2021 FORD F-150 Structurebody Problems

Please see Ford TSB SSM50543. In my case the driver's door has been freezing in the lock position. Door will not unlock and cannot be opened either from the inside or outside. The key in the outside will not unlock the door and pulling up on the knob inside cannot be done (even tried with pliers). The electric door locks for the frozen door do nothing. This made it possible for me to only get out of or into the driver's seat by climbing in/out from the passenger's side. I also tried to not lock the driver's door, and this just made the door frozen in the unlock position. Very inconvenient, but I am especially concerned if I had to exit or enter the driver's side in an emergency. Ford knows about this as can be seem from the issued TSB. This had happened more than once and goes away...

A certified independent inspection company discovered welding on the main chassis of my Ford F-150. The welding is located on the front left frame area. I purchased the vehicle brand new, and it has never been in any accident or collision. This welding on a critical structural part creates a serious safety risk. Frame integrity may be compromised in normal driving or in the event of an impact. I transport my children daily in this vehicle, and I am afraid to drive it due to the possibility of structural failure. The official Ford dealer inspected the vehicle and kept it for approximately three weeks but provided no explanation or repair. The regional Ford office has delayed their technical report for more than five months with no response. The defect has been confirmed and is permanent. No warnings or lights appeared prior to discovering the issue. This is a manufacturing-related structural...

The dash pad in front of steering wheel is coming apart and peeling back. It appears to a defect in installation, material use or wasn't glued down properly

The side rails that come out when door is opened to assist with getting inside the truck does not work properly. It has come out and will not go back in. The door is closed and I have to drive the truck with the rails hanging down. That is a hazard.

The saggy diaper is a hazard and major manufacturer defect that must be corrected ASAP. It needs to be metal period the end. The paper like cover bolted on the undercarriage is an awful engineering hazard. I have changed this item four times. The dealerships well established pattern of services for this issue and Google searches speak for themselves. I don’t know why Ford refuses to address this concern and blow me off.

What component or system failed or malfunctioned, and is it available for inspection upon request? The exterior door handles and latching mechanism failed due to freezing in cold weather. When temperatures drop, the door handles become stuck or the latch mechanism fails to engage or disengage properly. This issue is reproducible during cold weather and the affected components are available for inspection upon request. How was your safety or the safety of others put at risk? The malfunction poses a safety risk in multiple ways. The doors may not close securely, which could result in a door opening while driving. Conversely, frozen latches can prevent doors from opening, which is a serious concern in the event of an emergency where rapid exit from the vehicle is required. This could endanger both the driver and passengers. Has the problem been reproduced or confirmed by a dealer or independent service center? The...

DRIVER DOOR WON'T LOCK OR UNLOCK IN EXTREME COLD. TO EXIT AND ENTER TRUCK, I HAVE TO USE THE PASSENGER DOOR AND SLIDE INTO DRIVER SEAT, WHICH IS VERY DIFFICULT B/C OF THE CENTER CONSOLE. NO WAY I COULD GET OUT OF THE TRUCK IN A HURRY IF I HAD TO. TOOK TO A DEALER BUT OF COURSE IT COULDN'T BE DUPLICATED. INTERNET SEARCH SHOWS THIS IS A PROBLEM WITH THE 2021 FORD F150.

My rear passenger window shattered. My niece opened the door and the glass shattered. The window pane was held together by after market tint. It then fell under the vehicle. The vehicle is available for inspection until Friday, July 27, when it is scheduled for repair. The safety of the passengers was putt in jeopardy sure to the nature of the incident.

Tailgate periodically opens on its own

F150 is experiencing interior leaking from the windshield and other areas that Ford is unable to identify the cause. This can cause visibility issues and damage to electrical components resulting in a safety issue. The leaking causes the floor mats to be wet, which have also caused my foot to slip off the control petals. This could cause an accident. Ford is not able to identify the source, they were able to reproduce the leaks in the firewall but can't identify the source. Ford doesn't acknowledge this is a major issue and has only offered to caulk and seal in the most common areas. It was in the shop for four days March 25-27 and 22-23 2024. There are no warning issues just went floor mats and visible water on the interior of my windshield which I demonstrate to the dealership.

In freezing temps(usually under 25*), the interior door handle freezes and will not engage the door latch. The door will not stay latched until cabin of interior warms up. Running boards get deployed every time the vehicle comes to a stop.

Panoramic sunroof exploded. This happened on a country highway with no other cars or debris around.

While driving on a highway at 70 mph the hood unlocked and was caught by the safety latch. It is available for inspection. My safety was at extreme risk. Loosing the ability to see out of my windshield had the safety latch failed could have been catastrophic. This could have caused a crash at highway speeds from the sudden inability to see where I was driving. The problem has not been reproduced but should be confirmed by the trucks data system. A hood unsafe message appeared on my dash screen. The latch has not been inspected yet as this happened last night. There was no prior indication or warning that the hood would come unlocked.

EXTREMELY DANGEROUS DOOR CLOSING FAILURE. Both front door lock actuators malfunction below 10 degrees Fahrenheit. Rear doors of the crew cab are unaffected. The moving parts of the mechanism are not frozen and there is no water in the system. The lock actuator will not engage the clamp/pin mechanism to hold the door closed, even though the movable parts are freely moving. this happens whenever the temperature is below 10 degrees. In order to get out of the car you need to exit the rear door or climb out the window. Once the door does open, it will not securely latch in position. The Certified Ford dealership informed me that this is a "known problem" with the F150 and there is no known repair.

Vehicle was purchased new 06/08/2021. Since that time it has been back to the dealer 4 times with 3 being for repairs to the problem. There is a crunching / clanging sound every time a turn is made on an incline or decline. The vehicle has been inspected and gone over with body bolts loosened and re-tightened to factory specs to no solution. It was taken back again and now the dealer thinks it is something with the springs. The truck has been with the dealer a total or 27 days as of this date. ( 08-21-2021 ) and repair attempted 3 times. The dealer is not sure if springs are the problem, just chasing possibilities down. I have a loaner which myself and my wife heard the same noise starting. We feel unsafe with this vehicle and Ford seems to be passing the buck although the dealer rep believes...

The 2021 F150 active air dam does not function properly. The top stationary piece becomes lodged inside of the bottom retractable part every time it opens and closes. It's becoming weaker and loosely attached to the vehicle. I'm afraid one day driving it will completely fall off and fly into another vehicle's line of sight causing damage or a wreck. The dealer I went to service advisor called it a "wrinkle" like it was a joke to him and I should just deal with it. He supposedly put in a "TSB" but never calls me back when I ask about it. I need it replaced or repaired. It makes me extremely nervous. There are multiple threads complaining about it so it's not just a one truck issue.