2021 Ford F-150 Body & Structure Problems

Astro white exterior paint is chipping on the roof of the vehicle in multiple locations. See pictures attached of sever chipping above windshield and wear the roof meets. Also chipping occurring above both rear doors on roof. This was not due to an accident or normal wear and tear.

Please see Ford TSB SSM50543. In my case the driver's door has been freezing in the lock position. Door will not unlock and cannot be opened either from the inside or outside. The key in the outside will not unlock the door and pulling up on the knob inside cannot be done (even tried with pliers). The electric door locks for the frozen door do nothing. This made it possible for me to only get out of or into the driver's seat by climbing in/out from the passenger's side. I also tried to not lock the driver's door, and this just made the door frozen in the unlock position. Very inconvenient, but I am especially concerned if I had to exit or enter the driver's side in an emergency. Ford knows about this as can be seem from the issued TSB. This had happened more than once and goes away when the inside of the truck gets really warm, or the weather gets above sufficiently over freezing.

My 2021 Ford F-150 Lariat has a door latch defect that occurs in freezing or near-freezing temperatures. The failure occurs without warning in cold conditions, causing the door latch to freeze and not fully engage. When this happens, the door is able to freely swing open while the vehicle is in motion and also freely open when the vehicle is parked. This creates a serious safety hazard, including the risk of occupant ejection and loss of vehicle control. The vehicle has no aftermarket modifications and is maintained per manufacturer recommendations. The issue is temperature-dependent and has occurred on multiple occasions. Ford has issued recalls for similar door latch freezing defects on multiple other Ford vehicles and model years. Despite this, my vehicle has not been included, even though it exhibits the same failure mode. This defect presents a significant safety risk and should be investigated for potential recall inclusion.

A certified independent inspection company discovered welding on the main chassis of my Ford F-150. The welding is located on the front left frame area. I purchased the vehicle brand new, and it has never been in any accident or collision. This welding on a critical structural part creates a serious safety risk. Frame integrity may be compromised in normal driving or in the event of an impact. I transport my children daily in this vehicle, and I am afraid to drive it due to the possibility of structural failure. The official Ford dealer inspected the vehicle and kept it for approximately three weeks but provided no explanation or repair. The regional Ford office has delayed their technical report for more than five months with no response. The defect has been confirmed and is permanent. No warnings or lights appeared prior to discovering the issue. This is a manufacturing-related structural defect affecting vehicle safety, stability, and integrity. A proper safety resolution is required.

The dash pad in front of steering wheel is coming apart and peeling back. It appears to a defect in installation, material use or wasn't glued down properly

The side rails that come out when door is opened to assist with getting inside the truck does not work properly. It has come out and will not go back in. The door is closed and I have to drive the truck with the rails hanging down. That is a hazard.

The saggy diaper is a hazard and major manufacturer defect that must be corrected ASAP. It needs to be metal period the end. The paper like cover bolted on the undercarriage is an awful engineering hazard. I have changed this item four times. The dealerships well established pattern of services for this issue and Google searches speak for themselves. I don’t know why Ford refuses to address this concern and blow me off.

DRIVER DOOR WON'T LOCK OR UNLOCK IN EXTREME COLD. TO EXIT AND ENTER TRUCK, I HAVE TO USE THE PASSENGER DOOR AND SLIDE INTO DRIVER SEAT, WHICH IS VERY DIFFICULT B/C OF THE CENTER CONSOLE. NO WAY I COULD GET OUT OF THE TRUCK IN A HURRY IF I HAD TO. TOOK TO A DEALER BUT OF COURSE IT COULDN'T BE DUPLICATED. INTERNET SEARCH SHOWS THIS IS A PROBLEM WITH THE 2021 FORD F150.

What component or system failed or malfunctioned, and is it available for inspection upon request? The exterior door handles and latching mechanism failed due to freezing in cold weather. When temperatures drop, the door handles become stuck or the latch mechanism fails to engage or disengage properly. This issue is reproducible during cold weather and the affected components are available for inspection upon request. How was your safety or the safety of others put at risk? The malfunction poses a safety risk in multiple ways. The doors may not close securely, which could result in a door opening while driving. Conversely, frozen latches can prevent doors from opening, which is a serious concern in the event of an emergency where rapid exit from the vehicle is required. This could endanger both the driver and passengers. Has the problem been reproduced or confirmed by a dealer or independent service center? The issue has not yet been confirmed by a dealer, but it is a widely documented problem among 2021 Ford F-150 owners, and it occurs consistently during cold weather conditions. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No formal inspection by the manufacturer, police, or insurance representatives has been conducted to date. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? There were no warning lamps or dashboard messages. The issue was first noticed during freezing temperatures in the winter season. The symptoms are physical—frozen or stuck handles and malfunctioning door latches.

My rear passenger window shattered. My niece opened the door and the glass shattered. The window pane was held together by after market tint. It then fell under the vehicle. The vehicle is available for inspection until Friday, July 27, when it is scheduled for repair. The safety of the passengers was putt in jeopardy sure to the nature of the incident.

Paint is peeling in several separate area's on the truck

Tailgate periodically opens on its own

In freezing temps(usually under 25*), the interior door handle freezes and will not engage the door latch. The door will not stay latched until cabin of interior warms up. Running boards get deployed every time the vehicle comes to a stop.

Panoramic sunroof exploded. This happened on a country highway with no other cars or debris around.

The contact owns a 2021 Ford F-150. The contact stated that when the brake pedal was depressed, there was an abnormal sound heard. The vehicle was taken to a dealer, and the dealer confirmed there was no failure. In addition, the dashboard failed to work as needed. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 10,000.

While driving on a highway at 70 mph the hood unlocked and was caught by the safety latch. It is available for inspection. My safety was at extreme risk. Loosing the ability to see out of my windshield had the safety latch failed could have been catastrophic. This could have caused a crash at highway speeds from the sudden inability to see where I was driving. The problem has not been reproduced but should be confirmed by the trucks data system. A hood unsafe message appeared on my dash screen. The latch has not been inspected yet as this happened last night. There was no prior indication or warning that the hood would come unlocked.

EXTREMELY DANGEROUS DOOR CLOSING FAILURE. Both front door lock actuators malfunction below 10 degrees Fahrenheit. Rear doors of the crew cab are unaffected. The moving parts of the mechanism are not frozen and there is no water in the system. The lock actuator will not engage the clamp/pin mechanism to hold the door closed, even though the movable parts are freely moving. this happens whenever the temperature is below 10 degrees. In order to get out of the car you need to exit the rear door or climb out the window. Once the door does open, it will not securely latch in position. The Certified Ford dealership informed me that this is a "known problem" with the F150 and there is no known repair.

The contact owns a 2021 Ford F-150. The contact received notification of NHTSA Campaign Number: 21V986000 (Power Train, Structure) however, the part to do the recall repair was not yet available. The contact stated upon parking the vehicle, he noticed that the underbody heat and noise insulators had detached and was hanging on the ground. The vehicle was taken to the dealer who informed the contact that the parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure and a case was opened. The vehicle was not repaired. The failure mileage was approximately 7,000. VIN tool confirms parts not available.

The contact owns a 2021 Ford F-150. The contact stated while driving approximately 70 MPH, the hood was vibrating. The contact pulled over safely and noticed that the hood bolts were loose and one was missing. There were no warning lights illuminated. The vehicle was taken to a local dealer who diagnosed the failure with missing latches and bolts. The dealer repaired the vehicle. The manufacturer was notified of the failure. The approximate failure mileage was 8,000.

DOOR LOCK In freezing temperatures, the door locking mechanism can become inoperable (the door will not unlock and you cannot enter or exit the vehicle using that door). The door fails to unlock using manual key, auto unlock with keyfob in hand, pressing the button on the handle or entering the security code. Sometimes after a few attempts, you will be able to open the door despite the lock pin at the top of the down frame is still down. However, once in the vehicle, you will not be able to get back out until the vehicle is warm. This is a risk in case of accident or fire. The issue is currently being diagnosed by dealership. No other warnings. Only happens in freezing temperatures (in my case temps in the mid-teens and below).