Some 2021-2025 F-150 vehicles may exhibit an "Active Air Dam System Fault See Manual" warning message displayed in the instrument panel cluster (IPC) and/or an AAD hanging/not retracting. This may be due to a broken AAD actuator to air dam bolt or bolts. If diagnostics lead to ADD actuator as the causal part, a new lower-level service bolt and u-nut are available. It is not necessary to replace the AAD actuator if only the bolt(s) are damaged.
full bulletin at NHTSA ↗2021 Ford F-150 body problems
moderate 18 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Complaints
18
Recalls
0
Avg fix
$1,500
What stands out
No new NHTSA body complaint has been filed on this vehicle in over 3 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how
full bulletin at NHTSA ↗Some 2021-2026 F-150 and 2024-2026 F-Super Duty vehicles equipped with one-touch up/down front windows may exhibit a window not responding to one-touch controls and/or bouncing back when using the one-touch close function.<br /> <br /> For vehicles included in Field Service Action (FSA) 25P35 and/or 26P02, perform repairs as directed by the FSA(s).<br /> <br /> For 2021-2026 vehicles not included in the FSA(s), reprogram the driver door module (DDM) and the passenger door module (PDM) using the latest software level of Ford Diagnosis and Repair System (FDRS) scan tool according to the Workshop Manual (WSM), Section 501-11 for normal diagnostics and testing direction by symptom. For claiming,
full bulletin at NHTSA ↗Some 2021-2026 F-150 and 2024-2026 F-Super Duty vehicles equipped with one-touch up/down front windows may exhibit a window not responding to one-touch controls and/or bouncing back when using the one-touch close function.<br /> <br /> For vehicles included in Field Service Action (FSA) 25P35 and/or 26P02, perform repairs as directed by the FSA(s).<br /> <br /> For 2021-2026 vehicles not included in the FSA(s), reprogram the driver door module (DDM) and the passenger door module (PDM) using the latest software level of Ford Diagnosis and Repair System (FDRS) scan tool according to the Workshop Manual (WSM), Section 501-11 for normal diagnostics and testing direction by symptom. For claiming,
full bulletin at NHTSA ↗Some of the vehicles listed in the Model statement above equipped with one-touch up/down front windows may exhibit a window not responding to one-touch controls and/or bouncing back when using the one-touch close function.<br /><br /> For vehicles effected by Field Service Action (FSA) 25P35, perform repairs as directed by the FSA.<br /><br /> For 2021-2026 vehicles, update the driver door module (DDM) and the passenger door module (PDM) using the latest software level of Ford Diagnosis and Repair System (FDRS) scan tool. Refer to the Workshop Manual (WSM), Section 501-11 for normal diagnostics and repair direction by symptom. For claiming, use causal part 14B291 and service labor operations
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Cold-weather door latch failure dominates these 18 complaints. In temperatures below 10–25°F, front door locks and latches malfunction on multiple 2021 F-150s. Owners cannot unlock doors using key, key fob, or interior buttons; simultaneously, doors may swing open uncontrollably while driving or fall open when parked. One dealer confirmed this is a known problem with no repair available. Ford has recalled similar defects on other F-150 model years, yet this vehicle goes unrecalled. A Ford TSB (SSM50543) exists but provides no solution. Owners describe the hazard as critical—they cannot exit the driver's side in an emergency and must use the passenger door, squeezing over the center console.
Beyond the latch issue, owners report hood bolts loosening or missing at low mileage, an active air dam that jams and risks falling off, interior door handles freezing separately from the latch, and a sunroof that spontaneously shattered. Paint chipping, window glass failure, peeling dashboard padding, and stuck side step rails round out the body complaints. The cold-weather latch problem appears systematic, recurring across multiple vehicles and warranting serious consideration before purchase.
Same Ford F-150 body reports on nearby years: 2018 · 2019 · 2020
Failure modes owners describe
Door latch and lock mechanism freezing in cold weather
In temperatures below 25–10°F, the door latch and locking actuators become inoperable. Doors may fail to lock, fail to unlock, or fall open during driving. Owners report the lock pin at the top of the door frame stays down; manual key, key fob, handle buttons, and electric locks do nothing. The moving parts of the actuator are not frozen and there is no water in the system, yet the mechanism refuses to engage. The issue resolves when the vehicle warms up or outdoor temperature rises above freezing. A Ford dealer has indicated this is a 'known problem' with no known repair.
When: Below 10–25°F; first occurs in winter; reproducible in cold weather
Symptoms owners cite: Door will not unlock using manual key, key fob, or interior/exterior handle buttons; Door will not lock or stays locked; Door swings open while driving or falls open when parked; Lock actuator does not engage clamp/pin mechanism; Owner must exit through alternate door or climb out window; Once door opens, it will not latch securely
Repairs/costs cited: Dealer states no known repair available. One owner references Ford TSB SSM50543.
Recalls/TSBs owners mention: Ford has issued recalls for similar door latch freezing defects on other F-150 model years; this vehicle not included. Ford TSB SSM50543 issued.
Hood latch failure and loose hood hardware
Two separate incidents: one owner reported the hood unlocked while driving at highway speed, caught by the safety latch. Another owner found hood bolts loose or missing at 8,000 miles, diagnosed at dealer as missing latches and bolts. One complaint included a 'hood unsafe' dash message.
When: First incident at unknown mileage; second at 8,000 miles
Symptoms owners cite: Hood unlocked while driving at 70 mph; Hood vibrating at highway speed; Hood bolts loose or missing; Hood unsafe message on dashboard
Repairs/costs cited: One owner's vehicle was repaired by local dealer (bolts and latches replaced).
Recalls/TSBs owners mention: Manufacturer was notified in at least one case.
Active air dam malfunction and loose attachment
The top stationary piece of the active air dam becomes lodged inside the bottom retractable part during opening and closing cycles. The component is becoming weaker and loosely attached to the vehicle. Owner expresses concern it could fall off while driving and strike another vehicle.
When: Occurs during normal opening/closing cycles; multiple incidents reported
Symptoms owners cite: Top stationary piece lodges inside bottom retractable part; Component becomes weaker and loosely attached; Potential for complete detachment from vehicle
Repairs/costs cited: Dealer service advisor mentioned a TSB was submitted but did not follow up with owner.
Recalls/TSBs owners mention: TSB referenced but not formally named in complaint.
Interior door handle freezing (driver's side)
In freezing temperatures below 25°F, the interior door handle freezes and will not engage the door latch. The door will not stay latched until the cabin warms up. One owner reports running boards deploy every time the vehicle comes to a stop in these conditions.
When: Below 25°F; reproducible in winter
Symptoms owners cite: Interior door handle freezes and will not engage latch; Door will not stay latched; Running boards deploy unintentionally at every stop
Panoramic sunroof exploded
Sunroof glass exploded while vehicle was parked or stationary on a country highway. No other vehicles, debris, or apparent cause noted.
When: On country highway during normal operation
Symptoms owners cite: Sunroof glass spontaneously shattered
Rear passenger window shattered
Rear passenger window shattered when owner's niece opened the door. Window pane was held together by aftermarket window tint and fell under vehicle.
When: During normal door opening
Symptoms owners cite: Window glass shattered on door opening; Glass pane held together only by aftermarket tint
Astro white exterior paint chipping
Astro white paint is chipping in multiple locations on the roof: severe chipping above windshield, at the roof line, above both rear doors. Owner reports this is not due to accident or normal wear and tear.
When: Early in vehicle life; not accident-related
Symptoms owners cite: Paint chipping on roof above windshield; Paint chipping at roof-to-side transitions; Paint chipping above rear doors
Side step rails stuck in deployed position
The side rails that deploy when the door opens are stuck in the open/deployed position. Owner must drive with the rails hanging down, creating a hazard.
When: After becoming stuck; timing unclear
Symptoms owners cite: Side rails deploy and will not retract; Rails hang down while vehicle is being driven
Dashboard pad peeling and separating
The dash pad in front of the steering wheel is coming apart and peeling back. Owner suspects defective installation, poor material, or inadequate adhesive.
When: Early in vehicle ownership; no specific mileage given
Symptoms owners cite: Dash pad peeling back from dashboard; Separation of dash pad from substrate
Synthesized from 18 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
EXTREMELY DANGEROUS DOOR CLOSING FAILURE. Both front door lock actuators malfunction below 10 degrees Fahrenheit. Rear doors of the crew cab are unaffected. The moving parts of the mechanism are not frozen and there is no water in the system. The lock actuator will not engage the clamp/pin mechanism to hold the door closed, even though the movable parts are freely moving. this happens whenever…
Had body trouble with your 2021 Ford F-150?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the body problem on the 2021 Ford F-150?
It's a documented issue but not catastrophic. 18 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Based on the 18 complaints filed, body issues most often appear around 8,000 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,500 for body repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to body?
No active recalls currently cover body issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2021/Ford/F-150.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.