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.

Tonight when I started my truck there was a loud pop sound that came from the sound system. The stereo then had no volume with any source. I shut down the vehicle and restarted it. As soon as it turned on again, the sound system had incredibly loud static coming from every speaker. My ears were ringing and when I screamed to my eight year old to get out of the truck, she could not hear me. I tried to turn the truck on and off multiple times and I eventually had to abandon it and take my wife’s car. I have a video that shows my truck was turned off and the sound system would not stop making the awful noise. I just can’t attach it to this report.

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.

1. The back up brake assistant is not working. This has been defective since August 2022. It caused me to have an accident running into a post, filing an insurance claim for repairs. I have taken it to 2 different Ford dealers for service and to get the back up brake fixed. No resolve from FORD. 2. In September 2022 my F150 started going into low power mode then eventually into deep sleep mode. The battery was replaced at FORD. Now on 11/15/22 and 11/16/22 the vehicle went into low power mode and deep sleep mode again.

The contact owns a 2022 Ford F-150 Hybrid. The contact stated while attempting to start the vehicle, the engine failed to turn over and the engine was cranking as if the battery was drained. The contact stated that the "Stop Driving" and "Check Engine and "Check Battery" warning lights were illuminated. Additionally, the "Stop Safely Now" was displayed with the vehicle still in park(P). The vehicle failed to start. The contact stated that the failure was intermittent and that the vehicle had not been able to be started recently. The contact had the vehicle towed to a local dealer however, the vehicle was not diagnosed or repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 3,000.

Wile driving my vehicle after a rain storm (it was not currently raining) water started to drip from the speaker above the driver. The ceiling from the middle of the driver door to the center of the windshield was soaking wet. While the vehicle does have a sunroof it is never used. I checked for blocked drain ports and they are not blocked. There would be no reason for them to be blocked on a new vehicle that never opens the sunroof. I have been unable to get a dealership to schedule service to inspect for if the drain tubes are connected or not, or for any other issues that would lead to the leak. The only immediate safety issue was the distraction caused by water dripping on me while I was driving. The longer term safety concern is mold and water potentially affecting the numerous electronics for hands free driving, emergency braking, lane departure, etc. The headliner was wet all the way to the center of the windshield in the area where some of the emergency braking and lane departure electronics are.

As soon as I pressed the start button, an extremely loud and shrill sound came from every speaker. Horn also started blaring. All speakers continued to crackle, pop, and scream until I pressed the ignition button again and opened the drivers door. I was able to prevent it from happening again by removing fuse #28. My ears are still ringing 8 hours later and may have permanent hearing loss. This will absolutely destroy a child’s hearing.