NHTSA Complaint #11675078 — 2019 FORD F-150

Vehicle Information: •Make: Ford •Model: F-150 •Year: 2019 •VIN: [XXX] Complaint Summary: Cam Phaser Defect — Safety Risk and Manufacturer Negligence 1. Component/System Failure This complaint involves a mechanical failure of the cam phaser system (part of the variable valve timing system) in the 3.5L EcoBoost engine of the above-referenced vehicle. Specifically, the locking pin within the cam phasers fails to engage properly, resulting in a loud knocking or rattling noise on cold start. This condition is a known defect documented in Ford TSB 19-2208 and subject to Customer Satisfaction Program (CSP) 21N03, which extended coverage for cam phaser repair. However, no official safety recall has been issued, despite widespread evidence of failure. The defective parts are still installed in the vehicle and are available for inspection upon request. 2. Risk to Safety This defect compromises driver and public safety and constitutes a violation of 49 U.S.C. § 30101 and 49 U.S.C. § 30118, which obligate manufacturers to notify NHTSA and owners when a defect poses an unreasonable risk to motor vehicle safety. Specifically: •Failure of cam phasers leads to improper valve timing, risking engine hesitation, loss of power, or stall conditions. •These symptoms can occur during acceleration, highway driving, or merging, creating conditions that significantly increase the risk of collision or engine failure while in motion. The defect may also cause internal engine damage over time, raising the risk of mechanical breakdown in traffic. 3.Confirmation of the Problem This issue has been confirmed by a certified Ford dealership and an independent ASE-certified mechanic. Both diagnosed the startup noise as a cam phaser locking failure, consistent with widespread reports from other Ford 3.5L EcoBoost owners. Neither party could provide a fix without significant out-of-pocket cost, despite Ford’s knowledge of the issue and internal bulletins acknowledging the issu INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)