2022 Ford F-150

On July 29, 2024, the Office of Defects Investigation (ODI) opened PE24019 to investigate complaints of low-pressure fuel pump failures in MY 2021 Ford Bronco vehicles. Some consumers reported that the failure occurred without warning while driving, resulting in a complete loss of motive power with no ability to restart the engine. Ford determined that several other vehicle models contain low-pressure fuel pumps substantially similar to the 2021 Ford Bronco, including the 2022-2023 Ford Bronco, 2018-2023 Ford F-150, 2022-2023 Ford Expedition, 2019-2023 Lincoln Navigator, 2020-2023 Ford F-250-F-550, 2024 Ford Super Duty Chassis Cab, 2024-2025 Ford Ranger, 2020-2023 Ford Explorer, 2020-2023 Lincoln Aviator, and 2021-2025 Ford Mustang. ODI's investigation found that the affected vehicles may lose fuel pressure and flow from the fuel delivery module (consisting of a low-pressure fuel pump, jet pump, reservoir, and other parts) due to a low-pressure pump failure. This can cause the engine to stall while driving. The root cause is reduced internal clearance in the fuel pump, increasing friction and sensitivity to vapor lock. Fuel blockage from contamination inside the jet pump also contributed to the failure. Ford stated that the contamination source was unknown. On July 7, 2025, Ford filed recall 25V-455 for certain 2021-2023 Ford F-550 SD/F-450 SD/F-350 SD/F-250 SD, 2021-2022 Lincoln Navigator, 2021-2022 Ford Mustang, 2021-2022 Ford F-150, 2021-2023 Ford Explorer, 2022 Ford Expedition, and 2021-2023 Ford Bronco vehicles produced between July 1, 2021, and July 30, 2022. The recall also included certain 2021-2023 Lincoln Aviator produced between July 1, 2021, and December 21, 2022. Ford explained in its recall filingthat the production dates used for the recall were based on changes in the manufacturing process. Specifically, Ford determined that in June 2021, the supplier modified the jet pump manufacturing process, producing fuel pump chambers with a lower-than-specified internal clearance. In July 2022, the supplier implemented corrective actions to the manufacturing process by adding two additional vacuum pumps to reduce contamination during the production of the jet pump. ODI has identified approximately 1,000 reports involving vehicles covered in this investigation but excluded from recall 25V-455. However, even with such reports, these vehicles experienced comparatively lower failure rates than the vehicles that are subject to Recall 25V-455. Ford has explained that these vehicles were excluded from the recall population because they did not experience the manufacturing changes that prompted the recall. Specifically, according to Ford, vehicles built before July 1, 2021 (the recall production start date), were not affected by the supplier’s change to the jet pump manufacturing process. Even after closing this investigation, ODI will continue to monitor complaints for vehicles excluded from recall 25V-455 to consider whether they exhibit the same risks as the vehicles encompassed by the recall. The recall remedy is currently under development. In view of Ford’s recall action, ODI is closing this Preliminary Evaluation, but will continue to monitor the issue as a remedy is developed and implemented. ODI will take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family.  If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact owns a 2022 Ford F-150. The contact stated that while driving approximately 55-65 MPH, the vehicle stalled. The check engine and battery warning lights were illuminated. The contact associated the failure with NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline). The vehicle was towed to an independent mechanic, and the failure was associated with the recall and a diagnostic trouble code related to the ECM reprogramming for the fuel system. The vehicle was towed to the local Ford dealer, who diagnosed the vehicle with a fuel system failure. The vehicle was not diagnosed or repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 29,043.

NHTSA ID

11755908

Incident

Jul 31, 2026

Mileage

29,043 mi

On two occasions vehicle failed 3-4 upshift and abruptly shifted into first instead. Transmission harshness/flaring. I am experiencing intermittent flaring/slippage and harshness with the 3-4 upshift and 4-3 downshift, 4-5 upshift, and 7-8 upshift. Most of the time, it exhibits as a flare/slip/bogging down during the 3-4 upshift, sometimes accompanied by a slam once it catches. Less often there is a slam during the 4-3 downshift or 3-1 downshift, especially when coming to a stop. The issue is more pronounced when the transmission is cold but does occur when fully warmed up, just far less frequently.

NHTSA ID

11755603

Incident

Nov 8, 2025

LED strip for the headlight assembly burned out. No known repair other than to replace the whole headlight assembly for $2500. This is a common issue with a poor design from ford and can cause visibility and safety issues with the vehicle. The dealership at beach ford in myrtle beach, sc swapped LED modules to make sure it wasn’t a programming or module issue, the symptom did not change headlights.

NHTSA ID

11755524

Incident

Jul 27, 2026

The felt under shield on the Ford F150 ha came detached three times. I have replaced it each time. When I returned to the Ford dealer I was told not to replace because it will get wet and fall off again. More importantly they said it was not needed. Its function is to reduce noise and keep mud, dirt, and rain from getting under the vehicle. I was told if I wanted to replace it I could get an after market product made of metal to stop if from breaking. The part that breaks is the felt connection where it screws into the underbody. My point is that if the Ford dealership tells me I don't need it why is it there in the first place? Next, Ford dealerships know this is a problem, there are many complains on the Ford internet sites. Because it has happened so many times to me and others Ford should have a recall and they should pay for the metal replacement. This should be a class action suit because Ford manufacture and Ford dealers know it is a problem, but still sell the vehicle knowing the issue.

NHTSA ID

11754737

Incident

Aug 2, 2026

I purchased a 2022 Ford F150 in September 2024. I began to notice occasional sluggishness when accelerating as the weather warmed up around March 2025. I contacted my local Ford dealership sharing the issue. The service manager suggested I consistently use a high octane fuel, which I consistently do, explaining I may just have "bad gas". The problem continued primarily when I was in heavy traffic with high temperatures. The truck acted as if it had a clogged fuel injector, sluggishness from start, low idle reducing below 1,000 RPM. I contacted a privately owned mechanic shop advising of my idle issues. The mechanic stated he doesn't believe a fuel injector would clog at 50,000 miles. In June 2025 received notification of a recall for my vehicle which I confirmed by VIN. The recall (#25V455) summarized the vehicle could sustain a loss of fuel pressure and flow from the fuel tank due to fuel pump failure. The letter continued, I may experience poor engine performance, rough idle or reduction in power, the same issues I had been complaining about. I contacted the Ford dealership and they explained Ford had not determined how to remedy the problem. Fast forwarding to present, 3 August 2026, over a year since the recall letter and Ford has yet to remedy the problem. What's the hold up? Will Ford finally determine the remedy when my family is killed on the interstate because the vehicles fuel pump fails and it stalls? It appears to be apparent Ford does not want to take the financial hit of such a recall. This is unacceptable and needs to be looked into by the NTSB.

NHTSA ID

11754342

Incident

Mar 1, 2025

I am reporting a safety-related defect involving the 10R80 automatic transmission in my 2022 Ford F-150 STX. While slowing to a stop during normal driving, the transmission unexpectedly performed an extremely harsh downshift. The truck jerked forward violently as it shifted into a lower gear, making it difficult to slow the vehicle in a smooth and predictable manner. This occurred without warning and created a dangerous situation while approaching an intersection. A vehicle should decelerate in a controlled and predictable way. Instead, the sudden downshift upset the vehicle’s behavior and reduced my confidence in its safe operation. If this happens in heavy traffic, on wet roads, or near pedestrians, it could easily contribute to a crash. This is not simply an issue of comfort or drivability. It is a safety concern because it affects the driver’s ability to safely control the vehicle. My truck is equipped with Ford’s 10R80 transmission, which has been the subject of thousands of owner complaints describing harsh downshifts, delayed engagement, slipping, gear hunting, and other dangerous shifting behavior. Publicly available technical information also discusses failures involving the CDF clutch cylinder and sleeve, which can cause hydraulic pressure loss and unpredictable transmission operation. Based on my experience and the large number of similar reports from other owners, I believe this issue deserves a thorough safety investigation. NHTSA should review warranty claims, dealer repair records, transmission replacements, technical service information, and consumer complaints to determine whether this transmission contains a safety-related defect that warrants a recall or other corrective action. Owners should not have to wait until a harsh downshift causes a serious collision before this issue is addressed. I respectfully request that NHTSA investigate this defect and require an effective repair to protect drivers, passengers, and everyone sharing the road

NHTSA ID

11754230

Incident

Jul 23, 2026

I am reporting a safety-related transmission problem I experienced with my 2022 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission suddenly shift hard in lower gears. It upshifts hard and downshifts really hard, it feels like someone runs into you. This occurs in stop and go traffic or slow moving traffic creating a potentially dangerous situation because the truck did not respond as expected when I needed predictable acceleration or propulsion and braking. 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-circui

NHTSA ID

11754218

Incident

Nov 7, 2025

I am reporting a safety-related transmission problem I experienced with my 2022 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission shifts in fourth thinks about it then applies the power This occurred while I merge onto the interstate creating a scary moment of trying to get up to speed with the traffic and it happens often , 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.

NHTSA ID

11754185

Incident

Jul 31, 2026

Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine, 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine, and 2020-2023 Lincoln Aviator vehicles equipped with a 3.0L EcoBoost hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable to enter electric-only drive modes as expected during normal drive cycles. This may be due to the belt integrated starter generator (BISG). For vehicles with this condition, follow the necessary Pinpoint Test in Workshop Manual (WSM), Section 303-06 for DTC P0A1E and repair the vehicle as directed. Note that previous replacement of the BISG does not negate the need for subsequent BISG replacements if directed to do so by the appropriate Pinpoint Test diagnostics. Engineering is investigating this BISG quality concern. Monitor PTS for updates regarding this investigation.

25S75 Recall remedy -Powertrain Control Module update to introduce logic to prevent low pressure fuel pump binding and maintain fuel flow to the engine.

Some 2021-2026 Ford/Lincoln vehicles may exhibit various symptoms including but not limited to the auto start/stop system not operating as intended with a "Check Charging System" message in the instrument panel cluster (IPC) while the charging system is operating properly with no charging related diagnostic trouble codes (DTC) stored. This may be due to someone using an aftermarket programmer to change the body control module (BCM) configuration to disable the auto start/stop system or perform other unsupported programming modifications. To correct this condition on F-150 and Bronco vehicles, download and run the Ford Diagnosis and Repair System (FDRS) application titled "BCM-Charging System Configuration Correction". Running this application will determine if the BCM configuration was modified by the customer and if so, provide the option to return the configuration back to factory settings. For other vehicle models exhibiting concerns related to unsupported aftermarket BCM programming, submit a Technical Support Request (TSR) requesting support to revert the BCM configuration

Some 2021-2024 Ford and Lincoln vehicles may exhibit an "Updating SYNC" message on the vehicle center display screen after an over the air (OTA) update. The message can be cleared from the center display screen and SYNC can be used normally, but it will re-appear at every subsequent ignition cycle. Inform customers that engineering is currently working on a software update solution for this condition to be delivered OTA expected in late Q3 2026. Software will update automatically if vehicle connectivity is enabled in the vehicles settings. Monitor Professional Technician System (PTS) for additional information.

Some 2021-2026 Ford vehicles may exhibit inoperative heated/cooled seats, heated steering wheel and/or front/rear defrost features after a remote start is performed through the Ford mobile application or with the key fob. Customers may also experience heated/cooled seats, heated steering wheel and/or front/rear defrost features turning on in unexpected conditions such as during warmer weather. These features will operate normally when commanded in the center display screen. This may be due to the customer not setting up their "Climate Settings" through the Ford mobile application. To correct this condition, inform the customer they should perform a remote start from the Ford mobile application and then adjust the "Climate Settings" in the Ford mobile application as desired. These settings only need to be set once and will persist through subsequent remote starts. Heated and cooled seats will be set to Level 2 when turned ON via "Climate Settings" in the Ford mobile application during a remote start event. This is normal operating characteristic. This condition does not affect vehicle durability and no a

This bulletin supersedes 26-2066. Reason for update: To remove "(2024 only)" from the Issue statement to include 2021-2025 vehicles that may exhibit a clicking sound coming from the gear shift lever. Some of the vehicles listed in the Model statement above equipped with a console GSM may exhibit at least one of the following conditions: * Clicking sound coming from the gear shift lever after it is placed and kept in reverse, neutral or drive position. * Gear shift lever stuck in park * Gear shift lever will not shift into park * Gear shift lever will not shift out of gear * Gear shift lever will not stow/unstow * Gear shift lever will move past the park position * Loose gear shift lever arm at pivot * Illuminated powertrain malfunction (wrench) indicator with DTCs P0929:77, P0929:00, P0929:07 and/or P0929:9A stored in the GSM This may be due to the GSM. Note: If the gear shifter lever will not shift into park, the transmission will automatically shift into park when the return to park function is triggered.