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2021 F150 Powerboost massive electrical gremlins - dealers are USELESS

axial_pro

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Good day all,

My stepdad has a 2021 F150 Powerboost that he and my mom purchased to tow their camping trailer. The comfort, powertrain, and electrical capabilities of the truck ticked all of the boxes and, overall, he still loves the truck. It was a built-to-order vehicle that they patiently waited many months to receive.

While the truck currently the truck has 44,000km, almost since the outset, there have been all sorts of electrical issues with the vehicle: The running boards pop in and out seemingly at random, the trailer will sometimes show as disconnected, the infotainment screen sometimes goes black and unresponsive, sometimes he can unlock it and sometimes not, the ProPower onboard sometimes turns itself on and won't turn off (or vice versa), there are seatbelt warnings when no passengers are in the seats.

The selling dealer had the truck for months at a time in an effort to replicate and diagnose the problems. Every time they handed the truck back claiming that "everything was fixed", the original problems remained. Once, upon pickup, the very problems that they claimed to have fixed didn't allow my stepdad to start the vehicle in their parking lot to leave!

After dozens of visits to this Newmarket, Ontario Ford dealer that produced no solid progress, my stepdad was instructed to take the vehicle to Barrie Ford as they, allegedly, had a more competent service department. They are friendly and professional but have also been unable to remedy any of the ongoing issues. Almost two years into ownership, the dealers have had the truck for over 6 months and have made ZERO progress on fixing anything in a permanent way.

My mom and stepdad have recorded reams of video demonstrating the problems (as the dealers said the problems could not be replicated and, therefore, did not exist). There are mountains of documents, photos, emails, service orders and more on record. Ford corporate has not been particularly helpful in resolving this or trying to make our family whole.

Is anyone else experiencing similar electrical gremlins? At this point, this truck has NEVER actually been fully functional and there seems to be no possibility of it ever working. What could we do for a full resolution?

I feel partially to blame as I was the one who brought this truck to their attention when they were shopping as the Pro Power Onboard setup seemed a brilliant setup for their camping needs and the truck promised cost-efficient daily operation thanks to the hybrid setup. I would be an amazing vehicle...if it actually worked.

I'd love to hear the thoughts of the community here and perhaps some ideas that may point us to a fix.
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Gros Ventre

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My experience, in the world of submarines, says there's one or more (likely more) plugs/connectors that is/are loose. You might see if you can entice the dealer to have a tech go around and seat/reseat every plug in the truck. I learned in the world of electronics on ships that when you get intermittent "gremlins" it is likely a plug or connector of some kind that is loose and making intermittent contact with the truck's motion over bumps...
 

Gros Ventre

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Another thought... It is possible that heat stress on a component somewhere has caught up with you. I suspect this is less likely but you might think about their travels... Did they visit Death Valley along the way? Maybe sit in the sun for a day or two down there...? I view heat stress as unlikely but it does happen on the odd component. The way you figure this out is swapping out component by component... until it goes away... Your dealer won't like that approach.
 
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axial_pro

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Another thought... It is possible that heat stress on a component somewhere has caught up with you. I suspect this is less likely but you might think about their travels... Did they visit Death Valley along the way? Maybe sit in the sun for a day or two down there...? I view heat stress as unlikely but it does happen on the odd component. The way you figure this out is swapping out component by component... until it goes away... Your dealer won't like that approach.
Not likely to be heat stress related as Canada has pretty moderate summers (generally). In addition, problems started popping up before summer even hit and the vehicle had not really been heat cycled yet.
 

Popplemer

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I second checking for loose wiring harness connections and will suggest checking for loose or bad grounds.
 

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air2mag

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Are the PBs subject to the same battery issues us ICE guys are?
 

nitrobass24

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1. Do you have lemon laws in Canda? Might be worth a discussion with an an attorney.
2. Go back to the selling dealer and make them make you an insane deal on a trade-in. Threaten a law-suit if you need to.
 

Northguy

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1. Do you have lemon laws in Canda? Might be worth a discussion with an an attorney.
2. Go back to the selling dealer and make them make you an insane deal on a trade-in. Threaten a law-suit if you need to.
Unfortunately no lemon law in Canada though Quebec is looking to make one - will be first in Canada. Lemon laws would be very useful in OPs case. While these things are rare (thankfully) it is very real for OPs family and they should have an option to force the dealer to take it back.
 

nitrobass24

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Light truck on fire. Obviously it was an electrical fire accelerated by litihium batteries and a full tank of fuel. Collect insurance money.
 

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Snakebitten

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It's a 1.5 KW battery.
It would not be part of your dubious equation.
 

WhiteLightningnshitshadow

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I don't fully understand the scope of the issues from the post, but could be connections, ground, or software which I'm leaning towards. More details? What version update?

Frankly, this braintrust is better than 80% of the ford shops out there.

@Gros, was that rotten Groton? I was in Newport News Shipbuilding for a hot second myself.
 

Gros Ventre

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I don't fully understand the scope of the issues from the post, but could be connections, ground, or software which I'm leaning towards. More details? What version update?

Frankly, this braintrust is better than 80% of the ford shops out there.

@Gros, was that rotten Groton? I was in Newport News Shipbuilding for a hot second myself.
Rotten groton... been there, done that... but more time in Norfolk & Charleston...
 

EricR

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Are the PBs subject to the same battery issues us ICE guys are?
YES! If not more so.

@axial_pro , try installing a new 12V battery. The one under the hood.

It seems Ford has had quite a few batteries that test OK at the dealer, but are in fact bad.
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