NHTSA Complaint #11679461 — 2023 FORD F-150 HYBRID

On 7/18/25 I picked up F-150 from being repaired (failed Belt Drive Generator/Starter Tensioner). About 3 hours later I was driving up a long grade at about 5,000 feet when I stopped to check on my cargo (a bicycle). At this point I noticed the cooling fans were running increasingly fast, much faster then they had ever run before. I checked the digital temperature gauge and it showed a normal temperature. I opened the hood and saw there was no coolant in the overflow bottle. I assumed the truck was just a bit low on coolant and I had some (5 liters) water with me so I added that to the overflow bottle. Very little water was visible in the overflow bottle. I replaced the cap, turned off the A/C and immediately headed back to the dealer. At no point did the check engine light come on. At no point did the temperature gauge move from the "normal" area. At no point did any warning message of any time appear on the driver display - unless it occured when I was refilling the overflow bottle. The engine was not operating normally however, the gas engine stayed on at all times and did not cycle on and off as it normally would do (truck is a hybrid). When I arrived at the dealer they attempted to fill the coolant system and said it was completely empty - no sign of the 5 liters of water I put into the system. The cause of the leak was identified as the EGHR system, specifically the plastic coolant inlet port. This failure is discussed in Ford Customer Satisfaction Program 24N04 - attached. This failure should not have occured. But when it DID occur the vehcile should have warned the driver that a serious overheating event was occuring. No MIL was set. No driver warners were made and the temperature gauge remained in the normal range at all times. The ONLY way I because aware of the problem was by noticing the increasing speed of the cooling fans. This could lead to fire, or unexpected engine failure or burns from overheated radiator.