27 of the
466 complaints filed about the Ford Maverick
are about the body and structure —
6% of everything owners reported.
The worst model year for it is 2022.
The driver's side (left front) door failed at the check-arm attachment point inside the door assembly: the spot welds securing the check-arm reinforcement bracket to the inner door structure cracked and separated. The vehicle is a commercial fleet 2022 Ford Maverick XL SuperCrew with approx. 82,000 miles. The vehicle and failed component are available for inspection upon request. First symptoms were difficulty opening and closing the door with popping/cracking noises. No warning lamps or messages occurred; the failure is concealed inside the door. This is a safety risk because the check arm attachment supports the door's structure. The same weld separation on related vehicles has been documented by NHTSA (investigation PE23-013) to cause doors that fail to latch, fail to stay closed, or open while driving, risking occupant ejection and injury. The failure was confirmed 7/17/2026 by Grapevine Collision Center (Grapevine, TX) after a Ford dealership stated there is no recall or warranty coverage for the Maverick and referred me there. The shop diagnosed broken check-arm welds and quoted $2,602.46 for a door shell replacement, noting it has seen this identical failure on Ford Escapes and Lincoln Corsairs. Not inspected by Ford, police, or insurance. This is the same failure mode NHTSA investigated on 2020-2021 Escapes (PE23-013), which Ford addressed via Customer Satisfaction Program 23B56 covering 2020-2023 Escapes. The Maverick shares the same C2 platform and door design but is excluded, leaving owners to pay out of pocket for a defect Ford repairs free on sibling vehicles.
NHTSA complaint #11751291 — an unverified report by a vehicle owner.
Driver side door check hinge, rivets that hold the door hinge will break off. Door rivet panel will prevent the window to go down or up. The check hinge will break off during normal closing and opening of door.
NHTSA complaint #11736222 — an unverified report by a vehicle owner.
The contact owns a 2023 FORD Maverick. The contact stated he noticed a odd sound from the driver side door when closing and opening, the winch on the driver side door is loose and scraping the inside of the door frame. The vehicle was taken to a dealer where it was diagnosed it to need a new driver side door. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 83,000.
NHTSA complaint #11736106 — an unverified report by a vehicle owner.
The passenger side floor is soaking wet every time it rains. Google says this is a defect with the windshield cowl, which other owners say is a common problem. Our safety is at risk with potential for mold, rust, and water intrusion into the electrical system. The truck is going to the dealership on Monday to have this issue addressed. It has been reproduced every time it rains. It has not been inspected by anyone other than myself. There were no warnings or alerts. We've noticed the wet carpet a couple times and researched the problem.
NHTSA complaint #11728937 — an unverified report by a vehicle owner.
The vehicle was at the dealer for a loud noise on the hinge area of the driver side door. I was contacted by the dealer and told That the door has cracked spot welds and needs to be replaced. The dealer contacted Ford and for opening offered to pay for a portion of the repair leaving me with over $1000 dollars out of pocket.This is a common problem with this vehicle and the Ford escape see Ford TSB 2356B. The vehicle is still under warranty but this is a defective item and should be covered 100% by Ford.
NHTSA complaint #11728328 — an unverified report by a vehicle owner.
Driver side door limiter welds broke loose. Ford said they had to replace the entire door and it was not covered by warranty. The dealer said that this happened to a bunch of Ford Escapes, but they did not have a recall for the Maverick yet.
NHTSA complaint #11723780 — an unverified report by a vehicle owner.
Door check has failed in the frame. The spot welds have broken in similar fashion to the Ford Customer Satisfaction Program 23B56 on the Escapes. There are popping noises, creaking, alignment issues, and prevents the window from rolling down.
NHTSA complaint #11697075 — an unverified report by a vehicle owner.
Vehicle drivers front door is very hard to operate, very hard to shut, window wont roll all the way down. Vehicle makes popping noise when operating drivers front door. Door wont close all the way at times due to door check binding inside of door. Ford has had a customer satisfaction service repair for Escape model vehicles with similar problems. Ford reference for this action is 23B56. Due to the door not being able to close properly this vehicle will require repair and the vehicle taken out of service because it is not safe to drive with the door not latching properly. The spot welds are broken away from the door causing the door check and mounting bracket to be pushed into the door when closing, this causes the door to not be properly latched.
NHTSA complaint #11691841 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford Maverick. The contact stated while the door was closed, the window failed to roll down; however, upon opening the door, the window was able to be rolled up. A dealer was contacted. The vehicle was taken to the dealer where it was determined that door needed to be replaced. The vehicle was not repaired. The contact related the failure to a Customer Satisfaction Program: 23B56 (Inspect front door check-arm reinforcement spot welds); however, the VIN was not included in the CSP. The vehicle was repaired. The manufacturer was notified of the failure, and the contact was informed that there were no recalls on the VIN related to the failure. The failure mileage was 27,000.
NHTSA complaint #11682402 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford Maverick. The contact stated that while opening the front driver's side door, there was an abnormally loud creaking sound coming from the door. The contact stated that the sound became louder over time. There were fractures around the door frame, causing the sound. As a result of the failure, the contact stated that the front, driver side door window would only roll down at approximately an inch. The vehicle was taken to the dealer to be diagnosed; however, the contact was not informed which part needed to be replaced. The dealer stated that a door panel kit was to be sent to the dealer for the repair. The vehicle was not repaired. The manufacturer was informed of the failure and opened a case. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 72,000.
NHTSA complaint #11676224 — an unverified report by a vehicle owner.
Door check spot welds broke. Door has unsafe operation. Will not hold open, and swings wildly. No inspection yet. Ford Dealer aware of problem. 2 month out of warranty.
NHTSA complaint #11663661 — an unverified report by a vehicle owner.
Water intrusion on front passenger side of vehicle causing mold. Vehicle still has original windshield and all original carpet and interior. Ford Service department unable to do “leak detection at facility” but referenced several online sources believing it is a defective cowl or a/c part that is not sealed. Service department dried vehicle out for 3-4 days and water intrusion is still happening and mold came back.
NHTSA complaint #11661588 — an unverified report by a vehicle owner.
Ford provides a spare tire with their 2024 Maverick pickup truck, but does not provide a safe way to transport a damaged tire after performing a tire change. Ford's Owner's Manual for the Maverick shows on page 363 how the damaged tire is to be secured in the bed of the truck using the provided strap tied diagonally to one of the D-rings at the front of the bed and one of the cleats at the rear. Both tie down points for the strap are low enough in the bed to create a vertical force on the damaged tire and hold it down on the bed. Ford has not equipped the base model, known as Maverick XL, with the two D-rings shown in the manual. The only alternative tie down point at the front corners is a pair of cleats that are too high on the bed wall to put a vertical force on the tire. (These other cleats are shown in their Flex Bed diagram.) If attempted, the tire would be held down only by gravity and likely become a dangerous projectile. It would also be inadvisable to stow the damaged tire under the truck bed taking the place where the spare had been stored. If attempted, a damaged tire could have treads or steel cords hanging from it, which could either come in contact with a hot exhaust system or the cords could drag on the road and potentially spark a wildfire the way tow chains sometimes do. Ford's engineers have, in my opinion, designated in its Maverick Owner's Manual the only safe way to stow a damaged tire after using the Maverick's spare tire for an emergency tire change. Ford has provided the strap to secure the tire, but has not equipped all trim levels of the Maverick with the D-rings. Ford needs to provide Maverick XL owners with the two missing D-rings as well as the fasteners to mount them on the truck bed. It may also need to provide the correct size tapping tool if the existing holes were not threaded at the factory. This would remedy the inability to safely carry a damaged tire and also align with Owner's Manual instructions.
NHTSA complaint #11656563 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford Maverick. The contact stated upon opening the front driver's side door, the door made an abnormal cracking and popping sound. The vehicle was taken to the dealer, where it was determined that the door hinge or the entire door might need to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 57,000.
NHTSA complaint #11635931 — an unverified report by a vehicle owner.
I was involved in an accident. During the accident none of the airbags deployed. The impact was so hard that it lifted the truck up off the ground and spinned us around 90 degrees. This resulted in the individuals seated on the passenger side of the truck to be thrown into the door fairly hard, with one passenger hitting her head on the window even with the seatbelt on. The point of impact was the drivers side back tire and bumper area.
NHTSA complaint #11619483 — an unverified report by a vehicle owner.