NHTSA Complaint #11706853 — 2021 FORD F-150

Description of Incident: The vehicle exhibits a severe and unpredictable transmission "shudder," "stutter," and hesitation during gear synchronization, specifically during 1st–3rd and 8th–10th gear transitions. This manifest as a violent "shaking" sensation and a loss of momentary acceleration while merging into high-speed traffic. This issue was first reported to an authorized Ford dealership on December 17, 2024. At that time, the vehicle exhibited harsh shifting and "shuddering" consistent with Ford Technical Service Bulletin (TSB) 22-2428. Despite being under a 150,000-mile service contract, the dealer misdiagnosed the mechanical transmission defect as an engine misfire, resulting in ineffective repairs. The defect has persisted and worsened. The internal failure has been identified as a defective CDF Clutch Drum (Cylinder) where an internal bushing moves out of place, obstructing fluid flow and causing mechanical "slip." This is a known manufacturing defect documented in multiple Ford TSBs (22-2428, 23-2250, and 24-2101). Safety Risk: The failure causes unpredictable power delivery. On multiple occasions, the vehicle has hesitated or "stuttered" while attempting to merge onto highways or cross intersections, leaving the vehicle vulnerable to side-impact or rear-end collisions. The lack of consistent throttle response and the violent nature of the shifting creates a significant safety hazard for the driver and surrounding motorists. Verification/Inspection: The symptoms were reported to a Ford dealership multiple times. As of December 2025, the dealership has opened a formal case with the manufacturer to verify the internal "cause of failure" by the Shop Foreman. No warning lamps or Diagnostic Trouble Codes (DTCs) appeared on the dashboard, as the failure is a mechanical internal bushing slip that does not always trigger a software sensor until total failure occurs. The vehicle is available for inspection.