2022 Ford Maverick Hybrid Fuel System Problems

Owner reports

Selected complaints filed with NHTSA by 2022 Ford Maverick Hybrid owners, lightly cleaned up (personal details are redacted by NHTSA).

This has been a recall issue since I initially bought the vehicle brand new. I am active duty military and need this truck shipped to my next duty station and the shipping partner stated it won't ship cars that need recalls. Currently there is no planned action for this recall yet and it's estimated time for repairs states October 2023. It is now coming into the middle of November 2023 and no fix as of yet. Per Ford Motor Company: Manufacturer Recall Number23S27 NHTSA Recall Number23V380 Recall StatusRecall Incomplete, remedy not yet available Summary ON YOUR VEHICLE, THE ENGINE COULD FAIL PREMATURELY. IN THE EVENT OF AN ENGINE FAILURE, SIGNIFICANT QUANTITIES OF ENGINE OIL AND/OR FUEL VAPOR MAY BE RELEASED INTO THE UNDER HOOD ENVIRONMENT AND MAY MIGRATE TO AND/OR ACCUMULATE NEAR IGNITION SOURCES. …

Fuel tank failure at 18,000 miles and less than 3 years of ownership. I noticed that the vehicle had a strong gasoline smell when I was around it. When looking under the truck, I could see that there was a fuel leak coming from the fill pipe inlet into the fuel tank itself. Took the vehicle under warranty to the ford dealer, and was told that the hose clamp was loose connecting the fill pipe into the fuel tank itself. Was sent on my way with the vehicle, and noticed a smell of gasoline and fuel not even two months later. Took it back to the dealer and was told that they were unable to replicate it. Once the weather got cold again, took the vehicle back after noticing a much larger leak and smelling fuel, and am now being told by ford that the fuel tank does in fact need to be replaced as the tank is leaking from the fill pipe inlet. …

Just recently I've noticed that when the engine is running and I'm stopped or parked the truck will "lurch". Almost as if I'm trying to hit the gas while parked or holding the brakes. Since this has started, I've also noticed that from 25mph to 60/65mph there is a violent vibration ONLY under acceleration (20-25% on the power meter) while the engine is running. Issue worsens depending on the mode the truck is in (worse under sport, better under ECO/Slippery). Whole truck will shake, body, steering wheel and all. Not sure if these two issues are related? I'm not sure if these are considered to be powertrain or if it's the engine. Not sure if I could have it inspected upon request because I can't pin point any mechanical abnormalities visually. I feel my safety and others may be a concern because the unknown of the issue. …

Car would not accelerate under full power. When I fully depressed the gas pedal, the power meter (hybrid gauge instead of rpm) would only go up to 45%, the engine sounded like it was revving high but the car barely made any power. After a few minutes of this happening I got a message in my instrument cluster to immediately stop the vechicle, along with a red triangle with exclamation point dash light, at which point the car lost power, and started decelerating rapidly (as if in full regeneration mode (electric braking)) in the middle of the highway. I barely had enough time to get over 2 lanes of traffic and stop on the shoulder. …

Car stopped moving although still on, then had many flashing warnings. the "D" on the drive knob was flashing. Turned the car off and on a few times and eventually gor it moving then it tried to engage in its own determined speed! I only had a mile to get home so made it home with out it stopping again. The errors codes ( Vehicle alert) showing on my "Ford" app are: 1.precollison assist not available 2.Powertrain malfunction/reduded power 3.service engine soon(the engine has detected a fault) there were others while this was first happening but i was overwhelmed with fear and don't remember The car is at the local Ford Dealer and they have yet to find the problem I see on some online sites others having this same issue - it appears that it after a recall which i have had a few fixed This is so terrifying and if I had been going 75 on the frwy I was headed to it could have been deadly...

I experienced a loss of engine power/propulsion at 71 mph. There were no warning lights, messages or chimes to indicate something was wrong. I only noticed I was losing speed when the cruise control went to the standby/cancelled state from the 71 mph set point. The accelerator pedal was completely unresponsive. I coasted to the side of the freeway and performed a key cycle by powering the vehicle off, opening and closing the driver's door to put the modules to sleep. Once the instrument panel cluster and center stack screens went dark, I restarted the vehicle and was able to proceed with my trip. It's worth noting that I recently had the instrument panel recall repair performed which was a reflash of the IPC module. Other Maverick drivers have reported similar incidents after Ford 24C01/NHTSA 24V140 was "fixed." I will be reporting this to the manufacturer as well.

Under rapid acceleration requiring over 50% of the engine's power, the computer system detects a "fault" and shuts down the engine. This has occurred five times in the last 4 months while attempting to merge onto freeways, interstates, and local roads. In every instance, the engine shut-down cause oncoming vehicles to rapidly slow down in order to not hit my vehicle and I had to pull off to the side of the road to let the computer system "reset" in order to continue my travels. The problem was brought to the attention of the local Ford dealer twice (will be going back based on recent occurrence of March 5, 2023 ). There were no warning lamps, messages, or other systems prior to the problem occurring. This problem has occurred on December 8, 2022; December 12, 2022; December 23, 2022; March 2, 2023; and March 5, 2023.

1)After sitting for 2 days the battery was drained or dead. The truck would not start. I jumped the truck and it started up. Every time I park the truck i get a warning that the battery is low and I should drive it to recharge the battery. I drive the truck but it will not recharge. 2) The check engine light comes on. I went to the auto parts and scanned for diagnostics. The scan came back as a fuel tank pressure sensor failure. 3) When I drive the truck it smells as if something is burning. 4) The fuel gage is not showing accurate reading. 5)The fuel door wont open unless I have the truck turned on and then it takes several minutes. 6) After driving on the freeway I came to a stop on the off rap before entering a main street and the truck died.

On April 22, 2024 my truck had a loss of power foe the second time while driving on the interstate with my family. There was no warnings or anything, the truck simply lost power and I had to pull off the road at which point it went into limp mode. I had several lights on my dash, Mai ly the check engine light and my mobile app recorded a fault with the drive train. This is now the second time this has happened in a few months. I have taken it to the dealer both times and they've told me that nothing is wrong with my truck. I explained that it is extremely dangerous but they said they can't do anything because the truck isn't reporting any issues. Please put pressure on ford to fix this. It is getting out of control.

While driving at approximately 40mph, the 2022 Ford Maverick Hybrid suddenly went into "Limp Mode" with speed instantly dropping to approximately 10mph. Did not lose power, the dashboard stayed lit but showed no warnings. Vehicle would not accelerate above 10mph. This happened without warning. I pulled over and shut off the vehicle then restarted it and after that, it operated fine. If I had been driving on a highway at a higher speed I could have had a major accident. Currently trying to get a service appointment, waiting on a call back from the Ford dealer Service Manager. Again, there were no warnings or error messages before or after the problem occurred.

Fuel System complaints in other Maverick Hybrid years