2022 Ford F-150 Lightning BEV Problems

The forward dash instrument panel is completely out. Unable to see miles per hour, charge settings, odometer, cruise control etc. Completely blank.

The rear lightbar assembly on our 2022 Ford F-150 Lightning Lariat has developed micro-cracks in the outer lens, allowing moisture to accumulate inside. This has caused flickering or inoperative reverse lamps and now appears to be impacting the rear passenger blinker, which functions intermittently. We are concerned that the moisture has begun to corrode the rear wiring harness or electrical system, creating additional safety risks. When we reported the issue, a Kendall Ford representative told us the rear lightbar replacement was “mainly cosmetic,” but that assessment contradicts both Ford’s recall documentation and our experience. Moisture intrusion has already led to intermittent lighting failures that reduce signaling visibility to other drivers, posing a real risk of collision. The problem has been confirmed by the dealer and a Ford Field Service Engineer dispatched from Dearborn, who inspected the truck in 2025 after the same recall repair (23S30) failed. Ford has since issued a new recall (25V731 / 25S86) acknowledging improper dealer repairs as the cause. Visible condensation, flickering lights, and intermittent “charging system fault” and “sensor unavailable” messages began shortly after the 2023 recall repair and have continued to worsen. The vehicle remains in our possession and is available for inspection by NHTSA or Ford corporate upon request.

The rear lightbar assembly on our 2022 Ford F-150 Lightning Lariat has developed micro-cracks in the outer lens, allowing moisture to accumulate inside. This has caused flickering or inoperative reverse lamps and now appears to be impacting the rear passenger blinker, which functions intermittently. We are concerned that the moisture has begun to corrode the rear wiring harness or electrical system, creating additional safety risks. When we reported the issue, a Kendall Ford representative told us the rear lightbar replacement was “mainly cosmetic,” but that assessment contradicts both Ford’s recall documentation and our experience. Moisture intrusion has already led to intermittent lighting failures that reduce signaling visibility to other drivers, posing a real risk of collision. The problem has been confirmed by the dealer and a Ford Field Service Engineer dispatched from Dearborn, who inspected the truck in 2025 after the same recall repair (23S30) failed. Ford has since issued a new recall (25V731 / 25S86) acknowledging improper dealer repairs as the cause. Visible condensation, flickering lights, and intermittent “charging system fault” and “sensor unavailable” messages began shortly after the 2023 recall repair and have continued to worsen. The vehicle remains in our possession and is available for inspection by NHTSA or Ford corporate upon request.

I own a 2022 Ford F-150 Lightning Lariat (VIN [XXX] ). Around June 6, 2025, I brought my truck to Apple Ford Shakopee for a scheduled appointment because I noticed moisture collecting inside the rear light bar. The service representative told me Ford considers that moisture normal, likely from a car wash, and that it would dry out on its own. At that time the truck had fewer than 36,000 miles and was still under the bumper-to-bumper warranty. The moisture never went away, and the light bar is now failing — my backup lights are dimming and flickering. I’ve since learned there was a recall (23S30) on 2022–2023 F-150 Lightning Lariat and Platinum trucks for micro-cracks in the rear light-bar lens that allow moisture in. My VIN currently shows no open recalls, but this failure appears identical to what the recall described. Additionally, owner forums are full of reports from other Lightning owners experiencing the same issue — including those who already had the recall repair completed, whose replacement light bars are now showing moisture again. This suggests the defect may persist even after recall repairs. I’m reporting this because the issue compromises the rear lighting and visibility of the vehicle. I hope Ford and NHTSA will review whether the recall scope or remedy should be expanded to include affected vehicles like mine and ensure owners aren’t left with expensive out-of-pocket repairs for a known manufacturing defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Extreme corrosion on connector for headlamp assembly and front camera. Also, extreme corrosion on connector that powers lightbar. Ford denied warranty claim by considering it a lamp issue even though lamp was good. The lightbar and connector w/ corrosion are one single part. Corrosion was so bad multiple pins had rusted off. This could cause electrical short and potential fire risk.

VIN: [XXX] NHTSA recall number: 23V41800 Manufacturer recall number: 23S30 My car has a current NHTSA, I have scheduled over 5 appointments to have Ford address the reverse lightbar replaced. And all 5 appointments have been unsuccessful at replacing the light since [XXX]. It is now October 2024, over 17 months since the NHTSA recall from June 2023. As of the date of this letter, my next appointment is schedule for [XXX], once again I called Colonial Ford dealership in Plymouth, Massachusetts to confirm my lightbar is available and the service advisor told me it is not in stock, and rescheduled me to [XXX]. This letter pursues, after several failed appointment and long wait times waiting to hear the part is on backorder for the last year. I am attaching proof all appointments and phone calls, and email notices of scheduled appointments, but were unsuccessful since the part is not in at the dealership. Over the course of the last year, I have called monthly and after receiving email and recall notices, and to no avail, each time I am told the part is on backorder and to call back. I continue to have problems with my taillight flickering, and problems with my reverse light for the last six months, recently a few weeks ago, I was given a warning by Plymouth Police Department in Massachusetts. I explained and showed proof of the recall. I have patiently waited since I keep thinking it will be here next month, well it is now almost 1.5 years later and the part is still on “backorder”. Patiently waiting is now a safety issue. I have explained to the service advisor that my car detects an accident collision because of the faulty light and Ford has failed to promptly address and replace the tail light. Please see Ford attached invoices addressing the Collision Detection malfunctioning from November 2023. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Driving into the office today I was stopped at a stoplight. When it turned green I started to accelerate when a error came up on the screen saying the vehicle needed to be serviced immediately and the vehicle reduced power (<15 mph) in the middle of a busy road with a speed limit of 55 mph. In the FordPass App I got a message saying "Powertrain Malfunction/Reduced Power" What component or system failed or malfunctioned, and is it available for inspection upon request? Powertrain How was your safety or the safety of others put at risk? Yes, I was unable to go faster then 15 mph in a 55 mph zone while trying to move the vehicle to the side of the road. Has the problem been reproduced or confirmed by a dealer or independent service center? There are over 600 incidents reported of this problem by other F150 Lightning Owners in [XXX] that are compiled in the attached spreadsheet. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No warning lamps/messages were on before the failure happened. I bought the pickup used last Friday and the problem happened today for the first time after putting more then 500 miles on it this week. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I have received "High Voltage Battery Warnings" on 3 separate occasions (5/5/24, 5/9/24, 7/14/24), each time being told to stop the vehicle as soon as possible. On each occasion, once the vehicle is stopped it is bricked and cannot be driven at all. Fortunately, each of the three times I was able to stop the vehicle in a safe place. However, if others are experiencing the same issue, they may not be able to stop in a safe place. Furthermore, Ford has failed twice to fix the High Voltage battery issue, and the vehicle is currently at the dealer trying to resolve the issue for a third time. The fact that Ford does not know how to resolve this repeating issue is a large safety concern for two main reasons. First, as the high voltage battery is the main power unit for the propulsion system of the car, and with Ford clearly unaware of what or how to fix the issue, the car is at risk of stopping at any time or location. Second, the dealership working with Ford to fix the car mentioned that the repairs were taking a long time because Ford indicated that the High Voltage from the battery may be discharging into other components of the vehicle, e.g. frame, door panels, etc., and so they had to proceed with extreme caution. With Ford failing to resolve the issue at least two time, there may be a risk of very high electric current coming in contact with the driver or passengers in the vehicle. It would be shocking if that were to happen.

Within first two months of ownership of new F-150 Lightning, we found the windshield is covered by or contains in its lamination far too many tiny bright dots, specks, or tiny pin point bubbles (say, on average, less than 1/4" apart) that appear and cause glare when the sun shines almost directly through them. This glare from the tiny defects makes it hard to see the full road, especially when the sun is low. I assume it is a manufacturing defect. Reported to Ford Dealer back in December, 2022, but they never responded to me. And after windshield glass was replaced due to a rock hit with OEM glass, it has the same sun glare with the tiny bubbles, so manufacturing is consistently bad? I think this could be a recall situation.

About a year ago there was a wiper motor recall, bought jt in for that. Last few months wipers get “stuck” mid wipe for a few seconds and then rectify. Today wipers got stuck mid wipe indefinitely. I hit the button a few times and they completed the wipe. Annoying for a 2 year old vehicle , perhaps a problem with the recall replacement motors?

I have received "High Voltage Battery Warnings" on 3 separate occasions (5/5/24, 5/9/24, 7/14/24), each time being told to stop the vehicle as soon as possible. On each occasion, once the vehicle is stopped it is bricked and cannot be driven at all. Fortunately, each of the three times I was able to stop the vehicle in a safe place. However, if others are experiencing the same issue, they may not be able to stop in a safe place. Furthermore, Ford has failed twice to fix the High Voltage battery issue, and the vehicle is currently at the dealer trying to resolve the issue for a third time. The fact that Ford does not know how to resolve this repeating issue is a large safety concern for two main reasons. First, as the high voltage battery is the main power unit for the propulsion system of the car, and with Ford clearly unaware of what or how to fix the issue, the car is at risk of stopping at any time or location. Second, the dealership working with Ford to fix the car mentioned that the repairs were taking a long time because Ford indicated that the High Voltage from the battery may be discharging into other components of the vehicle, e.g. frame, door panels, etc., and so they had to proceed with extreme caution. With Ford failing to resolve the issue at least two time, there may be a risk of very high electric current coming in contact with the driver or passengers in the vehicle. It would be shocking if that were to happen.

During a long road trip my truck displayed a message stating that I had a Powertrain Malfunction/ Reduced Power. My truck, while driving, reduced itself to half power. It also would not charge. I was 3 states away from home when this happened. I took the vehicle to my Ford dealership once I was able to get it home. The technician simply cleared a code and said that the issue could not be replicated. Clearly there is an issue. I know several people with the same issue. Frankly, I don't think that I can trust my new truck a significant distance from my residence.

While driving, a loud static sound started over the speakers and would not stop. It was so loud I could not continue driving and I immediately developed a headache. Even after I pulled over, turned off the truck and left for about minute it still continued. I eventually let it sit for about 20 minutes and when i came back the sound had stopped and works normally now. Car reeks of a burning plastic smell. My apple watch recorded a 109dB spike. I posted a video of the sound at https://youtube.com/shorts/XMFUDQA70Ms?feature=share

I get into the truck and push the start button, a very loud explosive ear piercing sound comes out of every speaker at full volume. It sounded like a canon shot out all my windows, a huge POP sound followed by scratching crackling sounds coming from the speakers. I tried turning down the volume to no avail, I turned off the audio but the loud scratching sound kept going at a very loud volume. The scratching sound went on for about 2 minutes then shut off. My ears were ringing and I was in a lot of ear pain due to the loud POP noise, it felt like my ear drums were blown out. I could hardly hear after this incident, I think I my have hearing loss from this loud noise. No one has inspected the vehicle, they say they want me to bring them the car when the problem happens again. I did not see any warning lamps or messages before or after the incedent

The rear light bar and reversing lamp assembly, which was part of a safety recall, is filled with water and the lights are malfunctioning again. Ford is telling me that the replacement part has a 1 year warranty so that I would have to pay over $1600 for a replacement. This is a widespread issue with many of these trucks. Ford admitted that it was a manufacturing defect with the original part. However, the replacement part has the same issue so it is my belief that Ford has not fulfilled their duty to adequately repair an obvious safety issue and should be held responsible for the replacement of this part at no cost to the vehicle owner.

I placed groceries in my front trunk “Frunk” and they shifted while trying to leave. Once shifted they hit the emergency release button inside the frunk which opened the frunk hood unexpectedly. These should be covered or less accessible inside the frunk.

On several occasions I have unintentionally pressed the accelerator pedal in addition to pressing the brake pedal. The brake pedal is 2 inches "higher" (closer to the driver) than the accelerator pedal in its full up position. When attempting to quickly place my foot on top of the brake pedal from the accelerator pedal, my foot hits the side of the brake pedal. This issue has resulted in several near-hit accidents with a vehicle in front of me. The rapid acceleration of the Ford Lightning reduces response time to correct the braking disruption. The brake pedal may be placed higher to prevent the driver from also depressing the accelerator when depressing the brake. Other vehicles also have a higher brake pedal, but it feels like an unusually high foot lift is required in the Lightning. There is definitely something unusual about the brake and accelerator geometry in my Ford Lightning.

Unintended acceleration / rolling may occur when vehicle is remote started through Fordpass mobile application. The 1 pedal-drive vehicle setting is NOT preserved when using remote start. Vehicle may roll down hill upon entry. Default driver profile has 1 pedal drive OFF while all device profiles linked to Fordpass and Phone-as-a-Key have 1 pedal drive ON. Fordpass mobile app remote start needs to preserve 1 pedal drive setting due to potential unintended acceleration when on flat surfaces or unintended reverse acceleration rolling down hills.

I’ve had 11 times back at the dealer to fix my airbag, pre-collision and battery. Ford can’t figure out the solution and keeps throwing parts at it. Already replaced my computer, computers, my wiring, harnesses, my charge port, my wiring harness for the charge port, my seat cushion for the airbags. Ford no longer knows how to fix the problem And is leaving the truck in the backyard for over six weeks now. I’m seeing multiple people having the same problem and Ford doesn’t know how to fix the problem even though they’ve reset my modules and replace them. Ford hotline doesn’t know how to solve the problem either so they’re just resetting The code and telling customers to get back in their vehicle. I found out that Ford wanted me to drive my truck for a month with a code reader with no airbags, hoping that they could find the problem but I told them no and when I said that they said I’ve already been driving it for months even though they never fix the problem Not knowing if I had airbags. Ford is willingly putting people in vehicles with no airbags, hoping the problem is fixed, but they don’t know what’s causing the problem and I’m not the only person I know five other people with the same problem.

Component Failed & Inspection Status: The front-left upper and lower control arms, ball joints, wheel hub assembly, steering knuckle, and front axle shaft have failed. Severe environmental corrosion has completely seized and fused the steering knuckle inside the wheel hub. All original failed components are currently intact and are fully available for physical inspection upon request. Safety Risk: This severe structural corrosion causes the steering knuckle and axle to seize, creating an imminent risk of primary steering component separation while driving. A steering separation on a heavy electric vehicle (over 6,000 lbs curb weight) causes a sudden, complete loss of directional control, creating an immediate life-threatening hazard to the occupants and surrounding traffic. Confirmation & Testing:The failure and severe structural corrosion were officially diagnosed and confirmed by a certified technician at an authorized Ford dealership service center. Warning Signs & Symptoms: The symptom appeared as a very noisy, distinct creaking sound coming from the front-left suspension. This noise occurred specifically when turning the steering wheel and when operating the vehicle at speeds below 40 mph. The sounds may have been present but obscured by road noise at higher speeds. There were no dashboard warning lamps or error messages prior to the diagnostic inspection. Systemic Concerns: This 2022 model is experiencing a severe vulnerability to premature environmental corrosion that causes the steering knuckle, axle, and control arms to seize to the point of failure. This demonstrates a critical structural durability issue under heavy EV loads in road-salt regions that warrants federal safety tracking for the 2022 model year.

Component Failed & Inspection Status: The front-left upper and lower control arms, ball joints, wheel hub assembly, steering knuckle, and front axle shaft have failed. Severe environmental corrosion has completely seized and fused the steering knuckle inside the wheel hub. All original failed components are currently intact and are fully available for physical inspection upon request. Safety Risk: This severe structural corrosion causes the steering knuckle and axle to seize, creating an imminent risk of primary steering component separation while driving. A steering separation on a heavy electric vehicle (over 6,000 lbs curb weight) causes a sudden, complete loss of directional control, creating an immediate life-threatening hazard to the occupants and surrounding traffic. Confirmation & Testing:The failure and severe structural corrosion were officially diagnosed and confirmed by a certified technician at an authorized Ford dealership service center. Warning Signs & Symptoms: The symptom appeared as a very noisy, distinct creaking sound coming from the front-left suspension. This noise occurred specifically when turning the steering wheel and when operating the vehicle at speeds below 40 mph. The sounds may have been present but obscured by road noise at higher speeds. There were no dashboard warning lamps or error messages prior to the diagnostic inspection. Systemic Concerns: This 2022 model is experiencing a severe vulnerability to premature environmental corrosion that causes the steering knuckle, axle, and control arms to seize to the point of failure. This demonstrates a critical structural durability issue under heavy EV loads in road-salt regions that warrants federal safety tracking for the 2022 model year.

The contact owns a 2022 Ford F-150. The contact was made aware of NHTSA Campaign Number: 22V453000 (Tire). The contact stated that while checking the tire pressure, the tires were 35 PSI lower than normal. The contact called the local dealer and made them aware of the failure. The vehicle was not diagnosed or repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 12,000.