NHTSA Complaint #11702163 — 2023 FORD MAVERICK HYBRID

The 2023 Ford Maverick Hybrid is experiencing a recurring safety failure of the Front CV Axle Shafts. The vehicle exhibits violent, uncontrollable shaking of the front end during acceleration at highway speeds (40–65 MPH). This severe vibration compromises vehicle stability and steering control, creating a significant safety risk during merging or overtaking maneuvers. The vehicle was previously repaired for this exact issue by an authorized Ford dealer on May 30, 2024 (at ~32,000 miles). However, the failure has recurred 18 months and 33,000 miles later. Inspection of the current failed parts reveals that during the 2024 warranty repair, the dealership installed obsolete, superseded part numbers (Series "NZ", specifically NZ67-3B436) instead of the updated, corrected design (Series "SZ") released by Ford to fix this known defect. Because the dealership replaced defective parts with the same defective/superseded design, the safety hazard has returned prematurely. The defect was previously confirmed by a dealer technician. The current failure is confirmed by visual inspection of the part labels showing the obsolete "NZ" code. No warning lights appeared prior to failure; the symptom is immediate mechanical vibration under load.