One problem related to axle hubs has been reported for the 2021 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2021 Ford F-150 based on all problems reported for the 2021 F-150.
Please see attachment: to whom it may concern, I am writing to formally request NHTSA’s review and further action regarding Ford motor company’s handling of safety recall 23v?896 and 23s-65, affecting my 2021 Ford f?150 (f1 3509). I appreciate NHTSA’s oversight of this recall; however, based on my direct experience and the technical information available, I believe the current remedy strategy leaves owners exposed to ongoing safety risks. My vehicle experienced fractured rear axle hub bolts, a failure mode that Ford’s defect report attributes to micro?movement and backlash between the axle shaft splines and the wheel?end hub splines. This movement leads to loss of clamp load, fretting wear, and ultimately bolt fatigue and fracture. The fractured bolts on my truck confirm that this failure chain had already progressed to an advanced stage. Ford performed what they describe as an interim repair, which consisted of replacing the fractured bolts and inspecting the hub and axle components. However, Ford has acknowledged that the final remedy is not yet available, and that the interim repair does not address the underlying design issue that allows spline movement and progressive wear. As a result, the same conditions that caused the initial failure may reoccur. From a mechanical and safety standpoint, replacing bolts without correcting the root cause — the loss of clamp load and resulting spline backlash — does not eliminate the defect. It merely resets the system temporarily. Ford’s own documentation confirms that the interim repair uses the same bolt design, with the same torque and elongation characteristics, and therefore the same long?term vulnerability.