2022 Ford F-150 Hybrid

I removed my wheels for standard rotation. When I removed the wheel from the passenger side rear, I found the rear axle bolt was fractured. The portion of the bolt and washer were inside the wheel. This appeared to have been chronic. Pictures available. I did not attempt to remove this bolt. This spontaneously sheared off. It was literally sitting inside the wheel hub.

Vehicle has major shifting issues with the 10 speed transmission. Shifting down or up can cause violent shifts. Extremely scary on the highway when passing semi trucks as it slams into gear. Vehicle will then show vehicle needs maintenance with a Powertrain issue. When turning the vehicle off it goes away but will return when driving above 55mph. Then the service light may or may not come back on. Dealer told me that the vehicle needs to learn driving behavior and will go away. I dropped vehicle off today and told them it was unsafe to drive on highways as it could cause a crash.

Started vehicle and plugged phone im to play music/charge. Immediately, there was an incredible loud sound: it sounded almost like a gun shot. There was then a loud crackling sound which sounded like glass shattering. It scared me considerably. Thankfully I was parked. I shut the vehicle off and restarted. There was no more noise, but all audio ceased to work. Approximately 3 hours later, the problem went away when I went back put to start the vehicle. If this were to happen while traveling, especially in traffic, it could case a dangerous situation.

The heat exchanger on my truck is faulty per the serve department at Balise Ford of Wilbraham. I had a check engine light coming on intermittently starting in October of 2022. In late December, the check engine came on steady. I made an appointment with Balise to have it checked out as well as to have other recall issues resolved. They inspected the truck and found the heat exchanger was faulty and would have to be replaced. They ordered the part. In April, the part finally came in and I brought the truck in to get it sorted out. A couple days later when I went to pick up the truck, I found out that the wrong part had come in and that the repair would have to be done when the proper part came in. They told me at the time that it could take a month or so to arrive. It's been 2 months since that time and the part still isn't available and I'm told that Ford is planning on shipping 72 units nationwide around June 30th. It doesn't appear that I'm high enough on the list to get one of these parts when they become available. This is now over 6 months I've been waiting for the part. The issues are 2 fold, 1st, I don't know if any sort of damage is being done to the engine due to this issue. There is something overheating in the system. I drive 65 miles to work each way and some days I have to pull over 3 and 4 times to let the heat exchanger cool down. The engine temperature shows as normal, but I get an alert on my dash that tells me that the engine is going into low power mode due to overheating and it's not possible to maintain highway speeds and creates a situation where I need to get over to side of the road quickly since I can't maintain pace. I never know when this will happen. The second issue is that I live in Massachusetts, my truck has to pass a safety inspection. It won't pass with a check engine light on. Once rejected, I have 50 days to get it repaired. After that time, I legally cannot drive the vehicle.

On multiple occasions, the vehicle has exhibited, what I would call, a loss of acceleration. I first noticed this during a right-hand turn from a stop. I took my foot off the brake, initiated the turn and applied the throttle, and the vehicle took 1-2 seconds before it started to accelerate. The vehicle was in "Normal" drive mode. Currently, this issue is occurring during right and left-hand turns, and straight-line acceleration. For example, I was approaching a red light, so I lifted off the accelerator and started to coast. Before I applied the brake, the light turned green, so I went back to the accelerator, but the vehicle did not increase speed for 1-2 seconds. It suddenly lunged forward, and I had to lift off the accelerator so I could decrease my speed. There are occasions when you need to be quick, like merging onto a freeway, and this lack of responsiveness could lead to an accident. The vehicle has been to the dealer for known transmission issues and the dealer performed a reset on the adaptive tables. The issue I am writing about occurred before and after the adaptive table reset. No warning lamps or messages were displayed during the issue.

Injury caused when power tailgate failed to slowly lower upon release. Upon release, the tailgate fell open instead of slowly opening as normal (it is a power tailgate). The force of the falling tailgate twisted my wrist and the tailgate hit my arm as I was unprepared for the tailgate to fail and quickly fall. The tailgate operated normally immediately after this incident.

Opened door to truck, sat down, hit the start button and immediately following was a extremely loud popping noise followed by loud static. This is a hazard to adults driving and little ones with developing ear drums. Dealers refuse to see it when it happens, so when needing to make an appointment they can not duplicate it. No warning lamps or messages came on. There have been many complaints about this from other customers as well. Please address this matter.

While turning on my car, there was an extremely loud pop and deafening noise "exploding" in the truck cabin. If I had been driving at the time, the sudden and extreme noise would have caused me to react in a way to lose control of the vehicle. The noise was easy over 120db. It is been two hours since it happened and my ears are still hurting. I had to remove the radio fuse for this to stop. The issue has been reported to Ford by many users multiple times and no actions have been taken by Ford (see multiple cases here: https://www.f150gen14.com/forum/threads/extremely-loud-electrical-pop-followed-by-loud-static.9591/). There were not warning lamps or messages when this happened.