2023 Ford F-150 Body & structure Problems

There is a manufacturing defect that is causing water to to enter the vehicle when driving in the rain. Where this becomes a significant safety issue is that the water enters somewhere near the bottom of the windshield (source still not determined) and runs down the pillar over the fuse box and BCM (neither is protected from the water). This could lead to an electrical short on any of the major modules of the vehicle unpredictably. the leak is confirmed but source is still to be determined by the dealership after 2 visits. In searching the web, this seems to be a fairly common issue on this generation of F150 trucks. I'll attach the pictures I could get but can never get one with the water actually coming in live

NHTSA ID

11744763

Incident

May 11, 2026

Bolt in the hood latch fell out and nearly causing the hood to open on the interstate.

NHTSA ID

11724313

Incident

Mar 14, 2026

There is a leak somewhere in the truck. This leak is causing the carpet to retain and moisture and get caught between the floor mats causing a mildew and moisture smell.

NHTSA ID

11719704

Incident

Nov 20, 2023

The sunroof of my vehicle burst while I was driving on the highway. There was no warning and the vehicle was not hit by anything. The glass shattered and came into the truck cabin. Air starting getting in the vehicle as well. It was a dangerous situation as I was driving and glass was coming in. The vehicle was towed to the dealership. The dealership is refusing to repair the vehicle and they can’t confirm why the sunroof broke. The glass is caved outward. I have filed a claim with my insurance company to have the vehicle repaired.

NHTSA ID

11719493

Incident

Feb 19, 2026

As I was driving the right rear door flung open and would not engage when pulled back in. Had to drive home with a door that would not shut. Yes safety was at risk for kids in back seat. Confirmed by previous reports and service department at dealership. No warning lamps that were noticed.

NHTSA ID

11708276

Incident

Dec 14, 2025

I closed the passager side door and the back window shattered and blew out

NHTSA ID

11704879

Incident

Dec 12, 2025

During rain and snow events, water leaks into the interior of the vehicle through the roof area. The intrusion appears to occur during moderate to heavy precipitation and results in water collecting inside the cabin. This moisture has led to a persistent, moldy odor throughout the vehicle. The presence of mold poses a health concern, especially for my children and family members who ride in the truck. We are concerned about the potential inhalation of mold-contaminated air and the associated respiratory risks. This issue affects the safe and healthy use of the vehicle and requires attention, as the leak continues to worsen over time. First noticed this issue February of 2024, ongoing

NHTSA ID

11701307

Incident

Feb 1, 2024

The rear passenger window rolled down and is stuck in down position. This is the second time this has happened in our F-150. It happened when we first bought the truck nearly two year ago and was fixed. I worry it was replaced with another faulty component. There have been numerous complaints of this happening and the issue is within the driver side door components.

NHTSA ID

11688154

Incident

Sep 18, 2025

After a repair at Ted Russel ford that swapped my battery, the skid plate fell off while traveling in a parking lot. Fortunately this didn’t occur on the interstate.

NHTSA ID

11679504

Incident

Aug 8, 2025

Water entering cabin on Front passenger side of truck. Causing mold and mildew. Dealer 'fixed' this three weeks ago and now it is back again...

NHTSA ID

11678093

Incident

Aug 3, 2025

Bought used at 10k miles less than a year ago, has a severe leak from the passenger side windshield/cowl area that pours down the body seam saturates the floor, wire channel, and bcm area. This is a safety issue as you can smell a burnt/wet wire smell and the incoming water saturates critical wiring, and is nearby airbag wiring. Vehicle in question has only been owned for a year (of 3 year warranty) but any warranty repairs are being refused as it is 4100 miles outside of comprehensive warranty. However, this is not believed to be due to a component that failed due to mileage but rather a manufacturing defect/quality control in the body adhesive not being applied properly near the firewall/cowl/inner fender frame joint.

NHTSA ID

11671709

Incident

Jun 18, 2025

Bought new a year and a half ago, has a severe leak from the passenger side windshield/cowl area that pours into AC box and then saturates the floor. This is a safety issue as you can smell a burnt/we wire smell and the incoming water saturates critical wiring, and is nearby airbag wiring. Vehicle in question has only been owned for a year and a half (of 3 year warranty) but any warranty repairs are being refused as it is 2500 miles outside of comprehensive warranty. However, this is not believed to be due to a component that failed due to mileage but rather a manufacturing defect/quality control in the windshield or cowl seal.

NHTSA ID

11669465

Incident

Jun 10, 2025

The contact owns a 2023 Ford F-150. The contact stated that while driving at an undisclosed speed, the message "Active Air DAM System fault detected" was displayed. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the driver's Side Active Air Dam Motor Actuator. The contact was informed that the part displayed signs of external damage as if the driver had struck an object. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer, who again diagnosed a failure with the driver's Side Active Air Dam Motor Actuator. The vehicle was not repaired. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 4,000.

NHTSA ID

11654516

Incident

Apr 14, 2025

Mileage

4,000 mi

To Whom It May Concern, I am writing to formally report a recurring water intrusion issue with my vehicle, which poses a potential safety risk. Whenever it rains and the vehicle is parked outside, water consistently leaks into the passenger-side interior. While driving, especially during acceleration or braking, I can hear the sound of water moving within the passenger side area. Upon inspection, I have found water pooling in the front passenger footwell, where multiple electrical wires are located. Additionally, there is an electrical control box situated beneath the passenger seat that may also be exposed to moisture. I also discovered water leaking behind the rear seat area. This section contains two air vents, which may be contributing to the issue. The water intrusion raises serious concerns about electrical system integrity, especially given the presence of wiring and components in affected areas. Although my vehicle has not yet experienced electrical failure while driving, I am aware of multiple reports from other owners who have encountered similar leaks that led to sudden engine shutdowns, including while driving in traffic — a serious safety hazard. I brought my vehicle to the service center for evaluation, but as of now, I have not received any resolution or updates regarding a fix. I have several videos of the situation as well. Given the potential risk to both vehicle occupants and others on the road, I respectfully request that the NHTSA investigate this matter further to determine whether a recall or other safety action is warranted. Thank you for your attention to this serious issue.

NHTSA ID

11653843

Incident

Apr 1, 2025

The contact owns a 2023 Ford F-150. The contact stated while driving 60-65 MPH in the rain, the contact noticed water coming through the front driver's side floor, on the left side of the brake pedal. Additionally, the contact stated that while driving at an undisclosed speed with his wife occupying the front passenger's side seat, the contact's wife felt air coming through the front passenger's side floor of the vehicle. The contact stated that his wife placed her hand on the floor and felt the air coming through; however, the A/C was not engaged. The vehicle was taken to the dealer, where a water entry test was performed, and the dealer confirmed that water was entering underneath the brake pedal. The dealer determined that an unknown valve needed to be replaced. The manufacturer was notified of the failure and offered to partially cover the cost of the repair. The vehicle was not repaired due to the cost. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 36,000.

NHTSA ID

11641070

Incident

Aug 6, 2024

Mileage

36,000 mi

Right rear taillight lens has water ingression. The dealer states that they cannot replace the lens under warranty because of a technical issue bulletin issued by Ford Moter company that states that condensation is normal and that it should dissipate after a short period of time. Well this has not gone away. And after some time, it will start corroding the electrical connections for the lights and cause them to stop working. The dealer is telling me that it would no be covered under warranty until there is at least a quarter of water in the bottom of the lens. By that time the electrical connections for the lights will be damaged

NHTSA ID

11639449

Incident

Jul 8, 2024

2019 F150 Backup camera doesn't work. Ford recalled some 2019 F150's but not mine. I've noticed they are having a huge issue with backup cameras and was also told the same by the dealership. Seems as like they should be responsible for fixing mine too. 2019 Supercab door locks freeze. Ford fixed under a recall. The recall worked for a year. Called dealer back last year Ford won't fix it again. It's obviously a manufacturer defect that wasn't fixed correctly on the recall. Seems crazy that I have to pay them to fix it again. The lock freezes open and you can't lock the door. It will open while driving.

NHTSA ID

11625271

Incident

Oct 8, 2024

The contact owns a 2023 Ford F-150. The contact stated that while the vehicle was parked, the rubber sealant material around the hood of the vehicle had shrunken. The contact was concerned that during rainy weather; water would seep beneath the hood of the vehicle into the engine area and cause an electrical or molding failure. The vehicle was taken to a local Ford dealer. The vehicle was not diagnosed; however, the dealer ordered a replacement for the vehicle, and upon attempting to install the rubber sealant, the rubber sealant failed to fit. The dealer ordered another part; however, two months later the part had not arrived, and the vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 7,000.

NHTSA ID

11618966

Incident

Jul 8, 2024

Mileage

7,000 mi

The sunroof of the vehicle spontaneously shattered. At 65mph Glass rained down on myself (driver) and my occupants. Nothing impacted the roof of the vehicle. The sunroof just exploded, causing a loud bang, and prompting me to break quickly. Sharp shards of glass went all over the vehicle focused on the backseat.

NHTSA ID

11559289

Incident

Dec 9, 2023

1. Issue number one parking brake engages on and applies the brakes while the vehicle is moving. I had this issue happened to me at least three times; luckily I was not going very fast when it happened. Additionally, Parking brake light will come on at random times. (is not Auto Hold) 2. Multi-functions switch that controls turning signal gets stuck in the up or down position after engaging the switch to change lanes. When attempting to flip the turning signal to off the switch will get stuck and will only go back to off or neutral position after forcing the switch up or down. Additionally, when forcing the turning switch to the off position, it causes the high beams to turn on. 3. Pre-collision assist warning will come on at random times while driving. I have had this happen to me almost daily when I'm driving into work in the morning.

NHTSA ID

11545817

Incident

Jul 24, 2023

Panoramic sunroof panel exploded while driving the vehicle. The sunroof was closed with shade extended. Less than 2 months new. No debris/ collision or object came in contact with the vehicle.No other vehicles were within either side of the road. The glass panel shattered completely with a very loud explosion noise , raining glass into the truck and onto myself(driver). There were no warning or reason or symptoms prior to the event. I drove the truck to the Ford dealership for a warranty repair after the explosion they ‘inspected’ and reported Ford would not cover this because the glass shattered. Dealer and manufacture are avoiding responsibility for my safety. Truck is at dealer.

NHTSA ID

11517962

Incident

Apr 14, 2023