenger side footwells. The vehicle is currently at the dealership (Windward Ford), undergoing diagnosis/repair, and available for inspection upon request. The pooling of a large volume of water on both the driver and passenger side floorboards to include the path of where the water originates as it collects at the footwell, creates an unreasonable risk of safety failure due to the proximity of critical electrical systems; fire/short circuit risk, loss of vehicle control due to damage to electronic modules from water intrusion, as well as health hazard with prolonged saturation of pores material resulting to mold and mildew growth. The issue has been reproduced at the dealership (Windward Ford), and confirmed that the issue is an A/C evaporator drain clog, causing the leak, and the carpet and interior padding were saturated, requiring extensive cleaning and replacement. The failed component/system has been inspected by technicians at the dealership. The diagnosis and repair estimates are on file with the dealership. There were no warning lamp indicators or messages, just the damped smell, which was noticed a few weeks prior to the visual indicator of a water puddle in the floorboard. The odor is a direct result of the ongoing, hidden water leak and saturation of the carpet, indicating a slow, chronic problem caused by the defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2023 Ford Maverick. The contact stated that while driving approximately 65 MPH, the check engine warning light illuminated, and the "Service Engine Immediately" message was displayed. The contact stated that the vehicle started losing motive power. The accelerator pedal was depressed, but the vehicle decelerated to 5 MPH. The contact stopped and had the vehicle towed to a dealer, who was unable to determine the cause of the failure. The vehicle was not repaired. The contact stated that the failure reoccurred. The contact used a handheld scanner and retrieved DTC: P1061 (Faulty Rod Bearing). The vehicle was towed to the same dealer, but the dealer was unable to duplicate the failure. The vehicle was not repaired. The contact stated that the failure reoccurred, and the vehicle was towed to the same dealer where it was determined that the long block needed to be replaced. The vehicle was not repaired. The contact spoke with a mechanic and was informed that the failure was related to Customer Satisfaction Program: 23N06 (Long Block Replacement). The manufacturer was contacted for confirmation that the vehicle was covered under the CSP; however, the contact was informed that the vehicle was not covered under the CSP. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 80,000.

The 12-volt battery loses charge and issues a warning that remote features have been disabled. This issue has been going on since January 2025. To date, I have recharged the battery 15 times, plus taken it to 2-different Ford dealerships for warranty service. Both were unable to resolve the problem. Beginning with the 2025 model year, Ford commenced installing AGM 12-volt batteries which resolved the problem. The vehicle is still under warranty but the dealerships simply recharge the battery and return the vehicle. My vehicle is not part of the Ford recall for this problem. The root cause appears to be poor quality Chinese batteries used in the early model years.

At approximately 37,000 miles, the CV axles on my 2023 Ford Maverick Hybrid required replacement due to premature wear. Now, at around 62,200 miles, the vehicle is experiencing excessive vibration and shaking during acceleration, particularly noticeable at moderate to high speeds. This issue appears to be related to the powertrain or suspension system and may indicate a recurring or unresolved problem with the CV axles or associated components. The vibrations are severe enough to affect vehicle control, especially during lane changes or merging onto highways. When accelerating to merge into highway traffic, the vehicle shakes and vibrates so profusely that it feels like the car is going to shake apart. This makes it difficult to accelerate normally and safely, putting both the driver and surrounding vehicles at risk. The shaking could lead to loss of traction or steering instability, increasing the likelihood of an accident. This issue has been widely reported by other Ford Maverick owners and has been a frequently discussed problem in forums and owner communities for over a year. Despite its prevalence, there appears to be no long-term fix other than replacing the CV axle assembly with the same OEM part, which may be the root cause of the problem. That is why I feel it is important to bring this to your attention — it is a known issue with no real correction, and it continues to affect vehicle safety. No warning lights or messages appeared prior to the onset of the problem. The component is available for inspection upon request.

The contact owns a 2023 Ford Maverick Hybrid. The contact stated that while driving at an undisclosed speed and depressing the brake pedal, the pedal vibrated and pulsated, but the vehicle did not immediately stop, causing the braking distance to be extended. Additionally, the contact stated that the warning message "Pre Collision Activated" was erroneously displayed while driving with no other vehicles or large objects nearby. The vehicle was taken to the local dealer, who was unable to determine the cause of the failures. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was 10,000.