I own a 2023 Ford F-150 Lightning, with 48,200 miles and 2.5 years of ownership. Recently, my truck began displaying a “Powertrain / Reduced Power” warning while driving, and the air conditioning stopped producing cold air. The dealer scanned the vehicle and found DTC P0534 – A/C System Charge Loss. Further diagnostics indicated…
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I own a 2023 Ford F-150 Lightning, with 48,200 miles and 2.5 years of ownership. Recently, my truck began displaying a “Powertrain / Reduced Power” warning while driving, and the air conditioning stopped producing cold air. The dealer scanned the vehicle and found DTC P0534 – A/C System Charge Loss. Further diagnostics indicated that multiple vehicle modules may require reprogramming and software updates. The dealer stated they need to evacuate and recharge the AC system, add dye, and remove front trunk components to locate the leak. This AC system is part of the high-voltage battery and eDrive thermal management system, meaning that failure of the HVAC system affects battery cooling and powertrain performance. Loss of cabin cooling is a symptom of a thermal system malfunction, which can lead to battery overheating, powertrain derating, and reduced driving performance. The combination of unexpected reduced power and loss of cabin cooling creates a safety risk, particularly during highway driving, merging, or situations requiring acceleration. These failures occurred at relatively low mileage and are associated with the high-voltage EV system, which should be functioning properly to ensure safe vehicle operation. I am submitting this complaint to report a potential safety defect with the 2023 Ford F-150 Lightning affecting the battery thermal management, high-voltage AC system, and eDrive components, which can result in sudden power loss and compromised vehicle safety.
NHTSA ODI #11728387
Mileage unknown · Aug 22, 2025
Electrical SystemEnginePower Train
The front traction motor on my 2023 Ford F-150 Lightning failed without warning, causing the vehicle to lose all-wheel drive capability. The truck automatically limited available power to about 67%, which I later learned indicates the front motor was disabled and the vehicle was operating in rear-wheel drive only. The failure oc…
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The front traction motor on my 2023 Ford F-150 Lightning failed without warning, causing the vehicle to lose all-wheel drive capability. The truck automatically limited available power to about 67%, which I later learned indicates the front motor was disabled and the vehicle was operating in rear-wheel drive only. The failure occurred with no warning lamps, messages, or prior symptoms on the dashboard or in the FordPass app. I assumed AWD was functioning, which could have caused a serious accident in snow, ice, or gravel conditions because the loss of front-wheel traction significantly reduces vehicle stability. The component/system is still available for inspection. At this time, the issue has NOT been reproduced or confirmed by a dealer, and the vehicle has NOT yet been inspected by the manufacturer or any other party. Cause of failure is UNKNOWN. This lack of a warning or alert to the driver represents a major safety hazard because it changes how the vehicle handles without the driver’s knowledge.
NHTSA ODI #11682304
Mileage unknown · Sep 12, 2024
EngineFuel/propulsion SystemPower Train
“Powertrain Malfunction/Reduced Power” error message with accompanied vehicle propulsion reduction to approximately 5 mph.
Ford Motor Company (Ford) is recalling certain 2022-2026 F-150 Lightning BEV, 2024-2026 Mustang Mach-E, and 2025-2026 Maverick vehicles. The integrated park module may fail to lock into the park position when the driver shifts into park. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 114, "Theft Protection and Rollaway Prevention."
Consequence & remedy
Consequence: A loss of park function can allow the vehicle to rollaway, increasing the risk of a crash.
Remedy: The park module software will be updated over-the-air (OTA) or by a dealer, free of charge. Owner notification letters were mailed February 3, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25C69. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning January 26, 2026.
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150 Lightning BEV vehicles previously repaired under recall number 23V418. The rear lightbar may have microcracks in the outer lens that allows moisture to accumulate, which can result in inoperative or flickering reverse lights.
Consequence & remedy
Consequence: Inoperative or flickering reverse lights may not alert other driver's that the vehicle is reversing, increasing the risk of injury or crash.
Remedy: Dealers will inspect and replace the rear lightbar and fasteners as necessary, free of charge. Owner notification letters were mailed June 3, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SB6. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 29, 2025.
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150 Lightning vehicles previously repaired incorrectly under recall number 23V801. The SYNC software may fail to activate the electronic stability control (ESC) system at the beginning of each ignition cycle. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, "Electronic Stability Control Systems."
Consequence & remedy
Consequence: Failure to reset the ESC to active may result in the driver unknowingly operating the vehicle without electronic stability control, increasing the risk of a crash.
Remedy: Dealers will update the Accessory Protocol Interface Module (APIM) software, free of charge. Owner notification letters were mailed June 18, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25C15.
Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning vehicles. The fasteners that secure the junction box bus bars inside the high-voltage battery pack may not have been tightened securely, which can cause electrical arcing at the busbars.
Consequence & remedy
Consequence: Electrical arcing increases the risk of a fire. In addition, a loss of drive power may occur, which can increase the risk of a crash.
Remedy: Dealers will inspect and repair the busbar fasteners and replace any damaged components as necessary, free of charge. Owner notification letters were mailed on May 21, 2025. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 24S11. This recall expands previous recall number 24V-144.
Ford Motor Company (Ford) is recalling certain 2022-2024 F-150 Lightning battery electric vehicles. A manufacturing defect in the high voltage battery cells may result in an internal short circuit.
Consequence & remedy
Consequence: A battery short circuit increases the risk of a fire.
Remedy: Owners are advised to only charge their vehicles to a maximum of 80% battery capacity until the repair has been completed. Dealers will inspect and replace the high voltage battery array as necessary, free of charge. Owner notification letters were mailed June 27, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S18.
Ford Motor Company (Ford) is recalling certain 2023-2024 F-150 Lightning BEV vehicles. The front upper control arm ball joint nut may not have been tightened properly, allowing the front upper control arm to detach from the knuckle assembly.
Consequence & remedy
Consequence: A detached control arm can cause a loss of vehicle steering and control, increasing the risk of a crash.
Remedy: Dealers will inspect the upper control arm ball joint nut, and replace the nut and/or knuckle assembly, as necessary, free of charge. Owner notification letters were mailed February 10, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S76.
Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning vehicles. The fasteners that secure the junction box bus bars inside the high-voltage battery pack may not have been tightened securely, which can cause electrical arcing at the busbars.
Consequence & remedy
Consequence: Electrical arcing increases the risk of a fire. In addition, a loss of drive power may occur, which can increase the risk of a crash.
Remedy: Dealers will inspect and repair the busbar fasteners and replace any damaged components as necessary, free of charge. Owner notification letters were mailed on May 31, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S11.
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150 Lightning vehicles. The SYNC software may fail to activate the electronic stability control (ESC) system at the beginning of each ignition cycle. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, "Electronic Stability Control Systems."
Consequence & remedy
Consequence: Failure to reset the ESC to active may result in the driver unknowingly operating the vehicle without electronic stability control, increasing the risk of a crash.
Remedy: The Accessory Protocol Interface Module (APIM) software will be updated by a dealer or through an over-the-air (OTA) update, free of charge. Owner notification letters were mailed December 21, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C38.
Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning pickup trucks. The electronic cabin coolant heater module may be missing a solder joint, which can cause intermittent or no cabin heat and result in an inoperative windshield defrosting and defogging system. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 103, "Windshield Defrosting and Defogging Systems."
Consequence & remedy
Consequence: An inoperative windshield defrosting and defogging system may decrease the driver's visibility, increasing the risk of a crash.
Remedy: Dealers will replace the electronic cabin coolant heater, free of charge. Owner notification letters were mailed January 3, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C32.
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150 BEV vehicles. The rear lightbar may have microcracks in the outer lens that allows moisture to accumulate, which can result in inoperative or flickering reverse lights.
Consequence & remedy
Consequence: Inoperative or flickering reverse lights may not alert other driver's that the vehicle is reversing, increasing the risk of injury or crash.
Remedy: Dealers will replace the rear lightbar, free of charge. Owner notification letters were mailed October 9, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S30.
Ford Motor Company (Ford) is recalling certain 2023 F-150 Lightning pickup trucks. The high-voltage battery pack may experience an electrical short-circuit when the battery is fully charged or near fully charged.
Consequence & remedy
Consequence: A battery short-circuit increases the risk of a fire.
Remedy: Dealers will replace the high-voltage battery pack, free of charge. Owner notification letters were mailed March 31, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S15.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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