2024 Ford F-150

Re: Recurring Knock Sensor Failure — 2024 Ford F-150 STX (2.7L) I am writing to document a recurring mechanical issue with my 2024 Ford F-150 STX, 2.7L, currently at approximately 30,900 miles, purchased new. First Incident (late XXX): While driving, the check engine light illuminated, indicating a knock sensor fault. I brought the vehicle to Ted Britt Ford in [XXX], where it remained for five days for sensor replacement. I requested a loaner vehicle, which the dealership stated was unavailable, requiring me to rent a replacement vehicle at my own expense. Second Incident (XXX): Following a period of heavy rainfall, the check engine light returned with an identical knock sensor fault. The vehicle was again taken to the same dealership and held for five days for repair. When I again requested a loaner, I was informed one could not be provided because the vehicle was not originally purchased at that dealership. Rental Costs: Across both repairs, I have incurred rental vehicle expenses for a combined 10 days due to the dealership's lack of loaner availability. Suspected Root Cause: Based on the pattern of failures — particularly the correlation with heavy rain — I believe water may be intruding into the engine compartment through the hood cowl area and affecting the knock sensor. I have found numerous other reports from Ford F-150 owners describing similar symptoms, which suggests this may be a broader design or manufacturing issue rather than an isolated incident. Concerns: Given that this is a low-mileage, recently purchased vehicle experiencing the same failure twice within approximately three to four months, I am concerned this issue will recur once the vehicle is out of warranty, at which point repairs would no longer be covered. I believe this pattern warrants investigation, and potentially a recall, given the apparent frequency of similar complaints among other owners. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11766816

Incident

Jun 1, 2026

The seat belt will not latch when I insert the tongue normally. It will only click into the buckle if I hold the release button down while inserting it. This is the back seat behind the driver seat.

NHTSA ID

11762334

Incident

Sep 4, 2026

The contact owns a 2024 Ford F-150. The contact stated that following an unsuccessful Over-the-Air (OTA) software update, the display screen and instrument panel were constantly rebooting, with a loss of functionality for several electrical features. The vehicle was taken to a dealer, where technicians associated the failure with NHTSA Campaign Number: 26V104000 (Electrical System, Exterior Lighting). After several service repairs and the inclusion of a field service engineer, the vehicle remained unrepaired and had been with the dealer for over two months. The manufacturer was notified of the failure and provided the contact with a case number. The contact was not provided any status updates because the master technicians were on extended leave. The failure mileage was approximately 25,000.

NHTSA ID

11762243

Incident

Jun 28, 2026

Mileage

25,000 mi

The rear window of my 2024 Ford F-150 XLT violently exploded without warning. I was actively entering the truck when the explosion occurred. There was no collision, or object that stroked the glass. The extremely loud explosion terrified me, and because I initially did not know what had occurred, I contacted police. I have a police report of the incident. The failed component was the rear window/rear glass assembly. The shattered glass and vehicle were available for inspection following the incident and was towed to Ford. The sudden failure presented a serious safety risk because I was at the driver's seat when the glass exploded. I could have sustained significant lacerations from the glass. Other occupants could also potentially be injured. The failure has not been independently reproduced. The failure was directly observed by me, and the police were contacted immediately following the incident. I have reported the incident to Ford. Ford has been notified of the failure, but I have not received an adequate explanation establishing why the rear window suddenly exploded. I have subsequently researched similar reports involving Ford F-150 rear-window failures and discovered other consumer complaints describing sudden or unexplained rear-window shattering, including reports raising concerns regarding the rear defroster and/or associated electrical components. I did not use a rear defroster - the car was off. This raises concerns about whether Ford has adequately investigated a potential recurring defect and whether consumers should have been warned. The vehicle had had no warning lamps. This incident occurred on a vehicle purchased new in 2024. I have also experienced another major problem with the vehicle. I am requesting that NHTSA investigate whether sudden rear-window failure in the Ford F-150 represents a safety defect, whether Ford had prior notice of similar failures, and whether additional investigation, consumer notification, or a safety recall is warranted.

NHTSA ID

11760823

Incident

Aug 19, 2026

See attached document for complaint

NHTSA ID

11758506

Incident

May 12, 2026

Safety recall 25V512 has been open and unfulfilled for nearly a year. The dealer says parts are not available and cannot provide a date when they will be. I can’t believe Ford cannot get parts for a critical recall but can still produce over 1/2 million new trucks annually.

NHTSA ID

11754646

Incident

Aug 1, 2025

Purchased new vehicle May 2024 primarily for towing my recreational vehicle (2024 Ford F150 Pickup). June 2024 took vehicle to dealership indicating that I was intermittently getting a "Trailer Disconnect" warning while driving (loss of trailer brakes, lights etc.). Dealer indicated no issue found. Subsequently returned to dealership on 6 other occasions over 2 years after continuing to experience the failure. Replaced 7 pin connector on trailer and dealer has replaced the 7 pin on vehicle and Trailer Control Module (TCM) but problem persists. Early 2026 dealership performed a recall on TCM software - did not resolve the issue (vehicle intermittently indicates the trailer is disconnected while driving or manually activating the trailer brakes). Issue seems to occur typical on startup after several hours of driving with a trailer (heat related), and every time activate the trailer brakes manually. I get a "Trailer Disconnect" warning by activating the manual trailer brake even without a trailer attached. Working with Ford Customer Service Team and the dealership for 7 days, no solution was discovered. The dealership indicated (in writing) that it is normal operation to disconnect the trailer when the TCM is activated manually (while driving or stopped).

NHTSA ID

11754300

Incident

Jul 13, 2026

The contact owns a 2024 Ford F-150. The contact stated that while driving approximately 20 MPH, the steering wheel locked up and the vehicle stalled, and it rolled across an intersection and then stopped. The vehicle failed to restart. The contact stated that a tow truck arrived, and the tow truck driver could not shift into drive (D), but the vehicle was towed from the scene. The vehicle was towed to a dealer, but the failure was not duplicated. The manufacturer was notified of the failure. The failure mileage was approximately 11,000.

NHTSA ID

11752582

Incident

Jul 1, 2026

Mileage

11,000 mi

Updated instructions

Some 2025-2026 Aviator/Explorer/Expedition/F-150/Mustang Mach-E/Nautilus/Navigator vehicles may exhibit the hands-free BlueCruise feature intermittently/consistently unavailable when BlueCruise is active and when traveling in a "Blue Zone". Speed sign recognition may also be inaccurate. If there are no active relevant diagnostic trouble codes (DTC) present and the issue persists after multiple key cycles and if the BlueCruise System Health Check passes, download and run the "TCU - Reset Telematics Control Unit (TCU) Module" application using the latest software level of the Ford Diagnosis and Repair System (FDRS). If the condition is resolved, inform customers that this may be a temporary fix and engineering is currently working on a solution expected in Q4 2026. Monitor Professional Technician System (PTS) for additional information and schedule service appointments for customers once the repair becomes available. For claiming, use causal 14G229 and labor operations 12651D and 12651D4. If the condition persists after a test drive, refer to Workshop Manual (WSM), Section 419-03B for normal

Some of the following vehicles: * 2023-2025 F-Super Duty built on or before 02-Feb-2025 * 2024-2026 Ranger/Bronco/Mustang * 2024-2025 F-150 built on or before 15-Jul-2025 * 2024-2025 Nautilus built on or before 16-Feb-2025 * 2025 Explorer/Aviator built on or before 01-Feb-2025 may exhibit all of the following symptoms: - "No Key Detected" message displayed on the instrument panel cluster (IPC). - Key fob does not work in the backup slot. - Remote keyless entry (RKE) (lock and unlock from the key fob) functionality will work to lock/unlock the vehicle. If the vehicle exhibits these symptoms, start the vehicle using both key fobs. If the no crank/no start condition with "No Key Detected" concern is present, reprogram both key fobs and retest. If the no crank/no start condition with "No Key Detected" is still present, replace the body control module (BCM). Refer to Workshop Manual (WSM), Section 419-10. For claiming, use causal part 15604 and labor operation MT55118SSM up to 1.8 hours.

For Various Ford and Lincoln vehicles, if diagnostics lead to the replacement of the front seat cushion cover J-clips, lower-level service parts are now available. Use service part W709919-S901 if the J-clip is completely detached from the seat cover and W715386-S424 if the clip is still partially attached. It is not necessary to replace the seat cover if only the J-clip is separating from the cover. Refer to PTS Home > Technical Assistance > Technical Support Videos > Section 501- Body and Paint > Seat J-Clips. For claiming, use causal parts from list below and labor operations 63100A and 63100A5. Causal Parts for claiming: Bronco/Bronco Sport/Escape/Explorer/Expedition/Navigator: 7862900 or 7862901 F-150/F-Super Duty: 1562900 or 1562901 Ranger/Maverick: 6062900 or 6062901

Some 2022-2026 F-150 Lightning vehicles may exhibit a reduced distance to empty (DTE) projection, a high voltage battery pack state of charge (SOC) that drops from 100% to less than 90% within 60 seconds of being driven, and an inability to reach a target SOC using the scheduled charging feature without any diagnostic trouble codes (DTCs) in the battery energy control module (BECM). This may be due to an issue in one or more cells within the high voltage battery pack. To correct the condition, run the "BECM Battery Health" application using the latest software version of the Ford Diagnosis and Repair System (FDRS). If any cells are identified as exceeding state of charge and/or capacity thresholds, refer to the Workshop Manual (WSM), Section 414-03A High Voltage Battery, Mounting and Cables > Diagnosis and Testing > High Voltage Battery, Mounting and Cables  Electric. Perform Pinpoint Test High Voltage Battery Pack Cell Balancing Faults, Step 4 (PPT Step AO4 for 2022-2024 vehicles/PPT Step AQ4 for 2024-2026 vehicles) and proceed with Pinpoint Test directions following the results of Step 4.

Quality improvements include: -Resolves various user interface and data display bugs within the Towing menu