2022 Ford Maverick Body & structure Problems

The driver's side (left front) door failed at the check-arm attachment point inside the door assembly: the spot welds securing the check-arm reinforcement bracket to the inner door structure cracked and separated. The vehicle is a commercial fleet 2022 Ford Maverick XL SuperCrew with approx. 82,000 miles. The vehicle and failed component are available for inspection upon request. First symptoms were difficulty opening and closing the door with popping/cracking noises. No warning lamps or messages occurred; the failure is concealed inside the door. This is a safety risk because the check arm attachment supports the door's structure. The same weld separation on related vehicles has been documented by NHTSA (investigation PE23-013) to cause doors that fail to latch, fail to stay closed, or open while driving, risking occupant ejection and injury. The failure was confirmed 7/17/2026 by Grapevine Collision Center (Grapevine, TX) after a Ford dealership stated there is no recall or warranty coverage for the Maverick and referred me there. The shop diagnosed broken check-arm welds and quoted $2,602.46 for a door shell replacement, noting it has seen this identical failure on Ford Escapes and Lincoln Corsairs. Not inspected by Ford, police, or insurance. This is the same failure mode NHTSA investigated on 2020-2021 Escapes (PE23-013), which Ford addressed via Customer Satisfaction Program 23B56 covering 2020-2023 Escapes. The Maverick shares the same C2 platform and door design but is excluded, leaving owners to pay out of pocket for a defect Ford repairs free on sibling vehicles.

NHTSA ID

11751291

Incident

Jul 1, 2026

Driver side door limiter welds broke loose. Ford said they had to replace the entire door and it was not covered by warranty. The dealer said that this happened to a bunch of Ford Escapes, but they did not have a recall for the Maverick yet.

NHTSA ID

11723780

Incident

Feb 14, 2026

When it rains water gets into the passenger-side footwell and beneath the carpeting during rain events.

NHTSA ID

11710852

Incident

Jan 8, 2026

Door check has failed in the frame. The spot welds have broken in similar fashion to the Ford Customer Satisfaction Program 23B56 on the Escapes. There are popping noises, creaking, alignment issues, and prevents the window from rolling down.

NHTSA ID

11697075

Incident

Oct 2, 2025

The contact owns a 2022 Ford Maverick. The contact stated while the door was closed, the window failed to roll down; however, upon opening the door, the window was able to be rolled up. A dealer was contacted. The vehicle was taken to the dealer where it was determined that door needed to be replaced. The vehicle was not repaired. The contact related the failure to a Customer Satisfaction Program: 23B56 (Inspect front door check-arm reinforcement spot welds); however, the VIN was not included in the CSP. The vehicle was repaired. The manufacturer was notified of the failure, and the contact was informed that there were no recalls on the VIN related to the failure. The failure mileage was 27,000.

NHTSA ID

11682402

Incident

Jul 15, 2025

Mileage

27,000 mi

The contact owns a 2022 Ford Maverick. The contact stated that while opening the front driver's side door, there was an abnormally loud creaking sound coming from the door. The contact stated that the sound became louder over time. There were fractures around the door frame, causing the sound. As a result of the failure, the contact stated that the front, driver side door window would only roll down at approximately an inch. The vehicle was taken to the dealer to be diagnosed; however, the contact was not informed which part needed to be replaced. The dealer stated that a door panel kit was to be sent to the dealer for the repair. The vehicle was not repaired. The manufacturer was informed of the failure and opened a case. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 72,000.

NHTSA ID

11676224

Incident

May 25, 2025

Mileage

72,000 mi

Door check spot welds broke. Door has unsafe operation. Will not hold open, and swings wildly. No inspection yet. Ford Dealer aware of problem. 2 month out of warranty.

NHTSA ID

11663661

Incident

May 29, 2025

Water intrusion on front passenger side of vehicle causing mold. Vehicle still has original windshield and all original carpet and interior. Ford Service department unable to do “leak detection at facility” but referenced several online sources believing it is a defective cowl or a/c part that is not sealed. Service department dried vehicle out for 3-4 days and water intrusion is still happening and mold came back.

NHTSA ID

11661588

Incident

Apr 18, 2025

The contact owns a 2022 Ford Maverick. The contact stated upon opening the front driver's side door, the door made an abnormal cracking and popping sound. The vehicle was taken to the dealer, where it was determined that the door hinge or the entire door might need to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 57,000.

NHTSA ID

11635931

Incident

Jan 14, 2025

Mileage

57,000 mi

I was involved in an accident. During the accident none of the airbags deployed. The impact was so hard that it lifted the truck up off the ground and spinned us around 90 degrees. This resulted in the individuals seated on the passenger side of the truck to be thrown into the door fairly hard, with one passenger hitting her head on the window even with the seatbelt on. The point of impact was the drivers side back tire and bumper area.

NHTSA ID

11619483

Incident

Jul 29, 2024

In October 2023, we took our 2022 Ford Maverick to a local Ford dealership for a front airbag recall. However, after we picked up our Maverick and we got home we noticed a deep scratch across the top of the dash and the tool from the technician in the console. We contacted the dealership about this scratch. Our Maverick was taken to the dealership in January 2024 for this repair. Upon the completion of installing the dash, the technician scratched the outside of the driver’s side front door causing yet another delay. The Maverick was then taken to their body shop (on premises) to repair the scratch and repaint the door. Within a week of having our Maverick back, we started smelling a very foul odor in the truck. This smell made my throat and nose burn and was nauseating while riding in the truck even with the windows down. We went back to the dealership to meet with the owner about this odor. They removed the seats, carpet, and dash to locate the problem. They discovered a place at the bottom of the windshield that had not been sealed from the manufacturing production department. They discovered black mold in the insulation behind the dash near the firewall and under the carpet. They have discussed this with Ford Motor Company on how to handle this problem. Currently our Maverick is still on the lot at the local dealership, since the first week of April 2024. We have reservations about the mold/mildew odor as a health/breathing issue to continue driving this vehicle. Ford Motor Company has been attempting to come to some agreement of handling this situation but not addressing the odor in the vehicle. After some online research of the 2022/23 Ford Mavericks this seems to be a bigger issue across the nation. There are not any recalls to correct this problem for water intrusion into the vehicle.

NHTSA ID

11597824

Incident

Jan 22, 2024

In early April 2023 I opened my driver’s side door and the inside of my 2022 Ford Maverick was wet from the headliner down to the carpets. There WAS condensation throughout the interior of the vehicle even though the Repair Order stated there was none. The inside of the vehicle was damp. All windows were closed tightly. The headliner, back seat, front seat, carpets, and all the interior was damp. I had a book on my back seat that was damp and the pages were curled. There was MOLD underneath the floor mats. I contacted a MOLD specialist who stated that it is impossible to effectively rid a vehicle of MOLD. He stated that MOLD spores are in every crevice of the truck and it WILL return. On April 6, 2023 I took the truck to The Ford Store where I purchased it. There was 1294 miles on the odometer. They could not find the leak. My vehicle was there for several weeks and the interior was completely torn down from the headliner to the carpets. The Service Department finally said that they located the leak area and repaired it. The dealer guaranteed in writing that the MOLD was gone. On June 23, 2024 (today) I was getting ready to take the truck back to The Ford Store for tomorrow’s appointment. They will be addressing the three recalls. I just noticed MOLD under the mats again. The MOLD is on the floor board and is crawling up the footwells under the rubber mats. There is also MOLD on some of the plastic material close to the floor boards. My health and the health of all passengers who have ridden in my vehicle for the last 14 months have been and continue to be at risk. I have been contacted by other Ford Maverick owners who have experienced the same issue. The Ford Maverick Truck Club has many posts about leaks and subsequent MOLD issues.

NHTSA ID

11596012

Incident

Apr 6, 2023

My truck started collecting water in the front passenger side floor. Took it to the dealer and they couldn’t find the leak at first. Then they claim it was coming from the window seal on the back passenger window. I refused to have it repaired for 950$. 600 dollars in now with leaky rear window. This has already started a mold issue under the carpet. This needs to be addressed by the manufacturer.

NHTSA ID

11573213

Incident

Feb 21, 2024

The truck is leaking rain water into the cabin driver's side floor. Technicians have not been able to find the leak and the carpet is moldy and smells. The truck has been in the shop two times now and Ford has not offered to replace the moldy carpet under warranty.

NHTSA ID

11520836

Incident

Jan 1, 2023

The 2022 Ford Maverick has a design flaw the harms the environment and places driver and passengers at risk. Specifically the vehicle does not have a metal skid plate which places the Evap System at risk for damage. If the system is damaged the vehicle is still driveable, but doing so allows gas vapors into the environment and worse, possibly into the passenger compartment. Looking under the vehicle, one finds some sort of fabric or mesh material which is definately not robust enough to protect the evap system components from damage. Driving on paved roads....no problem. Using this vehicle as a truck involves driving on farm land, pastures, lightly wooded areas,etc. This is where the damage may occur. There is no warning posted on the vehicle or in the owners manual that warns drivers to avoid these areas. The solution is simple. A recall to replace the fabric or mesh material with a metal skid plate. Most trucks and off-road vehicles have metal skid plates as standard components. Why the 2022 Maverick does not is beyond my understanding.

NHTSA ID

11489982

Incident

Oct 1, 2022