NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
344 reportsClear category filter38,500 miles · Jul 13, 2017
Unknown Or Other
WHEN I AM DRIVING IN MOTION ON ANY TYPE OF ROAD AND I ACCELERATE I GET AN EXHAUST ROTTEN EGG SMELL INSIDE MY VEHICLE, I CALLED THE DEALER ABOUT IT, THEY ACKNOWLEDGED THERE IS A TSB AND PROBLEM BUT WOULDN'T FIX IT BECAUSE MY MILEAGE IS PAST WARRANTY COVERAGE. THEY TOLD ME IT WOULD COST ME ABOUT $2,000 OUT OF MY POCKET TO REPAIR. …
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WHEN I AM DRIVING IN MOTION ON ANY TYPE OF ROAD AND I ACCELERATE I GET AN EXHAUST ROTTEN EGG SMELL INSIDE MY VEHICLE, I CALLED THE DEALER ABOUT IT, THEY ACKNOWLEDGED THERE IS A TSB AND PROBLEM BUT WOULDN'T FIX IT BECAUSE MY MILEAGE IS PAST WARRANTY COVERAGE. THEY TOLD ME IT WOULD COST ME ABOUT $2,000 OUT OF MY POCKET TO REPAIR. I DON'T HAVE THE MONEY TO REPAIR IT OR BUY ANOTHER VEHICLE BEING ON SOCIAL SECURITY. FORD NEEDS TO RECALL THIS VEHICLE AND REPAIR IT, BUT THEY REFUSE, VERY SAD HOW THEY CAN GET AWAY WITH THIS FLAW AT THE COST OF SMALL CONSUMERS! AFTER READING ON HE INTERNET ABOUT THE HIS, I'M SURE THERE ARE THOUSANDS WITH THIS PROBLEM! THE US GOVERNMENT NEEDS TO STEP IN AND HELP US WITH THIS!
NHTSA ODI #11004987
76,000 miles · Jul 12, 2017
Unknown Or Other
PERIODICALLY WHEN DRIVING AND OR STOPPED OR SLOWING DOWN AT AN INTERSECTION I SMELL GAS OR FUMES OR WHAT MAY BE CARBON MONOXIDE. I NOTICE IT THE MOST WHEN DRIVING FOR A LONGER DISTANCE, LIKE MORE THAN 30 MINS. THIS HAS HAPPENED MULTIPLE TIMES OVER THE LAST 2 YEARS THE DATE LISTED BELOW WAS JUST THE LAST TIME I NOTICED IT. IT…
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PERIODICALLY WHEN DRIVING AND OR STOPPED OR SLOWING DOWN AT AN INTERSECTION I SMELL GAS OR FUMES OR WHAT MAY BE CARBON MONOXIDE. I NOTICE IT THE MOST WHEN DRIVING FOR A LONGER DISTANCE, LIKE MORE THAN 30 MINS. THIS HAS HAPPENED MULTIPLE TIMES OVER THE LAST 2 YEARS THE DATE LISTED BELOW WAS JUST THE LAST TIME I NOTICED IT. IT MAKES ME AND FAMILY SICK TO OUR STOMACH AND INSTANTLY HAVE HEADACHES. I HAVE TAKEN THE CAR IN TWICE TO WHERE I PURCHASED IT AND THEY CANT SEEM TO FIND ANYTHING WRONG. PURCHASED CAR FROM CARMAX ON 1/17/15.
NHTSA ODI #11004965
70,000 miles · Jun 7, 2017
Unknown Or Other
FRONT MOULDING AROUND WINDSHIELD ON BOTH SIDES CAME FLYING OFF THE CAR ON THE HIGHWAY. VERY DANGEROUS POTENTIAL ROAD HAZARD TO ALL DRIVERS ON THE ROAD. THERE ARE DOZENS OF DOCUMENTED CASES OF THIS HAPPENING. SEE LINK BELOW. FORD SENT ME TO YOU AS THEY SAID THEY WILL NOT DO ANYTHING. HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORE…
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FRONT MOULDING AROUND WINDSHIELD ON BOTH SIDES CAME FLYING OFF THE CAR ON THE HIGHWAY. VERY DANGEROUS POTENTIAL ROAD HAZARD TO ALL DRIVERS ON THE ROAD. THERE ARE DOZENS OF DOCUMENTED CASES OF THIS HAPPENING. SEE LINK BELOW. FORD SENT ME TO YOU AS THEY SAID THEY WILL NOT DO ANYTHING. HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2013/WINDOWS_WINDSHIELD/WINDSHIELD_TRIM_FLIES_OFF.SHTML
NHTSA ODI #10993756
51,000 miles · May 30, 2017
Unknown Or Other
WHEN THE A/C IS ON, OR IF THE CAR IS PARKED AND IDLING, THERE IS THE SMELL OF EXHAUST IN THE CAB OF THE VEHICLE.
NHTSA ODI #10992257
63,000 miles · May 16, 2017
Unknown Or Other
CABIN FILLS UP WITH EXHAUST FUMES AFTER SPEEDING UP
NHTSA ODI #10985989
65,000 miles · May 10, 2017
Unknown Or Other
WE HAVE HAD CONTINUOUS PROBLEMS WITH CARBON MONOXIDE ENTERING THE PASSENGER CABIN OF THE VEHICLE. THIS VEHICLE IS A MARKED POLICE DEPARTMENT PATROL VEHICLE, A 2013 FORD POLICE INTERCEPTOR UTILITY SUV (EXPLORER). WE HAVE TAKEN THE VEHICLE BACK TO THE DEALERSHIP 5 TIMES FOR THIS PROBLEM, AND IT STILL HAS NOT BEEN REPAIRED. THE …
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WE HAVE HAD CONTINUOUS PROBLEMS WITH CARBON MONOXIDE ENTERING THE PASSENGER CABIN OF THE VEHICLE. THIS VEHICLE IS A MARKED POLICE DEPARTMENT PATROL VEHICLE, A 2013 FORD POLICE INTERCEPTOR UTILITY SUV (EXPLORER). WE HAVE TAKEN THE VEHICLE BACK TO THE DEALERSHIP 5 TIMES FOR THIS PROBLEM, AND IT STILL HAS NOT BEEN REPAIRED. THE VEHICLE HAS BEEN EQUIPPED WITH AN AFTER-MARKET CARBON MONOXIDE DETECTOR. WHEN THE DRIVER QUICKLY ACCELERATES WHILE THE HVAC SYSTEM IS IN "RECIRCULATE" MODE, THE DRIVER CAN SMELL EXHAUST FUMES. THE CO DETECTOR ALSO GIVES AN ALARM. WE HAVE TAKEN THE VEHICLE TO A LOCAL FIRE STATION, WHERE THEY USED AN INDUSTRIAL GAS DETECTOR, AND THEY HAVE DETECTED UP TO 35 PPM OF CO IN THE FRONT SEAT AREA. (THE FIREFIGHTERS TOLD US THEY ARE REQUIRED TO WEAR A RESPIRATOR AT 35 PPM.) THE DRIVER'S BLOOD LEVEL OF CARBON MONOXIDE ALSO HAS BEEN TESTED, AND 5 PPM OF CO WAS FOUND IN HIS BLOOD IMMEDIATELY AFTER DRIVING THE VEHICLE (HE IS NOT A SMOKER). TWO PRIMARY REPAIRS ATTEMPTS HAVE BEEN PERFORMED. THE FIRST WAS TO REPAIR A "PINHOLE" LEAK IN A GASKET ON THE CATALYTIC CONVERTER. THE SECOND WAS A TECHNICAL SERVICE BULLETIN, WHERE THE REAR BUMPER WAS REMOVED AND SEALANT WAS APPLIED AROUND SOME VENTS. NEITHER REPAIR WAS SUCCESSFUL. WE ARE PREPARING TO RETURN THE VEHICLE TO THE DEALER FOR THE 6TH TIME. WE HAVE HAD TO PAY OUT-OF-POCKET FOR ALL REPAIR ATTEMPTS SO FAR. RIGHT NOW, THE VEHICLE HAS BEEN PARKED AND WE CANNOT DRIVE IT BECAUSE IT IS TOO DANGEROUS.
NHTSA ODI #10984763
168,000 miles · Apr 6, 2017
Unknown Or Other
I BOUGHT CAR MAY 3013 STARTED SMELLING EXHAUST INSIDE THE VEHICLE AND KEPT ASKING THE DEALER TO PLEASE CHECK IT OUT AND ASKED IF THERE WERE ANY OTHER COMPLAINTS FOR THE SAME. THEY ACTED AS THOUGH I WAS CRAZY NEVER CHECKED IT OUT AND I REQUESTED IT EVERY TIME TOOK IT IN FOR OIL AND TIRE ROTATION. AFTER A WHILE WHEN I WOULD BE …
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I BOUGHT CAR MAY 3013 STARTED SMELLING EXHAUST INSIDE THE VEHICLE AND KEPT ASKING THE DEALER TO PLEASE CHECK IT OUT AND ASKED IF THERE WERE ANY OTHER COMPLAINTS FOR THE SAME. THEY ACTED AS THOUGH I WAS CRAZY NEVER CHECKED IT OUT AND I REQUESTED IT EVERY TIME TOOK IT IN FOR OIL AND TIRE ROTATION. AFTER A WHILE WHEN I WOULD BE IN THE VEHICLE AND EXCELERATE IT WOULD SMELL AS THOUGH SOME ONE DUMPED A CAN OF GAS IN THE BACK OF THE CAR. WHEN TOOK IN THE LAST TIME DEALER I BOUGHT IT FROM TOLD ME WOULD COST ME TOO MUCH TO FIX AS IT WAS A BIG JOB JUST DON'T USE YOUR REAL AIR CONDITIONER. WE LIVE IN FLORIDA AND MY GRANDCHILDREN RIDE WITH ME THAT IS NOT AN OPTION. THE FUMES HAPPENED WHEN EXCELERATION AT LOW AND HIGHER SPEEDS NOT DURING SAME CIRCUMSTANCES. THE LAST TIME WHERE AS IT HAD BEEN ON THE OPEN HIGHWAY I WAS SIMPLY DOING A LEFT TURN AND THIS TIME THE EXHAUST WAS IN THE FRONT PASSENGER SEAT AREA. THIS HAPPENED FOR THE LAST FOUR YEARS I REPORTED TO FORD CUSTOMER SERVICE THE GAVE ME CLAIM NUMBER HAVE NOT HEARD BACK. CASE NUMBER IS CAS10895619
NHTSA ODI #10970939
50 miles · Apr 5, 2017
EngineFuel/propulsion SystemUnknown Or OtherInjury
THERE IS A CONSISTENT SMELL OF SULFUR OR GAS COMING INTO THE CAR THROUGH THE VENTS. I WAS LIGHT HEADED AND DIZZY WHILE DRIVING. STOPPED AND ROLL THE WINDOWS DOWN. THIS WAS NOT JUST ONCE BUT FORD IS DOING NOTHING ABOUT THE PROBLEM. I SEARCHED FOR RECALLS AND THEY SAID THERE IS NO RECALL ON MY FORD EXPLORER FOR THIS ISSUES. PLEASE…
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THERE IS A CONSISTENT SMELL OF SULFUR OR GAS COMING INTO THE CAR THROUGH THE VENTS. I WAS LIGHT HEADED AND DIZZY WHILE DRIVING. STOPPED AND ROLL THE WINDOWS DOWN. THIS WAS NOT JUST ONCE BUT FORD IS DOING NOTHING ABOUT THE PROBLEM. I SEARCHED FOR RECALLS AND THEY SAID THERE IS NO RECALL ON MY FORD EXPLORER FOR THIS ISSUES. PLEASE ADVISE AS TO WHAT I AM TO DO?
NHTSA ODI #10970670
56,000 miles · Mar 29, 2017
Unknown Or Other
FOR THE PAST SEVERAL MONTHS, I HAVE BEEN GETTING A FOUL ORDER EMANATING FROM MY VEHICLE. I SMELL IT INSIDE THE CABIN AS WELL AS THE EXTERIOR OF THE VEHICLE AFTER STOPPING. THE ODOR BECOMES STRONGER WITH LONGER ENGINE RUN TIMES OR HARSHER DRIVING CONDITIONS. THE ODOR DOES NOT SMELL LIKE OIL OR GAS. I CAN BEST DESCRIBE IT AS ACIDI…
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FOR THE PAST SEVERAL MONTHS, I HAVE BEEN GETTING A FOUL ORDER EMANATING FROM MY VEHICLE. I SMELL IT INSIDE THE CABIN AS WELL AS THE EXTERIOR OF THE VEHICLE AFTER STOPPING. THE ODOR BECOMES STRONGER WITH LONGER ENGINE RUN TIMES OR HARSHER DRIVING CONDITIONS. THE ODOR DOES NOT SMELL LIKE OIL OR GAS. I CAN BEST DESCRIBE IT AS ACIDIC OR CHEMICAL. I HAVE TAKEN IT IN TO MY LOCAL FORD DEALERSHIP FOR RESOLUTION. THE SERVICE ADVISOR ACKNOWLEDGED THAT HE CAN SMELL THE ODOR AS WELL. UNFORTUNATELY, THEY COULD FIND NO SPECIFIC CAUSE FOR THE ISSUE. THE ACTION THEY TOOK WAS TO POWER WASH THE ENGINE COMPARTMENT UNDER THE BELIEF THAT IT MAY HAVE BEEN A DEAD ANIMAL. UNFORTUNATELY, THE SMELL HAS NOT DISAPPEARED AFTER THAT DEALERSHIP ACTION. I AM OBVIOUSLY CONCERNED THAT IT IS POSING A SAFETY RISK.
NHTSA ODI #10969295
30,000 miles · Mar 28, 2017
Unknown Or Other
I PURCHASED MY VEHICLE AS A USED CAR COMING OFF OF A LEASE AT A CERTIFIED FORD DEALERSHIP. THE VEHICLE NOW HAS 31000 MILES. THE FACTORY WARRANTY ENDED 10/2016. I FIRST NOTICED THIS PROBLEM LATE 12/2016. THE VEHICLE EXHIBITS A STRONG EXHAUST ODOR IN THE PASSENGER CABIN DURING ALL TIMES OF OPERATION. THE ODOR IS MUCH STRONGER …
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I PURCHASED MY VEHICLE AS A USED CAR COMING OFF OF A LEASE AT A CERTIFIED FORD DEALERSHIP. THE VEHICLE NOW HAS 31000 MILES. THE FACTORY WARRANTY ENDED 10/2016. I FIRST NOTICED THIS PROBLEM LATE 12/2016. THE VEHICLE EXHIBITS A STRONG EXHAUST ODOR IN THE PASSENGER CABIN DURING ALL TIMES OF OPERATION. THE ODOR IS MUCH STRONGER WHEN THE VEHICLE IS STATIONARY (I.E., IDLING AT A TRAFFIC LIGHT) AND IS VERY STRONG DURING AND IMMEDIATELY AFTER HARD ACCELERATION. IT SEEMS AS THOUGH THE EXHAUST ODOR IS ACTUALLY COMING THROUGH THE VEHICLES VENTILATION SYSTEM. THE EXHAUST ODOR OFTEN LEAVES ME FEELING SICK IF I DO NOT CRACK OPEN THE WINDOWS FOR FRESH AIR. I HAVE CALLED MY DEALERSHIP (MILLER FORD, MOUNT HOLLY, NJ) AND EXPLAINED THE PROBLEM. THE DEALERSHIP ACKNOWLEDGED HAVING PREVIOUS SIMILAR COMPLAINTS AND STATED THAT THERE WAS A SERVICE BULLETIN DESIGNED TO ADDRESS THE ISSUE. HOWEVER, SINCE MY VEHICLE IS NO LONGER UNDER WARRANTY, THE COST OF THE REPAIR WOULD NOT BE COVERED. I NOW HAVE BEEN DRIVING THE VEHICLE FOR APPROXIMATELY 3 MONTHS, ENDURING THESE EXHAUST FUMES. I FEEL THAT THIS IS A SERIOUS SAFETY ISSUE THAT COULD ADVERSELY AFFECT MY HEALTH AND THE SAFETY OF OTHERS IF I WERE TO BECOME OVERWHELMED BY THE EXHAUST'S CO. I CANNOT AFFORD TO JUST STOP OPERATING THIS VEHICLE AND BUY ANOTHER.
NHTSA ODI #10969178
Official recalls
11Jan 19, 2024
Ford Motor Company (Ford) is recalling certain 2011-2019 Explorer vehicles. The A-pillar trim retention clips may not be properly engaged, allowing the trim to detach.
Consequence & remedy
Consequence: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.
Remedy: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model years. Owner notification letters were mailed between July 18, 2024 and December 16, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.
Sep 22, 2021
Ford Motor Company (Ford) is recalling certain 2011-2013 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. These vehicles may be equipped with a cross-axis ball joint (CABJ) replacement part that could seize, and result in a fracture of the outboard section of the rear suspension toe link.
Consequence & remedy
Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Dealer will inspect for the presence of a CABJ. If a CABJ of any design is found, the dealer will inspect the tightness of the CABJ, and replace the CABJ, knuckle, and/or toe link as necessary, free of charge. Interim notification letters were mailed November 10, 2021. Owner notification letters were mailed on March 17, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S43.
Jul 15, 2021
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin, and the District of Columbia. Exposure to road salt can cause the cross-axis ball joint to corrode and seize, resulting in a fracture of the outboard section of the rear suspension toe link.
Consequence & remedy
Consequence: A rear toe-link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Dealers will inspect and replace as necessary, the cross-axis ball joint (CABJ) knuckle, and replace the rear suspension toe links, free of charge. This recall is an expansion of previous NHTSA recall numbers 16V-245, 19V-435, and 20V-675. Certain vehicles previously repaired will need to return for the new remedy. An interim notification letter notifying owners of the safety risk were mailed on September 10, 2021. Owner notification letters were mailed on March 16, 2022. Owners may contact Ford's customer service at 1-866-436-7332. Ford's number for this recall is 21S32.
Mar 12, 2021
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin that were previously repaired under a prior recall numbers 16V-245 or 19V-435. The outboard section of a rear suspension toe link may fracture.
Consequence & remedy
Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will inspect the cross-axis ball joint (CABJ) knuckle attached to the rear suspension toe link and replace it as necessary, free of charge. The recall began November 27, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S62.
Jun 10, 2019
Ford Motor Company (Ford) is recalling certain 2011-2017 Explorer vehicles. The rear suspension toe links may fracture due to stress on the rear suspension.
Consequence & remedy
Consequence: A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, and inspect both rear toe link ball joints, replacing the rear wheel knuckle(s), if necessary, free of charge. The recall began June 26, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S17.
Dec 2, 2015
Ford Motor Company (Ford) is recalling certain model year 2013 Explorer, Explorer Police Utility, Taurus, Taurus Police Interceptor, Flex, Lincoln MKS, and Lincoln MKT vehicles. In the affected vehicles, the fuel delivery module may crack, allowing fuel to leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source may result in a fire.
Remedy: Ford will notify owners, and dealers will replace the fuel delivery module, free of charge. The recall began on December 21, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 13S04-S1.
Mar 24, 2015
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Explorer vehicles. In the affected vehicles, the interior door handle return spring may unseat, resulting in interior door handle that does not return to the fully stowed position after actuation.
Consequence & remedy
Consequence: If the interior door handle return spring is unseated, the door may unlatch in the event of a side impact crash, increasing the risk of personal injury.
Remedy: Ford will notify owners, and dealers will inspect all four of the interior door handles and either repair or replace them, free of charge. The recall began on July 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S11.
May 29, 2014
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Ford Explorer vehicles manufactured May 17, 2010, through February 28, 2012. The affected vehicles may experience an intermittent connection in the electric power steering gear, which can cause a loss of the motor position sensor signal resulting in a shut down of the power steering assist.
Consequence & remedy
Consequence: If the vehicle experiences a loss of power steering assist it will require extra steering effort at lower speeds, increasing the risk of a vehicle crash.
Remedy: Ford will notify owners, and dealers will update the Power Steering Control Module (PSCM) software, free of charge. If a vehicle shows a history of a loss of motor position sensor signal when the vehicle is brought in for the recall remedy, its steering rack assembly will be replaced, free of charge. The recall began on July 23, 2014. Owners may contact Ford customer service at 1-800-392-3673. Ford's number for this recall is 14S06.
Jun 26, 2013
Ford Motor Company (Ford) is recalling certain model year 2013 Ford Explorer, Taurus, and Lincoln MKS vehicles manufactured November 29, 2012, through December 12, 2012. In the affected vehicles, with sufficient door openings and closings, the child safety locks may change from an activated position to a deactivated position without notice.
Consequence & remedy
Consequence: If the child lock is deactivated, the door could be unlocked and opened from the inside which could lead to personal injury to an unrestrained child.
Remedy: Ford will notify owners, and dealers will test the safety locks. If necessary, the locks will be replaced free of charge. The recall began on August 2, 2013. Ford's recall number is 13S07. Owners may contact the Ford customer relationship center at 1-866-436-7332.
May 31, 2013
Ford is recalling certain model year 2013 Explorer, Taurus, Flex, Fusion, Police Interceptor Sedan and Police Interceptor Utility vehicles; and certain model year 2013 Lincoln MKS, MKT, and MKZ vehicles. In the affected vehicles, the fuel delivery module may develop a crack, allowing fuel to leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source may result in a fire.
Remedy: Ford will notify owners, and dealers will replace the fuel delivery module, free of charge. The recall began on July 20, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332. Ford's recall campaign number is 13S04.
Mar 27, 2013
Ford is recalling certain model year 2012 Taurus, Lincoln MKS, and model year 2013 Explorer vehicles manufactured July 19, 2011, through March 15, 2012. In the affected vehicles, the fuel tanks may have a marginally sealed seam in the side of the tank. As a result, the fuel tanks may not provide the expected strength in the event of an impact. The tanks may also leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source may result in a fire.
Remedy: Ford will notify owners, and dealers will inspect the fuel tanks and replace them as necessary, free of charge. The recall began on May 9, 2013. Ford's recall campaign number is 13S03. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
6PE23001 · Windshield Trim Molding Item Detachment
Opened Jan 27, 2023 · Closed Feb 8, 2024
Status: closed (inferred from source dates) · Structure:body:roof And Pillars
On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this failure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injuries. Some consumers have reported that the failure occurred while they were driving at highway speeds, with the detached trim panel entering the path of travel of the vehicle behind them, requiring the driver of the following vehicle to take evasive action. It is noteworthy that motorists who experience this type of road hazard are less likely to accurately identify the subject vehicle the item detached from and report the event to the NHTSA. In its April 17, 2023 response to ODI’s information request, Ford provided 175 consumer complaints (including field reports) and 14,162 warranty claims related to A-pillar trim panel detachment. Ford relayed that the subject vehicles utilize a plastic A-pillar bracket, which is bolted to the vehicle structure during assembly. The A-pillar trim panel is attached to the bracket utilizing 7 plastic clips. Contributory factors which have been identified by Ford as leading to the subject defect include incomplete installation at the assembly plant, inadequate part stack up, damage to fasteners during installation, and failure to follow proper repair procedure during windshield replacements or other services. On January 19, 2024, Ford filed safety recall 24V-031 for MY 2011-2019 Ford Explorer vehicles to address the subject defect. In the Part 573 Safety Recall Report, Ford identified that a detached A-pillar trim panel can create a road hazard for other road users, increasing the risk of a crash. The recall remedy includes an inspection of the existing A-pillar trim panel and, if necessary, the replacement of the component. The remedy A-pillar trim panels will be installed with an additional adhesive for robustness and utilize an inspection procedure to ensure full engagement of all the retention clips during installation. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
EA17002 · Exhaust Odor In Passenger Cab
Opened Jul 27, 2017 · Closed Jan 17, 2023
Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe; Structure:body
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
Additional source detail variants (2)
Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
Structure:body
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
PE16008 · Ford Explorer Exhaust Odor
Opened Jul 1, 2016 · Closed Sep 12, 2017
Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System; Structure:body
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
Additional source detail variants (2)
Engine And Engine Cooling:exhaust System
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
Structure:body
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
EA15005 · Front Brake Hose Failure
Opened Sep 28, 2015 · Closed Nov 2, 2018
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate a report alleging incidents of front brake hose failure in model year (MY) 2015 Ford Explorer Police Interceptor vehicles used by the Sacramento Police Department in its pursuit driving training program (VOQ 10705832).On September 28, 2015, ODI upgraded the investigation to an Engineering Analysis (EA15-005) to assess maximum front caliper crimp temperatures under various test conditions, test hose assemblies removed from police interceptor service for any signs of thermal degradation, and further assess field data for evidence of a defect trend related to the alleged defect.The alleged defect results from exposure to extremely high heat at the caliper-side hose crimp. NHTSA?s vehicle testing suggests that the conditions necessary to produce the critical temperatures in the subject components result from drive-soak intervals that can occur during the Sacramento training program.NHTSA's testing of hose assemblies returned from police interceptor service did not identify any evidence of thermal degradation.NHTSA has not confirmed any incidents of caliper crimp failures due to overheating in vehicles not subjected to the Sacramento training course driving.The low number of hose assembly failure reports and the absence of any verified incidents of heat related front brake hose crimp failures since 2015 suggests that the Sacramento PD incidents resulted from conditions unique to the training program.A safety related defect trend has not been identified at this time and further use of Agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The Agency will take further action if warranted by the circumstances.For additional information, see the Closing Report in the document file for EA15-005 on www.nhtsa.gov.
PE14027 · Front Brake Hose Failure
Opened Aug 22, 2014 · Closed Feb 3, 2015
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
The Office of Defects Investigation (ODI) opened PE14-027 based on a report of 13 front brake hose (jounce hose) failures in 11 vehicles in the District of Columbia Metropolitan Police Department (DCMPD) fleet of 46 model year (MY) 2013 Ford Explorer Police Interceptor (PI) vehicles (VOQ 10621634).The DCMPD fleet provided Ford with 71 jounce hoses for analysis, including 4 of the 13 failed hoses.Inspection of each of the failed hoses identified a small tear in the outer cover on the body end of the hoses on the outboard side. Ford?s lab analysis of these hoses identified splits in the inner liners 1.5-2.0mm from the end of the nipple (outside of the crimped ferrule joint).Ford conducted pressure testing of 10 randomly selected samples of the remaining 67 hoses that had not experienced leaks and 9 of the samples leaked at 6,000 psi.Ford?s examination of the 9 hoses that leaked in the pressure tests found 4 that failed on the outboard side of the hose (similar to the 4 leaking field parts) and 5 that failed on the body end of the hose on the inboard side.Four additional non-leaking hoses were sent to the hose supplier, Hitachi, for analysis.Broken yarn was observed in scanning electron microscope examinations at both the body side and caliper side hose to ferrule crimps, indicating severe bending stress had occurred at these locations. Hitachi supplied an additional set of non-leaking field return hoses and a brand new set of hoses to an outside laboratory (Element Materials Technology) for analysis.The lab did not identify any manufacturing or material deficiencies in the hoses and concluded that the hose failures were caused by excessive bending stresses.Based on the examinations of the returned jounce hoses, Ford conducted durability testing on new hoses that were the same design as those found on the subject vehicles.Ford first determined the worst case conditions for the hoses; jounce bumpers removed, internal rebound stops fully compressed, and shock absorbers attached. With the jounce hose installed, the steering was rotated to the maximum turn angle while the suspension was translated from full jounce to full rebound.This determined the maximum hose length of 13.0in (331mm) and a minimum hose bending radius of 1.6in (40mm).Using these conditions hoses tested on a Suspension Motion Simulator far surpassed Ford?s performance specifications. Twenty (20) complaints of front brake jounce hose failure were identified on a total of 18 Explorer PI vehicles, including the 13 hose failures in 11 vehicles from the DCMPD fleet that prompted PE14-027.The remaining 7 complaints included 3 from one fleet that reportedly occurred on the banjo block end of the hose assembly and single complaints from 4 other fleets.Only two brake hose assemblies were used in the subject and peer Explorer vehicles, with the BB53 level hose used until June 20, 2012, and an updated DB53 level hose used thereafter.No pattern of failures was observed by hose assembly, with 15 of failures involving the BB53 hose assembly (including the 13 from DCMPD manufactured in March 2012) and 5 the DB53 hose assembly built after June 20, 2012. No root cause was determined for the reported Explorer PI jounce hose failures, but Ford identified improper service repair procedures (e.g., hanging the brake caliper from the brake hose during brake pad replacement) as a possible contributor to higher than expected rate of front brake jounce hose leaks. ODI?s analysis of field data, hose inspection and test data did not identify evidence of any defects in hose material, manufacture or vehicle installation.The closing of this invest
PE12017 · Electric Power Steering Failure
Opened Jun 19, 2012 · Closed Jun 12, 2014
Status: closed (inferred from source dates) · Steering:electric Power Assist System
On May 27, 2014 and amended June 2, 2014, Ford Motor Company (Ford) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 179,027 model year (MY) 2011 through 2013 Ford Explorer vehicles equipped with electric power assisted steering (EPAS), including 82,328 MY 2011 Explorersthat are the subject of PE12-017.Ford has assigned the recall number 14S06.The NHTSA recall number is 14V-286.Ford's DIR indicates that loss of power steering assist while driving would require higher steering effort at lower vehicle speeds, which may result in an increased risk of a crash.Sudden loss of power steering assist while driving can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe mode, which removes power from the EPAS motor and defaults to manual steering.Ford's DIR indicates that the majority of steering assist failures in the recalled vehicles have been caused by an intermittent electrical connection in the Power Steering Control Module (PSCM) that can lead to a loss of the motor position sensor signal.Ford's remedy instructs dealers to check the PSCM for diagnostic trouble codes (DTC).If upon initial inspection a loss of steering assist DTC is present, dealers will replace the steering gear at no charge to the owner and update the PSCM with revised software.Following detection of a motor position sensor signal fault, the revised software will provide audible and visual warnings to the driver that a power steering system fault has been detected and will maintain steering assist for the remainder of that drive cycle.If no DTC is present, dealers will reprogram the PSCM with the revised software. Analysis of information from all sources identified a total of 969 complaints and 4,059 warranty claims related to loss of power steering assist while driving in the MY 2011 through 2012 Explorer vehicles, resulting in a complaint rate of 5.4 incidents per thousand vehicles and a warranty claim rate of 2.3 percent.ODI identified 15 crashes with evidence indicating loss of power steering assist may have been a factor.All 15 crashes involved low-speed impacts with roadside objects during turning maneuvers, resulting in minor vehicle damage or no damage.In one incident that occurred in a low-speed curve, the driver attempted to brake in response to the sudden increase in steering effort and inadvertently applied the accelerator pedal instead.This caused the vehicle to run off the side of the road and strike a wooden pole at approximately 15 mph.Another incident occurred when the driver was unable to to negotiate a left-turn at an intersection and ran off the road into a shallow ditch, resulting in moderate front-end damage to the vehicle and minor injuries to the driver that did not require medical treatment. This investigation is closed.All ODI complaints associated with this closing resume are listed in the Attachment 1.
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