NHTSA Complaint #11703649 — 2023 FORD F-150

My 2023 Ford F-150 XLT (base 4×4—2H, 4H, 4L only) is experiencing a front-axle/IWE malfunction that causes the hubs to partially engage on their own in cold weather. When temperatures drop below freezing, the truck produces a very loud, physical pop when turning in 2H and a mechanical grinding/rumble noise from the front axle while driving straight. This happens even though the roads are dry and I have not engaged 4WD. The noise immediately disappears when I switch into 4H, which indicates the integrated wheel ends (IWEs) are partially engaging due to vacuum loss or actuator failure. When the hubs fully lock in 4H, the grinding stops. This confirms the IWEs are not disengaging properly in 2H. This occurs only in freezing temperatures, to date, and it feels as if the front axle is binding or locking during turns. The loud popping feels violent enough that it could lead to CV axle, differential, or IWE gear failure. My Ford dealer stated they have “not heard of this issue,” but this condition matches the symptoms described in Ford TSB 25-2513 for incomplete IWE disengagement on 2021–2025 F-150 trucks. Despite Ford saying this is not a known problem, there is significant owner evidence online showing that many 2021–2024 F-150 owners experience the exact same symptoms. Multiple threads on F150Forum, F150Gen14.com, and Reddit describe identical cold-weather popping and grinding caused by IWEs partially engaging in 2H. In many of those cases, owners report that dealers dismissed the issue or stated it was “normal,” even though the symptoms are widespread and consistent. This is a safety concern because the front axle partially engages without driver input, causing binding, loss of smooth steering, loud mechanical pops, and grinding while in 2WD. This could lead to sudden front drivetrain failure, loss of control, or damage to steering/braking components. I am submitting this complaint so NHTSA is aware that this issue is occurring F-150s and may not be isolated.