2021 Ford F-150 Body & structure Problems

After a day of heavy rain, the vehicle stalled at a stop light and would not restart. The steering wheel and transmission locked, preventing the vehicle from being placed in neutral, creating a safety hazard as the vehicle was immobile in traffic. No warning lamps appeared prior to the failure. The vehicle required a tow. The dealer confirmed water had intruded through the passenger side cowl/firewall seam due to inadequate factory sealing, tracking down and pooling directly onto the Body Control Module (BCM) mounted on the passenger side firewall. The BCM failed due to water damage, causing PATS desynchronization and the no-start condition. The BCM failure subsequently shorted out the starter motor. Dealer replaced the BCM, repaired the leak, and replaced the starter. Total repair cost approximately $3,200. Failed components are available for inspection at the dealership. This identical failure; passenger side cowl water intrusion leading directly to BCM damage — is documented across numerous 2021+ F-150 owner forums, indicating a widespread factory sealing defect at the cowl/firewall/inner fender seam junction.

NHTSA ID

11742278

Incident

May 29, 2026

The contact owns a 2021 Ford F-150. The contact stated that while driving at 70 MPH, the contact noticed an unusual grinding sound. The vehicle was driven to the shoulder of the road. The contact noticed a lot of unusual clicking or rattling sounds. In addition, several unknown warning lights were illuminated. The contact stated that upon exiting the vehicle, the contact noticed a fire underneath the vehicle. In addition, the drive shaft was detached. The contact stated that the fire burned out independently. The vehicle was towed to the contact's residence. The contact stated that the drive shaft had scorching around it. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. In addition, the contact stated that the recall, NHTSA Campaign Number: 21V986000 (Power Train, Structure), was performed on the contact's VIN about six months ago. The dealer was not made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 111,000.

NHTSA ID

11729380

Incident

Apr 4, 2026

Mileage

111,000 mi

Paint is peeling in several separate area's on the truck

NHTSA ID

11727459

Incident

Jul 1, 2024

Astro white exterior paint is chipping on the roof of the vehicle in multiple locations. See pictures attached of sever chipping above windshield and wear the roof meets. Also chipping occurring above both rear doors on roof. This was not due to an accident or normal wear and tear.

NHTSA ID

11726170

Incident

Mar 1, 2026

My 2021 Ford F-150 Lariat has a door latch defect that occurs in freezing or near-freezing temperatures. The failure occurs without warning in cold conditions, causing the door latch to freeze and not fully engage. When this happens, the door is able to freely swing open while the vehicle is in motion and also freely open when the vehicle is parked. This creates a serious safety hazard, including the risk of occupant ejection and loss of vehicle control. The vehicle has no aftermarket modifications and is maintained per manufacturer recommendations. The issue is temperature-dependent and has occurred on multiple occasions. Ford has issued recalls for similar door latch freezing defects on multiple other Ford vehicles and model years. Despite this, my vehicle has not been included, even though it exhibits the same failure mode. This defect presents a significant safety risk and should be investigated for potential recall inclusion.

NHTSA ID

11721907

Incident

Dec 14, 2025

Please see Ford TSB SSM50543. In my case the driver's door has been freezing in the lock position. Door will not unlock and cannot be opened either from the inside or outside. The key in the outside will not unlock the door and pulling up on the knob inside cannot be done (even tried with pliers). The electric door locks for the frozen door do nothing. This made it possible for me to only get out of or into the driver's seat by climbing in/out from the passenger's side. I also tried to not lock the driver's door, and this just made the door frozen in the unlock position. Very inconvenient, but I am especially concerned if I had to exit or enter the driver's side in an emergency. Ford knows about this as can be seem from the issued TSB. This had happened more than once and goes away when the inside of the truck gets really warm, or the weather gets above sufficiently over freezing.

NHTSA ID

11713665

Incident

Jan 25, 2026

The contact owns a 2021 Ford F-150. The contact stated that while driving 40 MPH, the contact heard an abnormally loud booming sound. The contact pulled over to the right side of the road, exited the vehicle. Upon inspecting underneath the vehicle, the contact noticed that the driveshaft was fractured and damaged. The contact stated that the failure had occurred on several different occasions. The vehicle was towed to a dealer, where it was diagnosed that the heat shield had rubbed on the driveshaft, and the driveshaft needed to be replaced. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 21V986000(Power Train, Structure); however, the VIN was not included in the recall. The manufacturer was not notified of the failure. The failure mileage was 74,000.

NHTSA ID

11707786

Incident

Dec 28, 2025

Mileage

74,000 mi

A certified independent inspection company discovered welding on the main chassis of my Ford F-150. The welding is located on the front left frame area. I purchased the vehicle brand new, and it has never been in any accident or collision. This welding on a critical structural part creates a serious safety risk. Frame integrity may be compromised in normal driving or in the event of an impact. I transport my children daily in this vehicle, and I am afraid to drive it due to the possibility of structural failure. The official Ford dealer inspected the vehicle and kept it for approximately three weeks but provided no explanation or repair. The regional Ford office has delayed their technical report for more than five months with no response. The defect has been confirmed and is permanent. No warnings or lights appeared prior to discovering the issue. This is a manufacturing-related structural defect affecting vehicle safety, stability, and integrity. A proper safety resolution is required.

NHTSA ID

11702403

Incident

Oct 14, 2025

The contact owns a 2021 Ford F-150. The contact stated that the exhaust baffles were making an abnormal ticking sound while the vehicle was idling. The contact also stated that the A/C outlet vent tab had separated from the vehicle, and the other tabs were loose. Additionally, the contact stated that while accelerating from a complete stop, the vehicle hesitated while responding. The contact stated that the vehicle made an abnormal squealing sound while driving at various speeds and while idling. The vehicle was taken to the dealer, where it was diagnosed that the serpentine belt and one of the pulleys needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact the repairs could not be covered under the powertrain warranty. The failure mileage was approximately 48,000.

NHTSA ID

11675439

Incident

Nov 22, 2024

Mileage

48,000 mi

The dash pad in front of steering wheel is coming apart and peeling back. It appears to a defect in installation, material use or wasn't glued down properly

NHTSA ID

11672264

Incident

Jul 7, 2025

The side rails that come out when door is opened to assist with getting inside the truck does not work properly. It has come out and will not go back in. The door is closed and I have to drive the truck with the rails hanging down. That is a hazard.

NHTSA ID

11666896

Incident

Jun 14, 2025

The saggy diaper is a hazard and major manufacturer defect that must be corrected ASAP. It needs to be metal period the end. The paper like cover bolted on the undercarriage is an awful engineering hazard. I have changed this item four times. The dealerships well established pattern of services for this issue and Google searches speak for themselves. I don’t know why Ford refuses to address this concern and blow me off.

NHTSA ID

11662939

Incident

May 23, 2025

What component or system failed or malfunctioned, and is it available for inspection upon request? The exterior door handles and latching mechanism failed due to freezing in cold weather. When temperatures drop, the door handles become stuck or the latch mechanism fails to engage or disengage properly. This issue is reproducible during cold weather and the affected components are available for inspection upon request. How was your safety or the safety of others put at risk? The malfunction poses a safety risk in multiple ways. The doors may not close securely, which could result in a door opening while driving. Conversely, frozen latches can prevent doors from opening, which is a serious concern in the event of an emergency where rapid exit from the vehicle is required. This could endanger both the driver and passengers. Has the problem been reproduced or confirmed by a dealer or independent service center? The issue has not yet been confirmed by a dealer, but it is a widely documented problem among 2021 Ford F-150 owners, and it occurs consistently during cold weather conditions. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No formal inspection by the manufacturer, police, or insurance representatives has been conducted to date. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? There were no warning lamps or dashboard messages. The issue was first noticed during freezing temperatures in the winter season. The symptoms are physical—frozen or stuck handles and malfunctioning door latches.

NHTSA ID

11660637

Incident

Feb 1, 2025

The contact owns a 2021 Ford F-150. The contact stated while driving at an undisclosed speed, the contact noticed an abnormal swishing sound in the front and rear passenger's side door panels. The contact inspected the vehicle and discovered water in the front and rear passenger side door panels. The vehicle was taken to the dealer. The contact was informed that the water leak was coming from the roof of the vehicle. The vehicle was repaired; however, the failure reoccurred. The contact stated while the vehicle was parked, the contact noticed the water entering the interior of the vehicle through the rear passenger's side seat belt. The vehicle was taken to the dealer. The contact was informed that the water leak was due to a failed rear exhaust panel. The contact was informed that the rear exhaust panel needed to be replaced. The vehicle was repaired. Additionally, the contact stated that due to the failure, the carpet and the seats needed to be cleaned. The failure reoccurred. The contact stated while driving, there was an abnormal swishing sound in the front and rear passenger's side door panels again. The contact became aware of electrical switching sounds, and the horn failed to operate as intended. The vehicle was taken back to the dealer, where it was diagnosed with sunroof assembly failure. The contact was informed that the sunroof assembly needed to be replaced. The vehicle was being repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 44,000.

NHTSA ID

11649728

Incident

Aug 14, 2024

Mileage

44,000 mi

DRIVER DOOR WON'T LOCK OR UNLOCK IN EXTREME COLD. TO EXIT AND ENTER TRUCK, I HAVE TO USE THE PASSENGER DOOR AND SLIDE INTO DRIVER SEAT, WHICH IS VERY DIFFICULT B/C OF THE CENTER CONSOLE. NO WAY I COULD GET OUT OF THE TRUCK IN A HURRY IF I HAD TO. TOOK TO A DEALER BUT OF COURSE IT COULDN'T BE DUPLICATED. INTERNET SEARCH SHOWS THIS IS A PROBLEM WITH THE 2021 FORD F150.

NHTSA ID

11643699

Incident

Feb 14, 2025

My rear passenger window shattered. My niece opened the door and the glass shattered. The window pane was held together by after market tint. It then fell under the vehicle. The vehicle is available for inspection until Friday, July 27, when it is scheduled for repair. The safety of the passengers was putt in jeopardy sure to the nature of the incident.

NHTSA ID

11603079

Incident

Jul 17, 2024

F150 is experiencing interior leaking from the windshield and other areas that Ford is unable to identify the cause. This can cause visibility issues and damage to electrical components resulting in a safety issue. The leaking causes the floor mats to be wet, which have also caused my foot to slip off the control petals. This could cause an accident. Ford is not able to identify the source, they were able to reproduce the leaks in the firewall but can't identify the source. Ford doesn't acknowledge this is a major issue and has only offered to caulk and seal in the most common areas. It was in the shop for four days March 25-27 and 22-23 2024. There are no warning issues just went floor mats and visible water on the interior of my windshield which I demonstrate to the dealership.

NHTSA ID

11579759

Incident

Mar 1, 2024

Tailgate periodically opens on its own

NHTSA ID

11579681

Incident

Feb 21, 2024

In freezing temps(usually under 25*), the interior door handle freezes and will not engage the door latch. The door will not stay latched until cabin of interior warms up. Running boards get deployed every time the vehicle comes to a stop.

NHTSA ID

11571377

Incident

Feb 12, 2024

The contact's business partner owns a 2021 Ford F-150. The contact stated that while his business partner was driving at an undisclosed speed, the vehicle lost motive power. The vehicle was towed to the dealer, where it was diagnosed with a fractured driveshaft. The dealer replaced the driveshaft. The manufacturer was made aware of the failure but informed the contact that the VIN was not included in NHTSA Campaign Number: 21V986000 (Power Train, Structure). The failure mileage was 80,230.

NHTSA ID

11565186

Incident

Jan 3, 2024

Mileage

80,230 mi

Panoramic sunroof exploded. This happened on a country highway with no other cars or debris around.

NHTSA ID

11553534

Incident

Nov 3, 2023

The contact owns a 2021 Ford F-150. The contact stated while starting the vehicle, the instrument cluster and the infotainment system reset independently, which affected the trailer blind spot setting while towing a trailer. The vehicle was taken to the local dealer, and to a second dealer, Kenly Ford, Inc. (500 S Gardner Ave, Kenly, NC 27542), to be diagnosed; however, the dealer could not determine the cause of the failure. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: SSM 50975. The manufacturer was notified of the failure, and a case was opened. The failure mileage was approximately 100.

NHTSA ID

11550824

Incident

Jun 15, 2021

Mileage

100 mi

The contact owns a 2021 Ford F-150. The contact received notifications of NHTSA Campaign Numbers: 22V142000 (Visibility) and 22V623000 (Power Train, Structure) however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was not made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11521349

Incident

May 10, 2023

While driving on a highway at 70 mph the hood unlocked and was caught by the safety latch. It is available for inspection. My safety was at extreme risk. Loosing the ability to see out of my windshield had the safety latch failed could have been catastrophic. This could have caused a crash at highway speeds from the sudden inability to see where I was driving. The problem has not been reproduced but should be confirmed by the trucks data system. A hood unsafe message appeared on my dash screen. The latch has not been inspected yet as this happened last night. There was no prior indication or warning that the hood would come unlocked.

NHTSA ID

11502718

Incident

Jan 19, 2023

EXTREMELY DANGEROUS DOOR CLOSING FAILURE. Both front door lock actuators malfunction below 10 degrees Fahrenheit. Rear doors of the crew cab are unaffected. The moving parts of the mechanism are not frozen and there is no water in the system. The lock actuator will not engage the clamp/pin mechanism to hold the door closed, even though the movable parts are freely moving. this happens whenever the temperature is below 10 degrees. In order to get out of the car you need to exit the rear door or climb out the window. Once the door does open, it will not securely latch in position. The Certified Ford dealership informed me that this is a "known problem" with the F150 and there is no known repair.

NHTSA ID

11498959

Incident

Dec 24, 2022