NHTSA Complaint #11562339 — 2021 FORD F-150 HYBRID

3.6.2021 - Ford F150 purchased at Battlefield Ford (Ourisman Ford), Manassus VA / registered in CT 7.27.21 – inspected by Torrington Ford, Torrington CT for rubbing sound front left side, nothing found / 6,325 miles 2.10.22 – inspected for same issue / nothing found / 16,000 miles 7.27.22 – inspected for same issue / nothing found / 24,000 miles 12.24.2022 – “Catastrophic failure” of front differential / 34,369 miles. On Christmas Eve 2022 myself, husband and son were driving to family in NY when the truck very quickly started to make a severe grinding sound, became unable to steer, loss of control, and started to produce smoke & fire under the hood. We immediately stopped and got out unharmed. Fire was dripping out of the bottom of the truck and smoke/fire under the hood. We were lucky. Firetrucks came but were unable to do anything. The truck's wheels completely seized up - the tow truck had to skid it onto the flatbed. Repaired at Simmons-Rockwell Ford, Hallstead, PA. Complete new front differential and damaged parts in proximity to the failure (pinion gear, axle shaft, etc). 12.16.2023 – Again hearing a sound in front left side while driving; bring to the shop for inspection. Shop confirms front differential is failing again, per Torrington Ford, (where all maintenance and repairs were completed, except for the first failed front differential in PA). Advise not to drive for safety reasons. 52,922 miles. With both front differential failures - no warning lights or messages. Symptoms - a slight rubbing/grinding noise in the front left side of vehicle; “rough” sound while driving. 1st front differential – inspected at 6,000 miles, 16,000 miles, and 24,000 miles. Failed at 34,369 miles. 2nd front differential – inspected at 52,922 miles, failing differential, advised not to drive. Dec 2023 – Buy-back claim filed with Ford Motor Co. Denied - "outside of the 18-month warranty period for VA Lemon Law". Clearly, safety is not a guiding tenet for Ford Motor Co.