2021 Ford F-150 Hybrid Problems

I am filing a safety complaint regarding a recurring, hazardous transmission failure during highway and incline driving (specifically experienced on mountain highway passes in Arkansas). While driving at highway speeds on uphill inclines, the transmission severely hesitates and struggles to downshift under load. When it finally engages, it violently slams into gear. During these episodes, the truck experiences a sudden loss of motive power and acceleration lag, accompanied by an engine RPM flare of over 400+ RPM. And most recently, I have Live diagnostic data captured during operation revealed a downshift delay of over 3 seconds where the powertrain control module commanded 8th gear, but the transmission physically remained stuck in 10th gear due to severe internal hydraulic pressure loss. This defect presents a severe safety risk on high-speed roadways. Sudden, unexpected loss of power while climbing grades or merging into traffic creates an immediate risk of rear-end collisions from surrounding vehicles. This issue directly correlates with Ford Technical Service Bulletin TSB 26-2287, which identifies axial movement/slippage of the CDF clutch cylinder sleeve as the root cause of internal fluid leaks and gear failure. Because this internal hardware failure causes unpredictable power delivery and driveability loss at highway speeds, I request that the NHTSA investigate the 10R80/10R80-MHT transmission CDF drum sleeve defect as a critical safety hazard. Finally, Ford motor company, and most cases refuses to repair this known defect under warranty, many owners are experiencing this dealership pushback leaving them with a critical safety issue.

I am reporting a safety-related transmission problem I experienced with my 2021 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission suddenly shifts hard/lags on gears 3-5 and sometime higher gears 7-9 at higher speeds. I’ve also noticed a buzzing/metallic rattling coming near the engine from inside. There is also times i can tell i have no power when trying to speed up and the other day i almost thought i was going to get T-Boned. This occurred while on my daily traffic commute to work, creating a potentially dangerous situation because the truck did not respond as expected when I needed predictable acceleration or propulsion. I believe this incident may be related to the known 10R80 CDF clutch-cylinder/sleeve problem. Ford technical information identifies axial movement of the CDF sleeve that can cause hydraulic-circuit leaks and harsh or delayed engagement and shifting. This condition can result in slipping, RPM flares, delayed engagement, unexpected gear changes, harsh downshifts, lurching, or loss of propulsion. This is a safety concern, not merely a transmission quality or reliability issue. Unexpected loss of propulsion or unpredictable shifting while merging, accelerating into traffic, crossing an intersection, turning, or traveling at highway speed can create a collision hazard. Because I personally experienced this unexpected transmission event, I request that NHTSA investigate the 10R80 CDF clutch-cylinder/sleeve condition in Ford F-150s. Please review Ford warranty claims, dealer repair records, transmission replacements, consumer complaints, and field-failure data to determine whether this is a safety defect requiring a recall. I believe owners should not have to wait for a potentially dangerous transmission failure before this known condition is addressed.

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)

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.

The rear wheels are locking up at acceleration after stopping.

The contact owns a 2021 Ford F-150. The contact stated while driving approximately 65-70 MPH, the contact was flagged down by a nearby driver and advised to pull the vehicle over to the shoulder of the road. The contact stated that the vehicle was driven to the shoulder of the road. The contact exited the vehicle and proceeded to inspect the vehicle. The contact noticed that the rear driver's side rim cap had detached. The contact stated that the center axle bolt was still attached to the rim cap. The vehicle was towed to the dealer where it was diagnosed with a failed rear axle half shaft and hub and the rear axle half shaft and hub needed to be replaced. The vehicle was repaired. The contact stated that the driver's side rear axle bolt had previously been replaced and was under an unknown recall. In addition, the contact stated that the failure had occurred on five occasions within two years and that the vehicle was unsafe to be driven. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 20,000.

I am reporting a safety-related transmission problem I experienced with my 2021 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission suddenly shifts hard/lags on gears 3-5 and sometime higher gears 7-9 at higher speeds. I’ve also noticed a buzzing/metallic rattling coming near the engine from inside. There is also times i can tell i have no power when trying to speed up and the other day i almost thought i was going to get T-Boned. This occurred while on my daily traffic commute to work, creating a potentially dangerous situation because the truck did not respond as expected when I needed predictable acceleration or propulsion. I believe this incident may be related to the known 10R80 CDF clutch-cylinder/sleeve problem. Ford technical information identifies axial movement of the CDF sleeve that can cause hydraulic-circuit leaks and harsh or delayed engagement and shifting. This condition can result in slipping, RPM flares, delayed engagement, unexpected gear changes, harsh downshifts, lurching, or loss of propulsion. This is a safety concern, not merely a transmission quality or reliability issue. Unexpected loss of propulsion or unpredictable shifting while merging, accelerating into traffic, crossing an intersection, turning, or traveling at highway speed can create a collision hazard. Because I personally experienced this unexpected transmission event, I request that NHTSA investigate the 10R80 CDF clutch-cylinder/sleeve condition in Ford F-150s. Please review Ford warranty claims, dealer repair records, transmission replacements, consumer complaints, and field-failure data to determine whether this is a safety defect requiring a recall. I believe owners should not have to wait for a potentially dangerous transmission failure before this known condition is addressed.

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)

Ive noticed that the electric motor sometimes doesnt want to disengage quickly when I step on the brakes. In this incident I had to make a hard brake because someone pulled out in front of me. I had the cruise control on. When I slammed on the brakes the vehicle did not stop fast the vehicle felt as if it was still being pushed by something. Then a small jolt was felt and then the vehicle finally slowed. Had I been going faster or had the car that pulled been closer. This fault would have resulted in an incident

The computer system malfunctioned; the front panel warning was "Stop vehicle and check regen. brakes". I put my car in drive and when I hit the gas pedal the car reversed instead of going forward. I got it towed to the dealer at Piazza Hyundai in Limerick PA. The service did not provide me with an explanation about the warning and showed little concerns to the issues, I was given a month time frame for looking at my car. I consider this a safety issue as the car did not respond appropriately to D and R, I suspect a computer failure.

The contact owns a 2021 Ford F-150. The contact stated while driving at various speeds, the ABS, auto collision, and traction control warning lights illuminated on the instrument panel while depressing the brake pedal. The vehicle was taken to a dealer where the vehicle was diagnosed with a defective electronic brake booster. The vehicle was repaired by the dealer. Upon investigation, the contact discovered NHTSA Campaign Number: 21V533000 (Service Brakes, Hydraulic) which the contact linked to the failure. The manufacturer was notified of the failure and the contact was informed that the vehicle was not included in the recall. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 43,000.

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).

The contact owns a 2021 Ford F-150. The contact stated while driving 30 MPH during a snowstorm, the windshield wipers failed to function as intended. The contact became aware of an abnormal burning odor coming from under the hood of the vehicle, entering the vehicle through the A/C vents. There were no warning lights illuminated. The vehicle was taken to the dealer to be diagnosed. The contact was informed that the windshield wiper motors had failed and needed to be replaced along with the wiring. The vehicle was repaired. The manufacturer was made aware of the failure and informed the contact that the Extended Warranty was lapsed. The contact was referred to the NHTSA Hotline for assistance. The contact related the failure to NHTSA Campaign Number: 23V163000 (VISIBILITY); however, the VIN was not included. The failure mileage was 37,000.

Wipers failed during rain storm. Wipers initially started to operate sporadically and then stopped. Later they worked fine. Wipers then started to fail to operate every morning but if switch left on would randomly start working. Vehicle was taken in for service Vice but was told the issue could not be duplicated. As weather reached freezing temperatures wipers quit working completely. Replaced wiper motor myself and issue was fixed. Found out after replacing the motor had been previously replaced as part of a safety recall in April 2023.

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)

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.

I am reporting a safety-related transmission problem I experienced with my 2021 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission suddenly shifts hard/lags on gears 3-5 and sometime higher gears 7-9 at higher speeds. I’ve also noticed a buzzing/metallic rattling coming near the engine from inside. There is also times i can tell i have no power when trying to speed up and the other day i almost thought i was going to get T-Boned. This occurred while on my daily traffic commute to work, creating a potentially dangerous situation because the truck did not respond as expected when I needed predictable acceleration or propulsion. I believe this incident may be related to the known 10R80 CDF clutch-cylinder/sleeve problem. Ford technical information identifies axial movement of the CDF sleeve that can cause hydraulic-circuit leaks and harsh or delayed engagement and shifting. This condition can result in slipping, RPM flares, delayed engagement, unexpected gear changes, harsh downshifts, lurching, or loss of propulsion. This is a safety concern, not merely a transmission quality or reliability issue. Unexpected loss of propulsion or unpredictable shifting while merging, accelerating into traffic, crossing an intersection, turning, or traveling at highway speed can create a collision hazard. Because I personally experienced this unexpected transmission event, I request that NHTSA investigate the 10R80 CDF clutch-cylinder/sleeve condition in Ford F-150s. Please review Ford warranty claims, dealer repair records, transmission replacements, consumer complaints, and field-failure data to determine whether this is a safety defect requiring a recall. I believe owners should not have to wait for a potentially dangerous transmission failure before this known condition is addressed.

On July 15, 2026, I took the vehicle to Lafontaine Ford for maintenance and to address open recalls. I was informed that the open recall for the low-pressure fuel pump (campaign 25S75) did not have a solution available. Due to the severity of the recall, I contacted the Ford Customer Care Center. A representative stated that a solution would be available on July 17, 2026, and that they would contact Lafontaine Ford to prioritize the vehicle for repair on July 18, 2026. On July 17, 2026, I followed up with Lafontaine Ford and confirmed they had received no contact or notation from Ford regarding prioritization. Lafontaine Ford also stated they had no information on when parts would become available and that nothing could be done at that time. I then contacted the Ford Customer Care Center again because no action had been taken, even though the recall has been open since approximately July 8, 2025. A Ford Customer Care Center representative confirmed that no remedy was available for my model year and that they did not know when one would be available. Due to the seriousness of the recall, I requested a courtesy vehicle. The Ford representative contacted Lafontaine Ford regarding this request and then disconnected the call. The Lafontaine Ford representative informed me they could not provide a courtesy vehicle without written confirmation from Ford due to the dealership having no reasonable timeframe of when parts/remedy would be available. When I called the Ford Customer Care Center back and explained what Lafontaine Ford had told me, I was treated indifferently and was disconnected twice. I eventually spoke with a supervisor who refused to escalate the concern or provide any assistance with the documentation Lafontaine Ford said they needed in order to provide a courtesy vehicle. The low-pressure fuel pump is the component identified in the recall and can fail, resulting in loss of engine power or stall while driving. This creates a significant safety risk, part

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.

The contact owns a 2021 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle overheated, lost motive power, and stalled. While driving, there was an abnormal clucking noise detected. The check engine warning light was illuminated. The vehicle was taken to the local dealer, where it was diagnosed that the axle bolt and spacer were missing. Additionally, the exhaust system needed to be replaced. The vehicle was repaired. The manufacturer was not contacted. The failure mileage was approximately 15,500.

The steering wheel becomes crooked almost 90 degrees to the left and car still driving straight, just happened overnight I believe after system update

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.

Passenger side DRL assembly on headlight has failed. Dealer says the DRL is not repairable and the headlight assembly requires replacement. The safety of myself and others was put at risk by the absence of 50% of my vehicles DRL system, which diminished my visibility on the roadway. There were no indications of failure until it occured.

Daytime running lights have partially gone out. I am concerned that others may not see me as well without these lights. If the manufacturer felt they were important enough to put on the truck, then I feel it's important to for them to keep working. This happened without warning and seems to be an issue with a lot of these trucks. So many failures indicates a manufacturing issue which has now put lives in jeopardy.

The contact owns a 2021 Ford F-150. The contact stated that while the vehicle was parked, the vehicle was started, and several unknown warning lights illuminated. In addition, the contact stated that the gear shifter failed to shift into neutral while the vehicle was being towed. In addition, the contact stated that the gear shifter was stuck in park(P). The vehicle was towed to the dealer where it was diagnosed with powertrain control module failure. The contact was informed that the powertrain control module needed to be replaced. The vehicle was in the process of being repaired. The manufacturer was made aware of the failure. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 102,000.

There hasn't been an incident yet. But, I want a record of this somewhere. I'm assuming there may be an incident in the future; and, I'm concerned about that. Either an incident with my truck or an incident with the 100s of thousands of Ford and Lincoln vehicles from 2017-2023 that have this issue. The issue is Ford SSM 51939 - a whining noise coming from the bellhousing and the front of the transmission fluid pan. I have taken my truck to a dealership. I have called Ford about this. I have researched extensively online. I have called NHTSA. I have emailed the Office of Vehicle Safety Compliance. I am now filing this report online. The safety issue? For me, I'm now having to wear EARPLUGS when driving my vehicle. For others, they have been told to turn up the radio. I am now hearing the noise all the time -- believe it or not, even sometimes when I'm not even in my truck. Ford needs to address this. They send me to you. I don't have the 'option' of TRADING IN MY VEHICLE...others don't either. What am I to do? When something serious happens because people are remedying this themselves...it will be a very sad day. But, maybe only then will Ford do something. I don't know what else to do other than call Ford everyday, and email every agency that may be able to apply some pressure. Sadly, I have a full-time job...and this is really frustrating for me, in more ways that one. Hope you have a nice day! [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The drivers door lock sticks in the cold, so it will occasionally lock me into or out of my vehicle. I feel this is a safety issue, because I may not be able to exit my vehicle quickly in an emergency situation. It also may not lock leaving the vehicle vulnerable to theft.

The vehicle was unlocked, and I was in bed. At 1:35AM the tailgate just opened without any input from me (the remote was in another part of the house), and I received an alert from FordPass that the tailgate has been opened. I immediately checked the area outside and it was dark as I live in a very rural area. I turned on the all zone lightning, and nothing was seen. I closed the tailgate remotely, and I heard it latch properly.

The seat belt from my 2021 F-150 cause shoulder pain. Since the vehicle in the dealer for a month I have to drive a rental and the shoulder pain went away.

UNKNOWN Our F-150 was hit by a driver from a side street. The whole passenger side was damaged, front fender replaced, front door replace, post repaired, back door replaced, back panel of truck replaced, and back wheel. The long step was pushed up and under vehicle. It was replaced as well. The side airbag did not engage. I was thrown around in the passenger seat. I experienced a contusion on my right knee and three days later diagnosed with side impact whiplash. The truck was declared not safe to drive while we were trying to get estimates for repairs. They were concerned that the airbag didn’t go off and the door was not closing correctly even after they tried to tweak it. Our truck was towed off by the insurance company to a secured site until we could get it towed for repairs. We were never told why the airbag didn’t go off.

UNKNOWN Our F-150 was hit by a driver from a side street. The whole passenger side was damaged, front fender replaced, front door replace, post repaired, back door replaced, back panel of truck replaced, and back wheel. The long step was pushed up and under vehicle. It was replaced as well. The side airbag did not engage. I was thrown around in the passenger seat. I experienced a contusion on my right knee and three days later diagnosed with side impact whiplash. The truck was declared not safe to drive while we were trying to get estimates for repairs. They were concerned that the airbag didn’t go off and the door was not closing correctly even after they tried to tweak it. Our truck was towed off by the insurance company to a secured site until we could get it towed for repairs. We were never told why the airbag didn’t go off.