2021 Ford F-150 Hybrid

The premium leather covering on both upper dash panels of my 2021 Ford F-150 Limited has delaminated from its substrate and shrunk away from the defrost vents, at 28,776 miles. A Ford dealer inspection found that the passenger-side dash covering is integrated with the passenger airbag assembly, and that repair requires replacing the entire airbag. The covering is part of the airbag deployment system, which is designed to open along a tear seam. Its separation and shrinkage mean it no longer matches that design, which may affect how the passenger airbag deploys. I asked Ford in writing to confirm whether this affects airbag performance. Ford denied coverage and did not answer the safety question (Ford case #CXH-09661616-J4C9J8, CRM 03692001342). Other owners have reported the same dash delamination on Ford Limited trucks, and Ford previously issued TSBs 19-2041 and 20-2268 for dash separation at the defrost vents on 2015-2020 F-150s

NHTSA ID

11776780

Incident

Oct 19, 2026

Violent upshift and downshift, erratic shifting, difficulty finding gears, high revs, stuck in 10th gear more than two times, failure to find gears, loud bang when CDF drum seal blew along with loss of power causing it to rapidly slow down, unable to accelerate due to it being stuck in second gear, and unable to accelerate from takeoff causing close calls with traffic.

NHTSA ID

11776623

Incident

Aug 14, 2026

On January 16, 2026, my Ford F-150 experienced catastrophic 10R80 transmission failure while I was driving to work on the highway. Prior to the failure, I experienced increasingly severe and erratic upshifting and downshifting, particularly between 3rd and 4th gears. The transmission shifted harshly and unexpectedly, raising concerns about its reliability and safety. On the morning of January 16, 2026, the transmission suddenly failed without notable warning. It appeared to lock up, producing extremely loud and alarming mechanical noises. While traveling at highway speed, the rear wheels locked up, causing an immediate and dangerous loss of vehicle control. I was forced to perform evasive maneuvers to avoid striking nearby vehicles. Fortunately, I was able to regain sufficient control to pull onto the highway shoulder without a collision. This incident could easily have resulted in a serious crash, injuries, or fatalities. Following the incident, I contacted Ford and the dealership regarding the failure and safety concerns. Both denied warranty coverage, leaving me responsible for more than $8,000 in out-of-pocket expenses to have the transmission rebuilt. This was not merely a mechanical inconvenience. The combination of severe, erratic shifting followed by catastrophic transmission failure and rear-wheel lockup at highway speed presents a serious safety hazard. I am submitting this complaint because I believe the Ford 10R80 transmission may have a safety-related defect that places drivers and others on the road at risk. Other owners could experience the same sudden failure and loss of vehicle control without warning. I urge NHTSA to investigate these transmission failures, particularly the potential for sudden transmission lockup and rear-wheel lockup while driving at highway speeds.

NHTSA ID

11776405

Incident

Jan 26, 2026

Lurching/Hard shifting from engaging transmission shifter from park to drive. Audible clunk with lurching 1st to Second and Third gears.

NHTSA ID

11776275

Incident

Oct 21, 2026

My 2021 F-150 PowerBoost hybrid repeatedly lost propulsion while traveling on the highway in early October 2026, including four incidents on one trip around October 3. At approximately highway speed, the tachometer dropped to zero while the selector remained in D, and the truck coasted as if in neutral. There were harsh shifts around 9th/10th gear and difficulty accelerating beyond approximately 70 mph. A vehicle warning appeared. Disconnecting and reconnecting the battery temporarily restored operation. Sudden loss of drive power in highway traffic created a collision risk. The underlying cause has not been independently established. A Ford dealer's October 2026 inspection recorded an internal transmission hydraulic leak, clutch-disconnect trouble codes suggesting a hybrid drive unit concern, a recommendation to replace the transmission with the hybrid drive unit, and high-voltage battery cell-balance DTCs. More recently electric-driving mileage has remained at zero and the gasoline engine continues running while stationary. Severe shifting and vibration had varied between 2H and 4A modes. Around June 2025 the vehicle also stopped operating and was towed to the same dealer; I understand a 12-volt battery was replaced. Photographs from that period show Stop Safely Now and other warnings around 70,000 miles. I request investigation of whether that earlier incident and the present faults are related; I do not claim the same root cause has been proven. Exact diagnostic codes and earlier service details should be verified from the dealer records. The October intake odometer was recorded as 99,632; mileage at the highway incidents is not precisely known.

NHTSA ID

11774501

Incident

Oct 3, 2026

Daytime Running Lights (DRL) passenger side LED light bar burned out after only 64K miles.

NHTSA ID

11773403

Incident

Oct 24, 2026

Formal Financial Assistance Statement RE: Goodwill Cost-Share Request for 2021 F-150 King Ranch VIN: [XXX] Current Mileage: 119,000 miles Diagnostic Trouble Codes: P2704, P07E6, P2886, P2885 Dealer Repair Quote: $9,820.50 (Full Internal Transmission Replacement) To Whom It May Concern at Ford Motor Company and Dealer Leadership: I am formally requesting a corporate Goodwill Cost-Share for the catastrophic internal transmission failure on my 2021 F-150 King Ranch. While this vehicle is slightly past its 100,000-mile powertrain coverage, a total mechanical failure on a top-tier luxury vehicle at this stage—caused by well-documented, inherent factory defects—is entirely unacceptable. The diagnosis and fault codes pulled by the certified mechanic map directly to systemic, factory-recognized hardware flaws in the 10R80 10-speed transmission: 1. The Core Mechanical Failure (TSB 24-2209 / TSB 23-2250): My truck exhibits severe gear slippage and loud internal clunking, triggering code P2704 (Friction Element E Apply Time). As documented heavily by Ford’s own service network, this code is the direct result of a design flaw where the internal CDF clutch drum bushing migrates out of place under heat, slicing internal seals and destroying line pressure (triggering pressure codes P2885 and P2886). 2. The Safety Concern (Code P07E6): My transmission has also thrown code P07E6 (Unable to Engage Park), which directly mirrors the mechanical components Ford is actively tracking for transmission parking pawl issues. Ford Motor Company has issued multiple Technical Service Bulletins acknowledging this exact failure sequence and has since redesigned the CDF drum assembly to correct the manufacturing flaw. I should not be held solely responsible for a $9,820.50 repair bill caused by a component that Ford has publicly acknowledged was defectively designed from the factory. As a loyal Ford customer driving a premium vehicle, I expect Ford to stand behind its product. I am req INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION

NHTSA ID

11773317

Incident

Oct 12, 2026

The passenger Daytime Running Lamp (DRL) has stopped working on my 2021 Ford F-150. This condition potentially puts myself and others at risk because DRL's are a well-known safety feature to increase frontal visibility of vehicles while driving, especially during changing daylight conditions such as going under a bridge or tree-covered roadways. There were no symptoms of impending failure other than many complaints from owners of similar vehicles

NHTSA ID

11772533

Incident

Oct 19, 2026

Certain 2021-2023 Model Year F-150 HEV Vehicles Replacement of Exhaust Gas Heat Exchanger Coolant Spigot, If Required Owner Letters

Certain 2021-2023 Model Year F-150 HEV Vehicles Replacement of Exhaust Gas Heat Exchanger Coolant Spigot, If Required

Certain 2021-2023 Model Year F-150 HEV Vehicles Replacement of Exhaust Gas Heat Recovery Coolant Spigot In the affected vehicles, the Exhaust Gas Heat Recovery (EGHR) coolant spigot may develop a crack due to a weaker-than-intended coolant spigot having been used in a prior repair. As a result, coolant may leak out of the engine, and one or more warning lights, such as the Check Engine Light, may illuminate.