Multiple Issues: check engine light, door alignment, cab corner cover, door/window rattle, paint defect, vibration

[Groovicles]

I’ve had this 2024 King Ranch PowerBoost for a month, and it’s just under 5,000 miles. It was produced in late July 2024, as far as I know. This is my first truck and also the first new vehicle I’ve ever purchased. However, I can’t wrap my head around how Ford allowed this vehicle to pass quality control. It’s almost unbelievable that a $77K truck could have so many issues. The problems with this vehicle can’t just be chalked up to “Ford produces a lot of F-150s, so it’s normal for a few to have issues.” How does Ford let so many “occasional issues” occur on a single unit?

Here are the problems I’ve encountered so far. I’m still trying to work with the dealership, but based on past experiences, they seem unwilling to help. Any advice or recommendations would be appreciated. I’ve also included some fixes I’ve tried.

• Check Engine Light and Multiple Faults
  • This morning, I started the truck, and multiple fault warnings popped up, including:
    • "Antilock Brake Fault"
    • "Pre-Collision Assist Not Available"
    • "Hill Start Assist Warning"
    • "Check Engine Light"
  • After a few hours, only the Check Engine Light remained on. Has anyone else experienced similar issues?

• Fuses and relay were not fully seated from factory
  • All the fuses and relays in the engine bay weren’t fully seated from the factory. I had to check and push them into place myself, so make sure you inspect yours.
• Driver side rear door rubbing against cab and cab corner cover
  • The rear driver-side door rubs against the cab and the cab corner cover. This misalignment has caused paint to wear off in that area. From the outside, the body lines also don’t align properly.

• Windows/Doors Rattling on Uneven Surfaces
  • The driver-side window rattles whenever I go over uneven surfaces. The passenger side isn’t as bad, but there’s still some noise when accelerating or when gusts of wind hit at certain angles. The vertical window seal seems loose. I tried applying Tesa tape to prevent it from rubbing against the door frame, but it hasn’t completely fixed the issue.
  • the master window switch is choppy when closing the driver-side window. On the first click, the window moves only an inch or two before stopping, and I have to pull the switch repeatedly to fully close it. However, the one-touch up and down functions work fine. After pulling the switch up at windows close position seems to fix it though.
• Factory paint defect
  • The factory left dirt or slag on the body before painting the passenger-side rear door, resulting in multiple visible dots on the door.
    Additionally, the roof gutter lacks paint, exposing the primer color.
  • The roof gutter lacks paint, exposing the primer color

• Vibration above 70MPH
  • The gas pedal vibrates annoyingly while driving, and it doesn’t seem to be related to the wheels. It feels more like an NVH (Noise, Vibration, and Harshness) issue. However, the steering wheel and the entire truck shake noticeably above 70 mph, especially at 80 mph, which seems more like a tire balancing issue. This problem has been present since the truck was new. I tried increasing the tire pressure to 39 psi, but it hasn’t resolved the issue. Upon inspection, I noticed that the left front wheel has 15 pieces of 1/4 oz weights. Is this normal? It seems excessive, especially considering the other three wheels only have a few weights each.

​

The truck has some excellent design features and looks great, but the execution falls short in several areas. I’m heading to the dealership to address the door alignment issues and will try to have them resolve the other problems as well. Fingers crossed!

@Ford Motor Company here's a great chance to help out a customer

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[KingRanchW24]

And that is with Ford’s new zero defects campaign on the F-150 line. Imagine what the QC was like before they actually started trying?

All I can say is, if anyone is considering this truck, think twice. Don’t make the mistake I did by believing these issues are not widespread and normal.

 

[My 2ND Ford]

Inexcusable, warranty work is warranty work.

Your random electrical problems seem similar to low battery SOC (put it on a charger) -- these trucks do all kinds of random stuff w/ low batteries and it typically triggers immediately upon start and can have all symptoms disappear on subsequent starts.

Read the codes for the MIL

Yes warranty work is warranty work! It was explained to me by a Dodge dealer back in 97 that warranty work was his bread and butter! I have purchased vehicles at one dealer and had warranty work provided by another with no problems. But, as was also explained to me by an appliance dealer that sells high end stuff, think Sub-Zero fridges, that said he has to repair them even though they were not purchased from him, but he does not have to do it in a timely matter.
I'm sorry, did you purchase the truck here? No, then the earliest we can slot you in is 2-3 weeks. It's the way of the world now and there is nothing that can be done about it. A few unhappy customers with a defective product will accomplish nothing because there are thousands waiting to take their place.

 

[m_bt54]

@Ford Motor Company here's a great chance to help out a customer

Didn’t you hear the news? They’re gone

 

[Groovicles]

Didn’t you hear the news? They’re gone

Ha! Well shit

 

[frd024]

All I can say is, if anyone is considering this truck, think twice. Don’t make the mistake I did by believing these issues are not widespread and normal.

I feel your pain. I had a new truck in and out of the shop all year with various issues. I kept thinking they will finally get it all sorted out. That SOB is gone now and all the stress went with it.

 

[Lead Foot PowerBoost]

“The gas pedal vibrates annoyingly while driving, and it doesn’t seem to be related to the wheels. It feels more like an NVH (Noise, Vibration, and Harshness) issue.”

I recently bought a certified off lease ‘21 Powerboost. I also notice a lot of pedal vibration at engine/drivetrain frequency, not tire rotation frequency. Significantly more than my 2 other turbo 4 cars. I first noticed it after it stuttered and shook while creeping through a mall parking lot. I got some brief warnings on the dash. I wonder if something was jarred loose, like the tranny mount or something inside the tranny. Or maybe it was always there and I only noticed it after that one-time event. Anyway, let me know if you find anything out at, the dealer. I’m considering taking mine in for this.

 

[Old Hat]

I'm sorry you are having these issues, KR w24. I hope you are able to have them worked out.

 

[frd024]

 

[KingRanchW24]

I took my vehicle to Ford's body shop to address the issue. Unfortunately, their attempt to buff out the imperfections resulted in burning through the paint, leaving the door looking even worse. To make matters worse, they’re refusing to initiate a warranty claim, instead asking me to contact the original dealer and claiming the door has already been repainted once.

The level of frustration I’m experiencing is hard to put into words. I just want Ford to stand behind their product and make this right.

Does anyone have suggestions on how to push them to repaint the door under warranty?

 

[jhelrey]

There is another post here from Barry, hunt it down and start reading.

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