Alternator/generator/regulator problems of the 2011 Ford F-150

The speaker went out in my back left door, so I took the door apart to see what was going on. I tested the speaker and it worked fine, so I started working my way back through the wiring harness. When I touched the harness where it goes from the door to the body (in the door jam) the speaker started working. I removed the harness from the door and pulled back the rubber boot in the door jam. Everything was still wrapped in factory harness wrap, and when I exposed the wires, the speaker wires were severed and most of the wires in the bundle had cracked insulation. There were no signs of being pinched or damaged externally, and I am fairly certain this was just from the bending motion every time the door was opened and closed. I build custom automated machines for a living and we always use flex rated cable for applications like this. So this looks like they used cheap wire with insulation that is not rated for the number of bend cycles a door goes through. Luckily the power wires for the window regulator and door switch had not shorted out despite the copper being exposed. I am very concerned the rest of my doors are suffering the same problem. This could lead to not being able to unlock the door, not being able to roll down the window in an emergency, or even a fire if the power wires shorted out.

Wiring harness was shorted out from rubbing on top of differential housing causing alternator failure while underway in warren PA. Stopped dead shortly after at traffic light.

Started the truck in the morning (temperature was 45) and the battery light came on. Took it and had it check and had the battery replaced. After the battery was in, they ran a test and said the alternator was charging too much and the light will come on again. Sure enough after a few seconds, the battery light came back on. Took it to the dealer (apple Ford in red lion, PA) I purchased it from and they said the alternator is bad and charging too much. There stated that there are no after market alternators for this make and year. So after paying $1055. 00 for a Ford brand alternator, the truck was fixed. That is way too much money for an alternator. It is an outrage!! I checked around and I cannot believe that the price of this part is actually this expensive. I asked if they have heard about this problem, and the answer was no. I have been a Ford owner most of my life, but this may change my opinion on Ford trucks for my next purchase.

On the night of Dec 20, 2013, I was travelling south on i81 north of syracuse NY. Road conditions were not very good. A block of ice fell off a truck ahead of me, evasive action was not possible due to ice and traffic volume. The ice struck the alternator which is cleverly positioned about 10" off the ground on the lower left front of the vehicle. The vehicle began to lose electrical power system by system. I cant recall the exact sequence, as it was all happening pretty fast. Eventually, the electric power steering system lost power. When this happens on this vehicle, you lose all steering capability. Its not like its just manual steering, there is no steering other than the ability to slightly alter course by pulling extremely hard on the wheel. The vehicle had no lights, the shoulders were unplowed, stopping wasnt a good idea. As good fortune would have it, the cicero NY exit presented itself at that moment. I was able to pull extremely hard on the wheel and was able to steer the slight curve. At the bottom, I discovered I had no breaks. I shot across the usually busy NY 31 and into a kwikstop, where I stomped on the emergency brake and came to a stop. We shortly discovered a fire underneath the engine and were able to extinguish it with snow. I cannot believe a steering system like this is permitted. Had I known it had this system and its limitations, id never have bought the car. If my son and I had been killed that night, it would have all been chalked up to road conditions. In furious about this system. It needs to be recalled. . . . . Now.

Cpsc: i144350a. 2011 Ford F-150. Consumer stated the electric power steering system lost power. The consumer stated while driving, a block of ice fell off a truck that was ahead of him, and evasive action was not possible due to the ice and traffic volume. The ice stuck the alternator which was positioned 10 inches off the ground on the lower left front of the vehicle. Then vehicle then began to lose electrical power . Eventually, the vehicle lost electrical power steering. He was able to pull hard on the steering wheel and was able to steer a slight curve. He then realized he had no brakes, so he shot across the highway, which was usually busy, and he stomped on the emergency brake and came to a stop. The consumer then discovered there was a fire underneath the engine, but quickly put it out with the snow.

We were travelling down the interstate when the red battery light came on. Shortly thereafter loss of power steering, loss of stability control (per dash indicator), and loss of power brakes. I have had the alternator replaced 2 separate times since for a total of three (3) alternators as well as one new battery. Now truck is in shop again for same malfunction. 2011 Ford f150 lariat. Crew cab. V-6 engine. Only 54000 miles and I am anticipating my fourth (4th) alternator. I use the truck in non-mountainous terrain, mostly highway for errands, and rarely tow. I believe a recall investigation should commence.