2022 Ford F-150 Hybrid

The right rear axle bolt was found to be broken when the tire was removed for rotation. The bolt appears to have been over torqued at the assembly plant. At the time of the removal of the tire, the bolt head with about 5/8" of threads left and the corresponding washer fell out and hit the floor. This is a new truck built in February of 2022 and I picked up in March of this year. This is the first time this vehicle has been in for service.

a bolt (FoMoCo part# ML3Z19S426A) which secures the rear axle to the wheel hub sheared off. This bolt failure has happened to hundreds (thousands?) of other recent model F-150 owners as detailed in these two message board threads: https://www.f150forum.com/f129/2021-powerboost-rear-rotor-axle-bolt-sheared-515460/ and https://www.f150gen14.com/forum/threads/f150-powerboost-axle-bolt-sheared-off.10392 I don't know if this failure would cause a safety-related failure if ignored. It does seem like a either a poor design, improper manufacturing process, or a bad batch of parts. My local dealer is making repairs as I write this.

Passenger side rear axle retention bolt sheared off. Discovered during routine maintenance / tire rotation. Unknown how safety was at risk -- dealer told me once discovered that the vehicle would be repaired under warranty, and they could do in 24 hours, so no discussion about unsafe to drive as others have reported they were told. No warnings of the sheared bolt having occurred, no noise, no performance change that I could notice. Wear and patina on the bolt would indicate the break was not recent.

I took my 2021 Ford F-150 3.5L Powerboost in for it's 15k mile check up and when the driver side rear tire was removed the Rear Rotor/Axle Bolt Sheared off. Dealer informed me “unsafe” to drive and ordered new axle which is back ordered. - both dealer and ford have said truck is unsafe to drive - this is know problem on 2021 F150 trucks with max tow package with new 3/4 float axles - website with hundreds reporting same problem: https://www.f150forum.com/f129/2021-powerboost-rear-rotor-axle-bolt-sheared-515460/index52/

I took my 2022 f150 powerboost with max tow package to the dealer because of an audible noise coming from the rear passenger side. Ford discovered the axle bolt broke and is floating. Ford said the vehicle is “unsafe to drive” No warning lights. Just a slight squeal noise. If I hadn’t read about other people having this issue my wife would be driving this “unsafe to drive” vehicle right now with our baby.

I was driving about 50 mph traveling from Bethel, NC to Canton, NC and was approaching Canton so I was slowing down. The first traffic light was red so I stopped behind another car. When the light turned green I lightly pressed the accelerator and nothing happened, it was like the engine failed to power up. I looked at the instruments and noticed the transmission was stuck in 8th-gear. Suddenly it rolled down to 1st gear and the vehicle literally leaped across the intersection. Fortunately the car in front had moved out normally or the "leap" would have climbed his back. I have read of other Ford trucks with this 10-speed transmission sticking in 8th-gear when stopping. The hesitation starting into the intersection is dangerous and the sudden leap forward is very dangerous.