2021 Ford F-150 Hybrid Electrical Problems

The vehicle is currently at Kayser Automotive Group located at 2303 West Beltline Hwy Madison, WI 53713, their direct line is [XXX], since the diagnoses of the corrosion of the DCN. SYSTEMS & COMPONENTS THAT FAILED: A faulty or clogged engine bay drain plug failed to divert water, causing significant water accumulation that routed into the interior cabin. This water intrusion directly soaked interior carpeting and exposed the Data Communication Network (DCN) connector and Body Control Module (BCM) wiring harness to moisture, resulting in severe pin corrosion and electrical communication faults. The vehicle and all affected components are fully available for inspection upon request. SAFETY RISK: The DCN connector and Body Control Module control critical vehicle operations, exterior lighting, instrument clusters, and safety/driver-assistance systems. Water corrosion on these communication buses causes unpredictable, uncommanded electrical failures and module communication dropouts while operating the vehicle at speed, creating a severe crash hazard to occupants and surrounding traffic. DEALER CONFIRMATION & INSPECTIONS: The issue was physically inspected and confirmed by an authorized Ford dealership service department, Kayser Automotive Group located at 2303 West Beltline Hwy Madison, WI 53713. Dealership technicians verified the water accumulation path, identified the faulty/clogged drain pathway, and documented physical corrosion on the DCN wiring connector. A Technical Assistance Center (TAC) case was requested to escalate the defect to Ford Corporate. WARNING LAMPS & PRIOR SYMPTOMS: Initial symptoms appeared as heavily saturated interior floor carpets and standing water pooling near the cowl/dash area. Shortly thereafter, intermittent electrical glitches, warning lamps on the instrument cluster, and network communication Diagnostic Trouble Codes (DTCs) appeared as the corrosion worsened. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11753065

Incident

May 21, 2026

Good Afternoon. The Pro Power Onboard high-voltage electrical system has experienced a permanent malfunction, locking out with a "Ground Fault Detected" warning. The vehicle is a 2021 Ford F-150 Rocky Ridge conversion. This failure stems directly from a defective or incomplete execution of Safety Recall 23S35 (NHTSA Campaign 23V613000).The initial remedy applied by the dealership consisted only of adding protective tape to the rear wiring harness. However, due to the increased travel and ride height of the official Rocky Ridge suspension lift, the wiring harness pulled out of its factory retaining side clip. This caused excessive tension and stretching on the high-voltage lines, completely exposing the bare interior colored wires and leaving them vulnerable to road moisture and friction against the metal frame.The system now triggers a permanent short-to-ground error, creating an imminent risk of an electrical short circuit or vehicle fire under the high-voltage (120V/240V) lines. The Ford dealership and corporate customer care refuse to remedy this recurring safety hazard under the recall warranty because it was previously marked as completed, even though the applied remedy failed to safely secure the harness. The component is available for inspection.

NHTSA ID

11748514

Incident

Jul 1, 2026

2021 Ford F-150 PowerBoost Hybrid, VIN [XXX]. At 112,000 miles — just 1,000 miles outside of warranty — the vehicle experienced catastrophic failure of the hybrid battery system. Ford's own technician diagnosed a short in the high voltage battery system that caused damage to the hybrid electric drive unit. Repair estimate is $19,000. Ford declined goodwill warranty coverage despite the vehicle being only 1,000 miles outside warranty and the failure occurring on a known problematic system. This is a $72,000 vehicle purchased new in 2021 that has suffered a catastrophic drivetrain failure at only 3 years old. The high voltage battery short and hybrid drive unit failure represent a potential safety hazard to drivers and other motorists. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11744171

Incident

Jun 4, 2026

Vehicle Information 2021 Ford F-150 PowerBoost VIN: [XXX] Complaint Description While driving approximately 70 mph on a highway, my 2021 Ford F-150 PowerBoost suddenly displayed a “Stop Safely Now” message and immediately lost propulsion. The engine shut down without warning while I was in active traffic. After the shutdown, the vehicle automatically shifted into park and would not allow me to shift into neutral. This left me unable to move the vehicle out of a live traffic lane. I was forced to shut the vehicle off while still in a dangerous roadway position. This incident created a serious safety hazard, as I was traveling at highway speed and could have been rear-ended due to the sudden loss of power and inability to move the vehicle. This issue appears to match Ford Technical Service Bulletin (TSB) 23-2317, which describes “Stop Safely Now” warnings, no-start conditions, and gateway module (GWM) software faults. This indicates a known defect that can cause sudden loss of propulsion. A claim has already been opened with Ford Motor Company under case number [XXX], and the vehicle is currently at a Ford dealership for diagnosis. At this time, the issue has not been resolved. This failure occurred without warning and presents a significant risk to driver safety and others on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11726933

Incident

Mar 15, 2026

My Ford F150 was traveling on I95 North in Maryland when an emergency notice on the dashboard told be to pull over. The truck would not restart and had to be towed to a Ford dealer. I have since been told a controller module caught fire and damaged the hybrid battery and both would need to be replaced at a cost of over $10,000. This is a know issue and other Ford F150 Hybrid trucks as well as other Ford cars have already been recalled. Ford claims that my VIN was not included in the recall even though I experienced exactly what the recall was suppose to prevent. My wife and I could have been killed while traveling on the highway at 70 MPH and the vehicle was on fire without our knowledge.

NHTSA ID

11702253

Incident

Nov 14, 2025

The contact owns a 2021 Ford F-150. The contact stated while driving 45 MPH, the vehicle stalled. While at a stoplight, the accelerator pedal was depressed, but the vehicle failed to move or respond as needed. The contact stated that several unknown warning lights were illuminated. The vehicle was towed to the local dealer, who informed the contact that the failure might be battery-related. The vehicle was not diagnosed or repaired. The manufacturer was contacted and confirmed that there was no warranty coverage on the vehicle. The failure mileage was approximately 140,000.

NHTSA ID

11646031

Incident

Feb 19, 2025

Mileage

140,000 mi

When turning right there was a complete loss of power with no response from the throttle it was just stuck coasting at 20klm hr. For 20 seconds or so then throttle kicked in and normal operation again. This has happened twice now in the past week. Very dangerous especially when turning into traffic.

NHTSA ID

11636701

Incident

Jan 18, 2025

Mileage

115,000 mi

I purchased a 2021 Ford F-150 Powerboost Lariat in November 2022. It was advertised as a Gold Certified Used vehicle. In October I stopped and put the truck in park, and when I got back in the truck it wouldn’t shift out of Park. The Message in the instrument panel said to shift into Park to start. However, the shift lever was stuck in Park with the yellow light flashing next to P. I had to spend $100 to have my truck towed to Young Ford in Ogden, Utah which is the closest dealership to my home. They had my truck there for two days and then called me and let me know my truck was ready to be picked up. They told me the problem was a software update and once they had completed the update, everything was working fine. They then charged me approximately $360 for the update. So essentially, I just spent $460 for a software update on my truck that is set to automatically download and install updates several times each week. The technician at the dealership checked my vehicle history and verified that I was up to date with all available updates. In just under two years of ownership, I have now had to take it to the dealership twice for software updates, and even more times for multiple recalls. This latest issue is infuriating because a simple software upgrade cost me two days of use, towing charges, and $360 to diagnose and download the update. Why does a software update completely disable a vehicle, and why is it not Ford’s responsibility? What if this happened during driving on the freeway? I should not have to take it to the dealership to be updated so that the vehicle will operate. In my mind this is no different than a recall. If a car becomes inoperable because of a problem from the dealer than the dealer should be financially responsible and not pass those costs to the consumer!

NHTSA ID

11633808

Incident

Oct 19, 2024

Very frequent error message and bell/chime saying pedestrian warning alert system failure. It is at the dealer now for service and they are claiming that this safety device isn't covered by warranty. This happens at low speeds, doesn't happen on the highway. It is very frequent, multiple times per minute at times.

NHTSA ID

11630889

Incident

Dec 6, 2024

The contact owns a 2021 Ford F-150. The contact stated that while the vehicle was parked, there was a message on the infotainment screen that the "The Pro Power Onboard Has Detected a Fault" was displayed. The contact stated that the charging outlet in the vehicle became inoperable. The vehicle was taken to a dealer where it diagnosed and determined that a software update was needed. The outlet module was replaced, and the software was updated but the failure persisted. The manufacturer was notified of the failure and referred the contact NHTSA hotline to report the failure. The failure mileage was 46,000.

NHTSA ID

11629235

Incident

Nov 3, 2024

Mileage

46,000 mi

Continues issues with the electrical and hybrid system. This is the second time of complete vehicle failure, although the power steering went out completely and the automatic parking brake briefly activated before the truck completely failed / quit running.

NHTSA ID

11617191

Incident

Sep 30, 2024

While operating the vehicle, I shifted into park, using the console shifter. With no warning, the vehicle malfunctioned. The console shifter indicator light started blinking next to the "P" and it would not let me shift back into gear. I turned off the vehicle and tried to restart it in the hopes that it would clear the error. The vehicle engine would not start, and told me to shift the vehicle into park. I was unable to shift the gear into park or any gear. A tow truck driver came and we were able to force the vehicle into neutral for towing, but the vehicle's parking brake engaged and would not disengage. Every time we turned off the parking brake, it immediately turned itself back on. Thus, we could not push the vehicle into a better position for the tow truck to get the vehicle and the tow truck operator had to drag the vehicle with its back tires not turning. At the Ford dealership, a service employee inspected the vehicle and said there was no physical damage to any component and that some kind of electronics error had caused the fault. He said it was a known issue with F150 transmissions and that a Ford service bulletin indicated a 6-hour "module" reprogramming process was necessary to make the truck operable. He said that it could recur. I spoke to Ford customer service. A representative there confirmed that this is a known issue with F150 transmissions but that no recall had been made. She also stated that Ford did not know why it happens and that, even after being "reprogrammed", it could happen again. Based on my experience and discussions with Ford, the F150 can suddenly become inoperable and (because of the parking brake) immovable. Thankfully, the transmission error occurred for me in a safe location near my home. It could have been very dangerous had the vehicle become immovable in an unsafe location or far from home or help. I am concerned it will happen again. The vehicle is currently at the Ford dealership in Grand Ledge, MI.

NHTSA ID

11596848

Incident

Jun 22, 2024

OTA updated stuck unable to complete. Stuck update continued to drain battery below threshold to allow the update to complete. Systems started conserving power, shutting off infotainment system, fordpass app, gateway, passenger door entry, etc. Required call to Ford. Ford dictated to bring to dealership. Dealership corrected multiple module software updates, with cost for services. Vehicle under extended warranty. Root cause: faulty and incomplete Ford software update. Impact: vehicle, as sold and advertised, rendered inoperative due to poor workmanship by Ford OTA update process.

NHTSA ID

11594430

Incident

Jun 13, 2024

At a stop, in electric mode, truck will lunge forward as if you were rear ended. Most of the time, transmission failure will occur after some time due to this lunging forward, and it has happened to many truck owners. Electric auxiliary transmission pump tends to be the cause .

NHTSA ID

11594081

Incident

May 3, 2021

When you start the truck the radio rear view camera does not turn on you drive a mile or two and it will come on. This does not happen all the time it is intermittent

NHTSA ID

11593354

Incident

Jun 10, 2024

If you pull onto a road and try to accelerate, the vehicle is unresponsive. The RPMs will increase, yet the vehicle drive train (10 Speed Transmission) is unresponsive for several seconds. This has been an ongoing issue with the vehicle since new and was first reported to Ford Customer service on Jan 2022. Ford has made several attempts to fix this issue, yet the transmission continues to fail with the same issue. This is a critical safety issue that jeopardizes the passengers in the vehicle. Vehicle parking brake engages without notice. At any given time, the electronic parking brake engages without warning and you have to manually release. While sitting at a controlled intersection, on an inclined street, waiting for traffic light to change, with vehicle in Drive, foot on the brake, the electric parking brake engaged. Vehicle shift lever moved to the park position on its own. Vehicle engages it's parking brake and moves shift lever into Park while sitting in traffic is very dangerous. Vehicle shift column failed in drive and vehicle would not move or run. This caused drive train to lock in place, freezing all four tires. Ford had to drag truck onto flat bed with tires locked. It had to be dragged off flatbed when delivered to Ford dealer for repair. They had to put grease down on the flatbed so truck would slide off without tires rolling. While at the dealership, the mechanic had to manually disconnect the calipers in order to move vehicle. The safety backup features failed and would not release wheels (lever under steering column).

NHTSA ID

11585878

Incident

Apr 25, 2024

Calendar years 2022, 2023, and 2024 have replicated this issue. Under high sun and warmth, the dash mounted daylight sensor causes the infotainment system to decrease brightness. This decrease in screen brightness persists even when in reverse, compromising safety systems. Dealership has been unable to replicate while in for other service on at least 3 separate occasions. This appears to be a summer / fair weather issue that cannot be diagnosed inside the workshop environment. Dealership able to replicate, in person, with technician, that the sensor was inverting the intended automatic adjustment action on a "stop by if you see this actively happening again" request in 2022. As unable to replicate condition in workshop, unable to diagnose and repair.

NHTSA ID

11585823

Incident

Apr 29, 2024

2021 f150 POWERBOOST [XXX] Loss of engine power. Major electrical failure display on dash coast to a stop. Unable to restart, lock in park unable to be move from location. After 45 mins. of pushing restart button every 60 seconds get a restart, take to dealer unable to find problem.[XXX] Loss of engine power. Major electrical failure display on dash coast to a stop. Unable to restart, lock in park unable to be move from location. After 45 mins. of pushing restart button every 60 seconds get a restart. Notified dealer appt set for 20Jan2024 Special order pump was order for trans. {XXX] Truck was drop for the pump to be replace. [XXX] Dealership called, while the Tech was on a test drive, after the pump was installed, the Tech. had a Loss of engine power. Major electrical failure display on dash coast to a stop .Unable to restart , lock in park unable to be move from location. Dealer ship contacted Ford and and engineer has handle the repairs. The truck has been on the lot now for over 30days with now a needing a special order part on National back order. Have contacted Ford case # [XXX] with 2 attempts with no return phone calls. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11581092

Incident

Dec 11, 2023

My 2021 F-150 Powerboost randomly shuts down on the highway and while pulling out into traffic. When it shuts down the steering and brakes work but the engine is off/no acceleration and the truck displays a warning telling me to "Stop Safely Now". Truck has been look at many times by Ford and every time they give it back to me it happens again. There appears to be either and electrical or software issue but after 3 months Ford doesn't seem to know what's wrong with the truck even though they have reproduced the problem. It has happened over 20 times putting me and my family at risk of getting in an accident.

NHTSA ID

11568535

Incident

Nov 16, 2023

Vehicle came to complete stop in traffic with warning light "stop vehicle" would not restart. Taken to dealership. Dealership replaced ecu and some switches to power bank and wiring harness behind headlight. Vehicle was returned 1 week later Drove it 2 days later for 10 miles same thing happened, Ford towed it to another dealership where they cleared codes, and they said they can't replicate, Vehicle was returned after a week. 2 days later I drove yo work and again iy happened stopped in middle of road blocking traffic. Was towed by Ford to dealership where they found over 20 codes, said they can't fix. Ford and selling dealer towed to selling dealer, where they cleared codes and said they can't replicate. I refused yo take Vehicle on fear of getting in severe crash when Vehicle stalls and dies in heavy traffic again. I signed title and sent it to selling dealer, they told me that fordwill not let them buy it back. Do I don't have my money or a truck now

NHTSA ID

11550548

Incident

Sep 15, 2023

In the last year I have taken my F150 powerboost in Autonation Ford Orange Park in Jacksonville, Florida twice for recalls. For recall NHTSA # 22S26/22V250 the service department said they were ordering parts and would contact me when they arrived. Never contacted me, even after follow ups. I have recently taken my there for recall NHTSA 23S35/23V509. They have not contacted me.

NHTSA ID

11544277

Incident

Aug 25, 2023

Our truck is equipped with the B&O Unleashed sound system. One afternoon, upon starting the truck after completing a brief errand, an extremely loud POP sound occured, followed by terrible static and crackling from every speaker. The noises continued for several minutes, even after noticing the audio system was off and then also turning the truck itself off. The terrible noises simply continued. Although the sound eventually stopped, the truck now regularly makes two or three quieter popping sounds as the driver first approaches the truck; nearly every time. The sounds seem to come from the driver door's speaker. There is also faint crackling on occasion from the headrest speakers.

NHTSA ID

11531204

Incident

Jun 1, 2022

Audio/speaker system made extremely loud and surprising pop when vehicle on but audio system off. This could very easily startle the driver causing him to take an unsafe maneuver. The problem has not been reproduced by a dealer nor been inspected by anyone, but I have seen other reports of this problem for this model via an internet search. I saw no warning lights prior or after this occurred. Subsequent to this pop, the speakers crackled even when the vehicle was off, but this crackling stopped over the night.

NHTSA ID

11526221

Incident

Jun 8, 2023

Deafening pulsing noise coming from all speakers , volume button did not turn it off. Shut truck and locked it and did not stop the noise. Unplugged battery and did not stop noise. After about 15 minutes it stopped. Got into truck and there was an electrical burning smell. I have recorded the noise on video. Big safety concern, if the noise happened while I was moving I might have crashed. My ears were ringing for awhile after the incident.

NHTSA ID

11518507

Incident

Apr 23, 2023

UNKNOWN MY 2021 FORD F-150 POWERBOOST HYBRID CAUGHT ON FIRE ON FEBRUARY 03, 2023. THE TRUCK WAS NOT RUNNING AND FORTUNATELY I HAD IT IN MY DRIVEWAY BECAUSE I WAS HEADING OUT OF TOWN FOR THE WEEKEND. IT STARTED UNDER THE DRIVERS SEAT. THE FIRE WAS SO INTENSE THE FIRE DEPARTMENT HAD TO BE CALLED TO PUT IT OUT. IF THE TRUCK WOULD HAVE BEEN IN THE GARAGE IT WOULD HAVE EASILY BURNED MY HOUSE DOWN. MY INSURANCE COMPANY SENT OUT A FIRE INVESTIGATOR AND HE CONCLUDED IT WAS DEFINITELY SOMETHING ELECTRICAL.

NHTSA ID

11518346

Incident

Feb 3, 2023