Most Common Issues with 4th Generation Ford F-150 (2021-Present)

The fourth-generation Ford F-150, launched in 2021, brought an all-new aluminum-intensive body, a vastly updated interior, the revolutionary Pro Power Onboard generator, PowerBoost hybrid option, and class-leading tech features. While the truck has been a sales juggernaut and earned numerous awards, real-world ownership has revealed several recurring problems that current and prospective owners should know about.

Cam Phaser Rattle on 5.0L Coyote V8

One of the most discussed issues across owner forums, Reddit, and NHTSA complaints is the infamous cam phaser rattle on the 5.0L Ti-VCT V8 engine. The noise appears as a loud diesel-like clatter for 1–3 seconds on cold start and sometimes on hot restart. Ford has revised the cam phasers multiple times, with the latest "D" and "E" revision parts introduced in late builds and as service replacements. Many owners report the rattle returns even after the updated phasers are installed. In severe cases, failed phasers have caused complete engine damage requiring full long-block replacement under warranty.

3.5L EcoBoost Oil Consumption and Turbo Failures

The carry-over 3.5L EcoBoost continues to suffer from excessive oil consumption in some units, especially those built before mid-2022. Consumption rates of 1 quart every 1,000–2,000 miles are frequently reported. Carbon buildup on intake valves remains an issue despite the addition of port injection alongside direct injection. Turbocharger wastegate rattle and outright turbo failure (often the passenger-side turbo) have also been widely documented, with some owners needing turbo replacement before 50,000 miles.

PowerBoost Hybrid Battery Cooling Problems

The 3.5L PowerBoost full-hybrid powertrain introduced a 7.2 kW or 2.4 kW Pro Power Onboard and impressive fuel economy, but the high-voltage battery cooling system has proven problematic. The battery coolant pump frequently fails, triggering "Stop Safely Now" warnings and placing the truck into limp mode. Ford issued a recall (23S58) for coolant pump wiring chafing, but many owners report repeat failures even after the recall repair. Some trucks have had the entire hybrid battery pack replaced under warranty.

10-Speed 10R80 Transmission Harsh Shifting and Jerking

The 10R80 10-speed automatic continues to exhibit harsh 1-2, 2-3 and 3-4 harsh upshifts and downshifts, especially when cold. Ford has released multiple TCM calibrations and CDF drum revisions, but complaints persist on 2021–2024 models. A smaller number of owners report sudden neutral-outs or complete transmission failure requiring full replacement before 60,000 miles.

Pro Power Onboard 2.4 kW and 7.2 kW Outlet Malfunctions

The groundbreaking Pro Power Onboard system is a frequent source of frustration. The 120V/20A bed outlets and 240V/30A outlet often trip GFCI prematurely or stop working entirely. Many owners trace the problem to water intrusion into the inverter or loose harness connections behind the cab. Ford has revised the inverter module several times and extended warranty coverage to 8 years/100,000 miles on certain components, but field fixes are hit-or-miss.

Panoramic Moonroof Explosions and Leaks

Spontaneous moonroof glass explosion (tempered glass shattering outward while driving) has been reported dozens of times to NHTSA. Water leaks around the moonroof seals and interior headliner staining are also common, especially on trucks equipped with the twin-panel panorama roof. Drain tubes clog easily, leading to water pooling inside the cab during heavy rain.

IWE (Integrated Wheel End) Vacuum System Failures

The 4x4 system’s vacuum-operated IWE actuators frequently fail, causing grinding noises when in 2WD or failure to engage/disengage 4WD properly. The check valves and vacuum solenoids on the firewall are prone to cracking, and vacuum lines under the hood chafe against brackets. Many owners perform the popular "IWE delete" with manual hubs or permanent 4WD engagement kits to eliminate the problem permanently.

12-inch SYNC 4 Screen Delamination and Ghost Touch

The massive 12-inch vertical touchscreen suffers from screen delamination (bubbles under the glass) and ghost touch issues. Ford extended warranty coverage on the APIM (Accessory Protocol Interface Module) to 8 years/100,000 miles for delamination, but replacement screens often develop the same problem within months.

Tailgate Randomly Opening

Numerous owners report the electronic tailgate releasing and dropping open while driving or parked. The cause is usually a faulty tailgate release switch in the handle or water intrusion into the tailgate wiring harness. Ford has superseded the tailgate ajar switch and added shielding, but the issue continues on newer builds.

Front Camera Washer and BlueCruise Hands-Free Issues

The front camera washer jet (part of Max Recline Seats package) often leaks washer fluid into the headliner and windshield pillar, causing interior water damage. BlueCruise hands-free highway driving regularly disengages unexpectedly due to lane marking detection problems, sun glare, or minor windshield imperfections. Multiple over-the-air updates have improved reliability but not eliminated complaints.

Brake Master Cylinder Premature Failure

A rising number of to failures have been documented, with the brake pedal sinking to the floor and triggering ABS/DSC warnings. Ford issued SSM 51253 acknowledging low brake pedal or spongy feel on some builds and recommends master cylinder replacement.

Rear Window Defroster Tab Detachment and Leakage

The sliding power rear window defroster tabs frequently detach from the glass, rendering the defroster inoperative. The top seal of the power slider also leaks in heavy rain, dripping water onto the rear seat or package tray.

Zone Lighting and Exterior LED Light Condensation

The 360-degree Zone Lighting feature often stops working due to water intrusion into the body control module or individual LED modules. Heavy condensation inside headlight, taillight and mirror turn-signal assemblies is extremely common and considered "normal" by Ford unless actual water droplets are present.

Despite these issues, the majority of fourth-gen F-150 owners report high satisfaction when major components remain trouble-free. Most problems are covered under the 5-year/60,000-mile powertrain warranty or specific extended coverage programs Ford has quietly implemented. Pre-purchase inspection by a trusted technician and reviewing the truck’s Ford Oasis report for completed recalls and field service actions is strongly recommended.