NHTSA complaint #11744012

Owner complaint summary

2020 Ford F-150 custom-built in Sept 2020 developed severe, textbook warning signs of rear-end failure while traveling—specifically severe low-speed metallic clanging and high-pitched whirring from the rear wheels. Recognizing the potential danger, we safely exited the highway and sought an immediate diagnostic from an independent shop. The diagnostic confirmed the defect mechanism detailed in NHTSA Campaign 23V896000: fractured axle hub bolts, disintegrated pinion gears, and metal shaving contamination throughout the 9.75-inch axle housing. While we avoided a high-speed highway shutdown by proactively seeking repairs, the underlying structural manufacturing defect is identical to the active recall. My truck's build date sits squarely inside the part production window specified by Ford in that campaign (starting Jan 28, 2020), but my VIN is excluded due to a generation cutoff. Note: We have retained the full replaced axle assembly fully intact and available for physical inspection by NHTSA investigators.