2025 Ford Maverick Hybrid

Shortly after purchase, my 2025 Ford Maverick Hybrid AWD experienced a sudden and severe electrical burning or melting odor while driving at freeway speed (approximately 75 mph). The odor was extremely strong and clearly coming from my vehicle. At the same time, the vehicle produced a loud, continuous whirring or growling noise and experienced a sudden loss of power, as if under heavy load or braking. I exited the freeway as soon as safely possible. No visible smoke or fire was observed, but the odor raised serious concern for overheating electrical or hybrid drivetrain components Since the initial incident, the vehicle has experienced multiple similar but less severe events, including intermittent electrical odors, abnormal hybrid noises, hesitation or lag when switching between electric and gasoline operation, and a significant and permanent reduction in fuel economy. The vehicle has been taken to a Ford dealership multiple times for inspection. I requested inspection for signs of overheating or electrical damage. No diagnostic trouble codes were found and the vehicle was returned without repair. I am concerned this condition may involve overheating or failure of hybrid or electrical drivetrain components, such as the inverter, electric motor, or wiring, which may not immediately trigger diagnostic trouble codes but could pose a safety risk. I am also aware of other 2025 Ford Maverick Hybrid owners reporting similar electrical odors, abnormal hybrid noises, and power loss symptoms in public owner forums, suggesting this may not be an isolated incident. I am submitting this complaint to document a potential safety-related defect involving overheating or electrical failure in the hybrid drivetrain system.

I took delivery of vehicle from dealer on [XXX]. On [XXX] I was driving on the freeway when a high voltage sign and the message "Pull off road when safe" lit up the dashboard. The engine lost all power and I was able to coast to a stop on the shoulder. After 10-15 minutes, the vehicle would restart and I dropped at the dealership for a fix - it had less than 2,000 miles. They kept it until 7/28/25 when they said it was a "glitch" and updated software. On [XXX] I was again driving on the freeway when the "Pull off road when safe" message displayed again and the engine once again stopped but I was fortunately able to coast to an exit ramp. There was a Ford dealership right there and three guys came out to try to get it started. Again after 10 minutes of sitting the vehicle started and we pulled into a service bay where the dealership still holds my vehicle. Their diagnostic was the hybrid battery junction box needed to be replaced. It is on backorder and is still not fixed. However, both times the engine shut completely down which is extremely dangerous on freeways with semi-trucks and traffic driving fast and all you can do is coast to a stop. I was fortunate in each episode that the truck was not hit by another vehicle. I have zero trust that this vehicle will run properly even with the dealer fix. I have been in contact with Ford about buying the vehicle back as I read similar stories online. This seems to be a huge safety issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)