FORD F-150 LIGHTNING BEV

ELECTRONIC STABILITY CONTROL (ESC)

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."

Risk: 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.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

Ford Motor Company (Ford) is recalling certain 2025 F-150 Lightning BEV vehicles. The front brake jounce hose bracket screws may loosen and detach, which can allow the jounce hose to contact the tire and result in a brake fluid leak.

Risk: A brake fluid leak can extend the distance needed to stop the vehicle, increasing the risk of a crash.

TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

Ford Motor Company (Ford) is recalling certain 2022 F-150 Lightning BEV vehicles equipped with 20" or 22" all season tires that were repaired incorrectly under recall 22V-453. The tire pressure monitoring system (TPMS) light may not illuminate as intended, failing to warn the driver of low tire pressure. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 138, "Tire Pressure Monitoring Systems."

Risk: Low tire pressure can lead to poor vehicle handling and a loss of vehicle control, increasing the risk of a crash.

SUSPENSION:FRONT:CONTROL ARM:UPPER BALL JOINT

Ford Motor Company (Ford) is recalling certain 2024-2025 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.

Risk: A detached control arm can cause a loss of vehicle steering and control, increasing the risk of a crash.

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

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.

Risk: A battery short circuit increases the risk of a fire.

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

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.

Risk: 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.

SUSPENSION:FRONT:CONTROL ARM:UPPER BALL JOINT

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.

Risk: A detached control arm can cause a loss of vehicle steering and control, increasing the risk of a crash.

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

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.

Risk: 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.

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

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."

Risk: An inoperative windshield defrosting and defogging system may decrease the driver's visibility, increasing the risk of a crash.

ELECTRICAL SYSTEM

The contact owned a 2024 Ford F-150 Lightning BEV. The contact stated that while the vehicle was parked and unoccupied, it caught on fire. The contact stated that the Police knocked on the door and informed the contact that fire was shooting out of the vehicle. The fire department arrived and extinguished the fire. The vehicle was towed to a local tow yard. The vehicle was deemed a total loss. In addition, the vehicle was parked in a secluded area of the tow yard. The contact stated that the Fire Department, Police, and Insurance Agent unofficially referred to the failure as electrical or battery-related. The manufacturer was made aware of the failure. The failure mileage was 5,000.

EXTERIOR LIGHTING

Rear tailgate light bar has multiple cracks

ELECTRICAL SYSTEM

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.

ENGINE

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.

POWER 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 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.

UNKNOWN OR OTHER

I was driving into a parking space and my 2024 Ford F-150 Lightning had a sudden unintended acceleration, which caused vehicle to crash into the concrete block wall in front of the parking space.

SERVICE BRAKES

When the Ford Lightning is in reverse and the 1-pedal braking system is applied, the brakes don't engage when switching to drive causing the car to roll back an additional 3-5 feet depending on speed. In the situation that caused the fender bender, the Ford lightning was reversing in a street at approx. 5 MPH then the driver released the pedal for the brakes and switched to drive. The car rolled back 5 feet into a parked car during this transition.

ELECTRICAL SYSTEM

While braking slowly to park at my home, my 2023 Ford F-150 Lightning XLT suddenly accelerated forward without any throttle input. The vehicle struck a wall. My foot was on the brake and I did not touch the accelerator. There were no warning messages prior to the incident. This could have caused serious injury or worse if anyone was in front of the vehicle. I believe this may be a critical safety defect.

SERVICE BRAKES

While braking slowly to park at my home, my 2023 Ford F-150 Lightning XLT suddenly accelerated forward without any throttle input. The vehicle struck a wall. My foot was on the brake and I did not touch the accelerator. There were no warning messages prior to the incident. This could have caused serious injury or worse if anyone was in front of the vehicle. I believe this may be a critical safety defect.