2021 Ford F-150 Hybrid Wheel & Tire Problems

Which parts fail

• Lugs/nuts/bolts/studs
  1

Components named in complaints (wheels, lug nuts, original-equipment tires, TPMS).

Mileage when the problem started

Owner reports

Selected complaints filed with NHTSA by 2021 Ford F-150 Hybrid owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2021 Ford F-150. The contact stated while driving approximately 65-70 MPH, the contact was flagged down by a nearby driver and advised to pull the vehicle over to the shoulder of the road. The contact stated that the vehicle was driven to the shoulder of the road. The contact exited the vehicle and proceeded to inspect the vehicle. The contact noticed that the rear driver's side rim cap had detached. The contact stated that the center axle bolt was still attached to the rim cap. The vehicle was towed to the dealer where it was diagnosed with a failed rear axle half shaft and hub and the rear axle half shaft and hub needed to be replaced. The vehicle was repaired. The contact stated that the driver's side rear axle bolt had previously been replaced and was under an unknown recall. …

The contact owns a 2021 Ford F-150. The contact stated while driving approximately 25 MPH, the sheared axle bolt became faulty. There were no warning lights illuminated. The vehicle was taken to several dealers who diagnosed the same failure. The vehicle was repaired several times however, the failure reoccurred. The manufacturer was notified of the failure. The approximately failure mileage was 9,622.

On November 29, 2023 I took my 2021 F150 to Larry Miller Ford for servicing and repairs related to Recalls 22S71 and 23S35. When the tech was rotating the wheels he discovered that the axle shaft bolts were sheered off on both the left and right rear wheels. The service manager called to tell me that this was a serious safety issue and that only the brake rotors were preventing the wheels from falling off the truck. The service manager told me there was a "Customer Satisfaction Program 22B34" issued by Ford, but no Ford Recall relating to the problem. Larry Miller Ford has replaced both axles and axle bolts. I am waiting to find out if there is damage to the rotors, calipers or brake pads, a concern since the sheered off bolts were rattling around within that area since breaking off apparently between service visits. …

I took my truck in for it's first oil change and tire rotation. I was called by the dealer a few hours later and told that when they pulled my rear tire off, the rear rotor axle bolt was seared and the vehicle is unsafe to drive. As the tire had never been removed previously they said it had to come from the factory that way, and that I was lucky the tire did not fall off while driving the truck. I was told the parts would be ordered and repairs done under warranty but it's been over a week with no information or results. I researched the internet and found hundreds of owners experiencing the same issue with the rear axle bolt being seared, apparently at the factory. If this makes the vehicle unsafe for the road and it's obviously affecting 100's of vehicles that I can find in some internet search, the problem is likely much worse. …

The wheel hub axle bolt sheared off under normal conditions-dealer was unaware this was even an issue and told me the bolt they found within my wheel assembly and its attached washer was picked up off of the road (road debris) that they removed it and it would not grind anymore. I did basic research as an uninformed consumer and within seconds learned this is an issue on hundreds of other power boost pickup trucks. There is extensive documentation online regarding this issue. I called my dealer who has yet to respond to me. This is a major safety issue-the only thing holding the wheel on is the brake caliper. With as many documented cases as I can easily see online-the fact that my dealer is not aware of this indicates Ford has done nothing about it. This should be a recall. Please advise.

Left rear axle bolt sheared off into the wheel spontaneously. It is available for inspection. . Currently at dealer right now for repair. Dealer indicates vehicle not safe to drive due to potential for loss of wheel, brake components and wheel hub/axle during travel. I have not experienced loss of a wheel while driving luckily. There were no warning lamps/messages etc. No symptoms of the problem prior to failure were noted. The only sign of an issue was loud squealing from the left rear wheel when brakes were applied or when turning the steering wheel slightly either right or left. Refer to the following for additional cases. https://www.f150forum.com/f129/2021-powerboost-rear-rotor-axle-bolt-sheared. No TSBs have been issued on this based on database search.

The rear axle bolts sheared off for unknown reasons. The symptom was a metallic rattling noise from the back of the vehicle - the noise was pieces of the axle bolts bouncing around inside the wheel center cap. The bolt in questions holds the rear axles in place. Vehicle has been at dealership for 2 weeks as they said it was a common problem that is a safety issue. Said it was possible for one or both of the rear wheels to fall off if I had continued driving it. Obviously losing one or two wheels is a huge safety concern. My dealer said he has seen this exact issue 4-5 times on similar trucks. Vehicle is less than 9 months old and has less than 13,000 miles on it. Vehicle is being repaired under warranty but using the same parts.

The Axle bolts on both sides of the truck sheared off. The passenger rear axle bolt sheared at 15,000 miles into having the new truck. The driver side rear axle bolt sheared at 21,000 miles. This is a large safety concern and is not unique to just me. The first axle bolt sheared and was repaired once I figured out the problem at a Ford dealer. The second bolt is currently being repaired in the same dealer's service department. There was no warning or detection of this problem other than a rattling sound during acceleration and a wizzing sound during braking. I do not have either of the sheared axle bolts. They were kept by the dealer.

My truck has the Maximun payload axle upgrade. The axle bolts on the end of the shaft have broken. I first notice squealing sound of metal from rear of truck. I searched on line for the symptom and found the problem. I then removed passenger rear wheel to verify broken bolt. I took my truck for service to Morries Grand Ledge Ford in Michigan. They verified the problem, told me it was not safe to drive and have ordered parts. They also informed me that the defective axle is not covered by recall on my vehicle. The service representative did confirm that there are recalls for the same axle but not my vehicle.

There is a fairly common issue where there are bolts at the end of the rear axles (P/N 19S426) have the bolt head shearing off and rattling around inside the wheel. I had one such broken bolt. The issue is large enough that hundreds of owners are reporting this on Ford Truck forums, namely on the 2021 Ford F-150 Powerboost with the Max Tow Package like mine. Ford needs to recall this.

Wheel & Tire complaints in other F-150 Hybrid years