The agency’s Office of Defects Investigation (ODI) confirmed it has identified 329 incidents where transmissions unexpectedly shifted into first or second gear without warning. According to the federal report, these sudden downshifts cause rapid deceleration and, in several instances, have led to temporary rear-wheel lockup or skidding. This move follows a preliminary evaluation initiated in March, signaling that regulators require a deeper technical review of the popular pickup line.

Mechanical Failures and Safety Hazards

Beyond the risks at highway speeds, the ODI identified a secondary hazard involving sensor signal loss. Preliminary testing suggests that if a sensor signal is interrupted while the vehicle is reversing uphill, the transmission may inadvertently shift into neutral, causing the truck to roll forward unexpectedly. The engineering analysis will now focus on identifying the root cause of these shifts to determine if a full-scale recall is necessary for vehicles built between 2015 and 2017.

The NHTSA's expanded probe will include several critical phases:

• Component-level testing of the transmission control system.
• Extensive vehicle track testing to replicate the reported failures.
• An audit of Ford’s internal technical data and manufacturing records.

The investigation remains in the analysis phase, and the National Highway Traffic Safety Administration has not yet mandated a formal recall. However, the agency stated that the goal of the current testing is to better understand the alleged defects that lead to a loss of vehicle control, ensuring that any potential remedy addresses the full scope of the mechanical failure.