2021 Ford F-150 Electrical System Problems

Vehicle Information 2021 Ford F-150 PowerBoost VIN: [XXX] Complaint Description While driving approximately 70 mph on a highway, my 2021 Ford F-150 PowerBoost suddenly displayed a “Stop Safely Now” message and immediately lost propulsion. The engine shut down without warning while I was in active traffic. After the shutdown, the vehicle automatically shifted into park and would not allow me to shift into neutral. This left me unable to move the vehicle out of a live traffic lane. I was forced to shut the vehicle off while still in a dangerous roadway position. This incident created a serious safety hazard, as I was traveling at highway speed and could have been rear-ended due to the sudden loss of power and inability to move the vehicle. This issue appears to match Ford Technical Service Bulletin (TSB) 23-2317, which describes “Stop Safely Now” warnings, no-start conditions, and gateway module (GWM) software faults. This indicates a known defect that can cause sudden loss of propulsion. A claim has already been opened with Ford Motor Company under case number [XXX], and the vehicle is currently at a Ford dealership for diagnosis. At this time, the issue has not been resolved. This failure occurred without warning and presents a significant risk to driver safety and others on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am reporting a serious safety issue with my 2021 Ford F-150. This truck has already been subject to multiple recalls, yet the problems have continued. On several occasions while driving, the truck has suddenly shut off without warning, causing a complete loss of power while the vehicle is in motion. This has happened while my family and I were in the vehicle and has nearly resulted in a serious crash. Losing power in traffic without warning creates an extremely dangerous situation and has put my family’s lives at risk. A vehicle shutting off while being driven is a major safety hazard. Despite multiple visits for service and ongoing recall issues, the problem has not been resolved, and the truck continues to fail in a way that could easily lead to a catastrophic accident.

Two things, the dash stopped displaying speed. As I was driving the dash glitched out and the digital speed would not display. It started only showing the top half of how fast I was going. Then it completely went out. Second, the radio also glitches. Won't let me change station or sources. I usually have to turn the truck off for 10 to 15 minutes, then it starts fixing the issues. This has been an ongoing problem. And no recalls for this issue have been placed

The contact owns a 2021 Ford F-150. The contact received notification of NHTSA Campaign Number: 26V104000 (Electrical System, Exterior Lighting); however, the part to do the recall repair was not yet available. The local dealer was contacted but the vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

The vehicle reported a charging system failure alert and came to a jerking stop. The battery was completely drained and the alternator had failed at 71,000 miles. The vehicle stopped in the drive lane on a heavily trafficked road. The emergency release lever was found and pulled to allow the truck to pull over.

When temperatures are below freezing, the passenger side door remains locked, and cannot be unlocked with the key fob or the unlock buttons on either the driver side or passenger side door. The manual door lock cannot be pulled out, as it sinks down inside the door, and there is no external locking/unlocking mechanism to use the key to manually unlock the passenger side door. Dealer said there was nothing wrong with it, but brought it into the shop to look at it, where the temperature is higher than freezing.

The hybrid battery in a 2021 Ford F-150 Powerboost failed due to apparent shorting. (P/N ML3Z-10B690-D) Pictures were taken by service department at the Ford dealership, and can be provided upon request. There is concern that the system could catch fire and spread under the vehicle. There have been other similarly identified failures reported in online communities, but cannot verify the information. Failed component is currently with dealership service department, therefore, cannot verify if there has been further inspection of part. Prior to failure, there were no indicators of problems or faults. As the failed part is not easily accessible and there is no routine maintenance, there is no way to validate when the part failed.

My truck thinks my parking brake is engaged so it constantly flashes the “brake” light, constantly chimes while driving and says parking break malfunction, talk to dealer. I brought it to Webber family Ford in Detroit lakes MN 56501 and they checked it over including the safety recall location for recall 23S35. They said it was not the recall location and I would have to bring it in Monday for another appointment. When I got it home that day I crawled under to check that location. I see visible green which usually means corrosion and the protection around the harness seems warm. I also noticed the "recall" was not completed how it is shown on fords recall paperwork using the zip tie as a wear location so it isn't the harness itself. That is not how mine is. I have photos to prove that. I spoke with corporate ford today and they said they can't re open the recall because it has been closed and it is past its 12 month warranty being it was done in October of 2023 before my ownership and at a different dealer. I don't believe it is fair to me the current owner to pay for the cost of a rerepair of a recall that was done incorrectly.

Transmission downshift to first gear on the highway

Vehicle lost all power and stalled while driving. Vehicle also stalled at idle when waiting at an intersection, and another time while waiting at a stop sign. No longer starts. Appears to not be receiving fuel and is returning code P0627 "Fuel Pump A Control Circuit / Open" and will crank but not start. Required towing back to my residence. FordPass sent a "Service Engine Soon Warning" stating "the powertrain control system has detected an electrical fault with the fuel pump and its associated wiring". The symptoms match those in 25V455 but this VIN number is not listed in the affected group.

Gear shift selector gets stuck in park, drive & reverse. Unable to move vehicle & blocking traffic for a period of time.

The alternator failed at 60,000 ish miles. Specific mileage can be provided upon request. It appears this is a common problem as alternators and alternator parts are unavailable. I have had to order a custom alternator.

Vehicle: 2021 Ford F-150 Component: Exterior Lighting – Daytime Running Lights (DRLs) / Headlights (High Beams) Safety Concern: Vehicle visibility and forward illumination Both daytime running lights (DRLs) on my 2021 Ford F-150 have failed completely. After the DRLs stopped working, the high beams also became inoperative, leaving only the low beams working. The Ford dealer attempted a repair by replacing the control modules, but that did not fix the issue. They advised that the entire headlight assemblies need to be replaced. However, these assemblies are very expensive, so I have not replaced them yet. I am currently limited to using only the low beams. Without DRLs, the truck is less visible during daytime driving, increasing the risk of a collision. Without high beams, nighttime visibility is reduced, especially on rural or dark roads. This failure affects federally required lighting functions, compromising safety in both day and night driving. The problem is not normal wear: these are sealed LED assemblies that should last the life of the vehicle. The fact that both assemblies failed strongly indicates a manufacturing or design defect. Owners face high out-of-pocket costs because the only fix offered is full assembly replacement. Other 2021 F-150 owners have reported similar failures of DRLs and headlights online, showing this is not an isolated incident. I request that NHTSA investigate this issue as a safety defect and require Ford to issue a recall to replace the defective headlight assemblies at no cost to owners.

Fords Sync system fails to connect to internet and won’t update resulting in transmission failing to relearn as you drive

Random times my clockspring makes clicking sounds and the car iant able to be driven. Getting many messages about issues with the vehicle

Black screen on main vehicle screen. Ford has a Customer Satisfaction Program (12M02) that extended the warranty coverage for the Accessory Protocol Interface Module (APIM), a key component of the SYNC system in certain Ford vehicles. This program covers the APIM for 5 years from the warranty start date, regardless of mileage, which is a longer coverage than the vehicle's original warranty provisions for this part. The coverage automatically transfers to subsequent owners. However, Ford is saying that I do not qualify and cannot define the qualification criteria. If some affected vehicles are eligible for repair under this CSP, then all affected vehicles should be.

What component or system failed or malfunctioned, and is it available for inspection upon request? -The electrical system malfunctioned causing a complete system failure and shutdown of the vehicle. The vehicle came to a sudden stop in an intersection and could not be moved. How was your safety or the safety of others put at risk? -The vehicle instantly died going through an intersection causing the steering column to lock up, the parking brake to engage and transmission to remain in drive while the vehicle was stopped without any power. This was a sudden and abrupt stop where all control over the vehicle was lost, and I came to an immediate stop in the middle of an intersection. The vehicle would not restart. I could not disengage the parking brake to move the vehicle out of the intersection due to the complete loss of power. The transmission would not shift into Neutral due to the complete loss of power. The hazard lights would not turn on due to the complete loss of power. If this happened on the interstate, I would have very likely been in a serious life threatening /taking accident. This is as big of a near miss that I can think of, and only because it happened on a neighborhood street when no other vehicles were approaching from in front or behind. This is a major safety issue. Has the problem been reproduced or confirmed by a dealer or independent service center? -The vehicle is currently at the dealer for a diagnostic review. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? -in process at the ford dealership Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? -the vehicle had been running for 30-45 minutes prior to this happening without any warning lights / symptoms.

The contact owns a 2021 Ford F-150. The contact stated that while opening the front driver’s side door, there was an abnormal grinding coming from the motor for the retractable running board on the front passenger’s side, and the running board failed to deploy as designed. The vehicle was taken to the dealer where it was diagnosed and determined that the motor in the retractable running board had failed and needed to be replaced. The vehicle was not repaired. The contact attempted to replace the motor for the retractable running board himself and failed. The manufacturer was not notified of the failure. The failure mileage was 81,000.

Drove it out to CA from Texas. Purchased for Planet Ford who told me the truck was k to drive and no axel problem. Drove it out to CA from Texas when we moved in late April - after that went to Santa Barbara and dashboard controls went dead. Speedometer and may other controls stopped working. Truck felt sluggish. Took it into Tuttle Click Ford Lincoln in Irvine and they said they real axel was about to fall off and took the truck away. They've had it for a month and said they may have it for another 2-4 week or longer.

Unable to update automatically, vehicle was constantly attempting to connect, draining the battery (I replaced the battery and carry jumper cables and a quick starter now). Took into dealer and they are unable to perform updates. They have had the vehicle for 2 weeks and no progress. The forums online have indicated the vehicle was built with whatever parts they could get due to the COVID supply chain disruptions to normal parts. The software and subsequent updates do not remedy matters. I have no documents to upload, still in shop.