NHTSA Complaint #11660141 — 2020 FORD F-150

After completing a 200-mile highway drive with my family in the vehicle, I performed a routine visual inspection of the undercarriage. During this inspection, I immediately noticed that one of the front coil springs appeared to be off-center in relation to the shock assembly. Upon closer examination, I discovered that both front coil springs had shifted significantly out of position. Even more alarming, the coil spring on the passenger side had a complete fracture—it was fully cracked through. In addition, the misalignment of both springs had caused visible damage to the shock bodies, suggesting metal-on-metal contact had been occurring during operation. This is not a wear-and-tear issue or a cosmetic concern—this is a catastrophic suspension failure on a relatively new and well-maintained vehicle. Coil springs are a critical structural component designed to support the weight of the vehicle, absorb shocks, and maintain proper handling and ride height. A complete failure of one coil spring, coupled with misalignment of both, indicates either a serious design flaw or material defect. Had this failure progressed during our highway drive, especially at speed or during an evasive maneuver, the consequences could have been tragic—not only for my family, but for other drivers on the road. The loss of suspension integrity at highway speeds could lead to sudden loss of vehicle control, steering instability, or even a rollover. The fact that this occurred without any warning signs (no abnormal noises, ride quality changes, or handling issues were noticed prior to inspection) makes it even more concerning. This type of failure should not be happening on a modern pickup truck, especially one marketed for its toughness and reliability. I am filing this complaint in the hope that NHTSA investigates whether this is an isolated incident or part of a broader issue affecting other 2020 F-150s. If other vehicles are at risk of similar suspension failures, this poses a serious publ