NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
196 reportsClear category filter2,000 miles · Oct 29, 2015
Engine
EXPERIENCING VERY STRONG EXHAUST / SULFUR SMELL IN CABIN AREA UPON MEDIUM TO HARD ACCELERATION. BOUGHT CAR IN SPRING OF 2014 AND NOTICED IT WITHIN THE FIRST MONTH OR TWO. AT FIRST I THOUGHT IT MIGHT HAVE BEEN A CAR IN FRONT OF ME, BUT THAT IS NOT THE CASE AS I HAVE EXPERIENCED THIS NUMEROUS TIMES THIS WITH NO ONE ELSE ON THE R…
Read full complaint
EXPERIENCING VERY STRONG EXHAUST / SULFUR SMELL IN CABIN AREA UPON MEDIUM TO HARD ACCELERATION. BOUGHT CAR IN SPRING OF 2014 AND NOTICED IT WITHIN THE FIRST MONTH OR TWO. AT FIRST I THOUGHT IT MIGHT HAVE BEEN A CAR IN FRONT OF ME, BUT THAT IS NOT THE CASE AS I HAVE EXPERIENCED THIS NUMEROUS TIMES THIS WITH NO ONE ELSE ON THE ROAD. IT OCCURS WHEN YOU PASS SOMEONE OR GO UP A STEEP INCLINE. WHEN TOWING MY BOAT THE SMELL IS UNBEARABLE AND YOU HAVE TO HAVE THE WINDOWS ROLLED DOWN, BUT EVEN WITH THAT IT TAKES A LONG TIME TO GET THE SMELL OUT OF THE CABIN. SITUATION OCCURS WITH THE FRESH AIR VENTS ON AND/OR THE RECIRC AIR ON ' VENT SETTING DOESN'T MATTER. I'VE BEEN PUTTING OFF GETTING THIS LOOKED AT SINCE IT SOUNDS LIKE THERE IS NO DEFINITIVE FIX, BUT SINCE THE CAR NOW HAS 29,000 MILES ON IT, I WANT IT TO GET CHECKED OUT BEFORE WARRANTY IS UP. IT IS ALARMING THAT WITH ALL THE COMPLAINTS FOR THIS HAZARDOUS/DEADLY SITUATION THAT THERE HAS NOT BEEN A RECALL FOR A BETTER FIX THAN THE TSB.
NHTSA ODI #10787074
15,000 miles · Sep 3, 2015
Electrical SystemEngine
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE LOW OIL PRESSURE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS RESTARTED SEVERAL TIMES AND THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE AIR FLOW SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPA…
Read full complaint
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE LOW OIL PRESSURE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS RESTARTED SEVERAL TIMES AND THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE AIR FLOW SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 15,000. MA 10/6 UPDATED 12/21/15. *JB
NHTSA ODI #10761325
5,000 miles · Aug 23, 2015
EngineUnknown Or Other
A FEW MONTHS AFTER PURCHASING OUR 2014 EXPLORER, WE NOTICED AN EXHAUST/SULFUR ORDER IN THE PASSENGER COMPARTMENT FOLLOWING A MEDIUM ACCELERATION ENTERING AN INTERSTATE HIGHWAY. WE REPORTED THE ODOR TO THE DEALERSHIP AND TURNED THE VEHICLE IN FOR REPAIR. DEALERSHIP WAS UNABLE TO RECREATE THE ORDER SO NOTHING WAS DONE. A FEW M…
Read full complaint
A FEW MONTHS AFTER PURCHASING OUR 2014 EXPLORER, WE NOTICED AN EXHAUST/SULFUR ORDER IN THE PASSENGER COMPARTMENT FOLLOWING A MEDIUM ACCELERATION ENTERING AN INTERSTATE HIGHWAY. WE REPORTED THE ODOR TO THE DEALERSHIP AND TURNED THE VEHICLE IN FOR REPAIR. DEALERSHIP WAS UNABLE TO RECREATE THE ORDER SO NOTHING WAS DONE. A FEW MONTHS LATER, UNDER SIMILAR CIRCUMSTANCES, THE ODOR RETURNED. ONCE AGAIN, WE TURNED THE VEHICLE IN FOR REPAIR. THE DEALER PERFORMED A REPAIR BASED ON A TSB. A FEW MONTHS LATER, THE ODOR RETURNED AND ONCE AGAIN TURNED THE VEHICLE IN FOR REPAIR. THE DEALER PERFORMED A CONTINUATION OF THE SAME TSB. A FEW MONTHS LATER, WHILE PULLING A BOAT, THE ODOR RETURNED. ONCE AGAIN, WE TURNED THE VEHICLE IN FOR REPAIR. THE DEALER OWNER AND THE SERVICE TECH DROVE THE VEHICLE FOR SEVERAL DAYS AND WERE UNABLE TO DETECT THE SMELL. THE VERY NEXT DAY WHILE PULLING THE BOAT, THE ODOR RETURNED. THE DEALER NOW SAYS THEY DON'T WANT TO PERFORM THE LAST PART OF THE TSB BECAUSE IF THEY SEND FORD A PART THAT'S NOT DEFECTIVE, FORD WILL CHARGE THEM BACK FOR THE PART....MEANWHILE I'M STUCK DRIVING A VEHICLE THAT MAY BE PUTTING SULFUR AND/OR CARBON MONOXIDE INTO THE PASSENGER COMPARTMENT. THE DEALER WANTS ME TO BRING MY BOAT AND VEHICLE IN SO THEY CAN TEST IT WHICH ISN'T GOING TO HAPPEN BECAUSE IF THEY WRECK THE VEHICLE WITH THE BOAT, MY INSURANCE HAS TO COVER IT THROUGH THE PERMISSIVE USE CLAUSE AND MY RATES WILL GO UP.
NHTSA ODI #10758647
9,898 miles · Aug 6, 2015
Electrical SystemEngineService Brakes
WHEN APPLYING FULL BRAKING AT A STOP SIGN OR RED LIGHT THE VEHICLE STOPS BUT THE ENGINE AND TRANSMISSION CONTINUE TO RACE AT FULL SPEED. THE BRAKE PULSATES LIKE THE ANTI LOCK BRAKING SYSTEM IS ENGAGED. IN ORDER TO GET THE VEHICLE BACK TO NORMAL THE ENGINE MUST BE SHUT OFF OR THE TRANSMISSION DISENGAGED. IT WILL THEN START UP NOR…
Read full complaint
WHEN APPLYING FULL BRAKING AT A STOP SIGN OR RED LIGHT THE VEHICLE STOPS BUT THE ENGINE AND TRANSMISSION CONTINUE TO RACE AT FULL SPEED. THE BRAKE PULSATES LIKE THE ANTI LOCK BRAKING SYSTEM IS ENGAGED. IN ORDER TO GET THE VEHICLE BACK TO NORMAL THE ENGINE MUST BE SHUT OFF OR THE TRANSMISSION DISENGAGED. IT WILL THEN START UP NORMALLY. WE HAVE HAD 11 OCCASIONS WITHIN THE PAST 2 MONTHS WHERE THIS HAS OCCURRED, THIS HAS OCCURRED WHEN COMING DOWN FROM HIGHWAY LONG DISTANCE DRIVING AND IT HAS ALSO HAPPENED ON A PARKING LOT VERY LOW SPEED. IT IS ALL I COULD DO TO PRESS HARD ENOUGH ON THE BRAKES TO STOP. THE VEHICLE HAS BEEN RETURNED TO THE DEALERSHIP, THEIR DIAGNOSTICS SHOW NOTHING AND THE DEALERSHIP STATES THEY MUST BE ABLE TO EXPERIENCE THE PROBLEM FIRST (DUPLICATE IT). FORD MOTOR COMPANY HAS BEEN CALLED THE REGIONAL SALES MANAGER TOLD ME TO TAKE THE VEHICLE TO ANOTHER FORD DEALERSHIP TO HAVE THEM LOOK AT IT. MR. MCHALE THE MANAGER AT FMC (866-631-3788 EXT. 77713) ASSIGNED A CASE NUMBER 7644437 TO THE PROBLEM BUT HE ALSO STATED THAT THEY WOULD HAVE TO DUPLICATE THE PROBLEM BEFORE IT COULD BE RESOLVED. I TOLD HIM IF I MISJUDGE OR AM UNABLE TO BRING THE VEHICLE TO A STOP THAT I MAY BE PUSHING UP DAISIES. THEY DO NOT SEEM TO UNDERSTAND THE SEVERITY OF THE PROBLEM. IT WOULD SEEM TO ME THAT A MECHANIC WOULD LOOK FOR A SENSOR OR SWITCH THAT WOULD DISENGAGE THE TRANS MISSION WHEN THE BRAKE WAS APPLIED OR A SENSOR OR CONTROL THAT SLOWS THE ENGINE. I AM GETTING TO THE POINT I FEAR FOR MY LIFE DRIVING THIS VEHICLE UNTIL IT IS REPAIRED. I ALSO MENTIONED THAT WHEN I TURN THE VEHICLE OFF DURING THE INCIDENT THERE IS A LOT OF CLUNKING FROM THE ENGINE AND TRANSMISSION, I AM SURE DAMAGE HAS BEEN DONE TO THEM. *CN
NHTSA ODI #10746671
20 miles · Feb 1, 2015
Engine
A SULFUR SMELLING STENCH COMING THROUGH THE VENTILATION SYSTEM WHEN DRIVING OVER A HIGH RPM RATE. THE SMELL ENTERS THE CABIN EVEN WITH THE AC TURNED ON AND ALSO WHEN RECIRCULATION IS TURNED ON. I HAVE REPORTED TO THE DEALER AND THEY FOUND NOTHING WRONG. *TR
NHTSA ODI #10680410
4,000 miles · Nov 9, 2014
EngineFuel/propulsion SystemVehicle Speed Control
TWICE WHILE DRIVING (ONCE ACCELERATING TO PULL INTO TRAFFIC AND ONCE GOING UP A MOUNTAIN) AN EXHAUST SMELL ENTERED THE CABIN THROUGH THE AC SYSTEM AND RECIRCULATING MODE DID NOT IMPROVE IT. THE VEHICLE WAS ACCELERATING OVER 3500 RPMS. I HAVE TESTED THIS AGAIN AND AGAIN AND IT HAPPENS EVERY TIME UNDER THESE CONDITIONS. I AM VERY …
Read full complaint
TWICE WHILE DRIVING (ONCE ACCELERATING TO PULL INTO TRAFFIC AND ONCE GOING UP A MOUNTAIN) AN EXHAUST SMELL ENTERED THE CABIN THROUGH THE AC SYSTEM AND RECIRCULATING MODE DID NOT IMPROVE IT. THE VEHICLE WAS ACCELERATING OVER 3500 RPMS. I HAVE TESTED THIS AGAIN AND AGAIN AND IT HAPPENS EVERY TIME UNDER THESE CONDITIONS. I AM VERY CONCERNED AS WE JUST BOUGHT THIS VEHICLE A COUPLE OF MONTHS AGO AND HAVE TWO YOUNG DAUGHTERS. I WILL BE TAKING IT TO OUR LOCAL DEALERSHIP BUT BASED ON THESE COMPLAINTS I AM NOT HOPEFULL THIS WILL BE RESOLVED. *TR
NHTSA ODI #10653747
100 miles · Oct 8, 2014
EngineFuel/propulsion SystemStructure
WHEN ACCELERATING TO PASS A DANGEROUS TRUCK (58 MPH) STRONG FUMES COMES INSIDE THE CABIN, ACCELERATION TOOK 8 SECONDS, INSTANTLY WE START COUGHING AND GET WATERY EYES, OUR YEAR OLD BABY START CRYING SHOWING SYMPTOMS OF DISTRESS, WE TELL THIS TO SALES PERSON, WHICH QUICKLY TOLD US THE STORY THAT THIS HAPPENS WITH NEW CARS.. SUPPO…
Read full complaint
WHEN ACCELERATING TO PASS A DANGEROUS TRUCK (58 MPH) STRONG FUMES COMES INSIDE THE CABIN, ACCELERATION TOOK 8 SECONDS, INSTANTLY WE START COUGHING AND GET WATERY EYES, OUR YEAR OLD BABY START CRYING SHOWING SYMPTOMS OF DISTRESS, WE TELL THIS TO SALES PERSON, WHICH QUICKLY TOLD US THE STORY THAT THIS HAPPENS WITH NEW CARS.. SUPPOSEDLY NEW ENGINES SHOULD NOT BE HIGHLY ACCELERATED. NAIVELY WE BELIEVE THIS AND DECIDE TO GIVE IT A FEW DAYS? DAY BECOME MONTHS AND PROBLEM GOT WORST, AFTER FEW MONTHS WE DECIDE TO TAKE THE CAR IN FOR SERVICE, UNFORTUNATELY FORD FROM FIRST DAY TREAT US LIKE IF WE WERE INVENTING THE MATTER, AND MAKE MY WIFE LOOK LIKE IF SHE WERE CRAZY, THE WORST PART IS THAT THEY KNOW THAT CAR HAS THE DEFECT AS PREVIOUS GENERATIONS HAS THE SAME PROBLEM(FORDTECHNICAL BULLETIN CONFIRM THIS ).WE CONTINUE TO FOLLOW THE REGULAR PROCEDURE AND WENT TO THE DEALERSHIP ASKING THEM TO FIX THE PROBLEM,THEY ONLY SHOW THEY WERE CLUELESS ABOUT IT AND AFTER MORE THAN SEVEN TIMES LEAVING THE CAR THERE THEY SAY THERE??S NOTHING THEY CAN DO ABOUT IT. WE CONTACT FORD MANUFACTURER DIRECTLY,WHICH MAKE US GO THROUGH A LONG PROCESS OF VERIFYING BACK AND FORWARD, AND AT THE END AN ??ENGINEER?? SEND ESPECIALLY DIRECTLY FROM FORD TO THE DEALERSHIP TELL US PRACTICALLY THAT JUST DON??T ACCELERATE TO AVOID THIS !!!!.WE TOOK THE CAR TO SPECIALIST THAT MEASURED CO WITH A PROFESSIONAL TOOL THAT SHOW MORE THAN 140 PART PER MILLION!!!!!.THIS IS SERIOUS PROBLEM THAT FORD SHOULD BE RESPONSIBLE FOR IT, MY FAMILY HAS BEEN SICK WITH FLUE LIKE SYMPTOMS FOR A LONG TIME, MY WIFE EXPERIENCED A VERY LONG LASTING COUGH THAT ONLY START GETTING BETTER AFTER FORCEFULLY I HAVE TO GET HER ANOTHER CAR AS I COULD NO LONGER EXPOSE MY FAMILY TO MORE OF THIS DANGERS. I REQUEST TO FORD TO REPLACE THE CAR AND THEY DENIED MY REQUEST I BELIEVE NHTSA SHOULD STEP UP ON TO THIS AND PROTECT THE CONSUMERS, THANKS *TR
NHTSA ODI #10643273
500 miles · Oct 5, 2014
EngineFuel/propulsion System
SINCE I'VE OWNED MY 2014 FORD EXPLORER FOR THE PAST SIX MONTHS I GET SULFUR SMELLING EXHAUST FUMES COMING FROM THE A/C VENTS WHEN QUICKLY ACCELERATING EVEN IF THE A/C IS IN RECIRC MODE AND EVEN WHEN THE FUEL TANK IS NOT FULL. IT IS DEFINITELY EXHAUST ODORS AND NOT FUEL ODORS. *TR
NHTSA ODI #10641511
14,550 miles · Sep 17, 2014
Engine
WHILE DRIVING ON THE FREEWAY I NEEDED TO ACCELERATE TO PASS A VEHICLE AND WHEN I DID A EXHAUST SMELL ENTERED THE CAB IT TOOK ABOUT 5-10 SECONDS AFTER ACCELERATING OVER 3500 RPMS. I HAVE TESTED THIS AGAIN AND AGAIN AND IT HAPPENS EVERY TIME UNDER THESE CONDITIONS. SITTING STILL THERE IS NO EFFECT AT ALL. FIVE STAR FORD OF PLAN…
Read full complaint
WHILE DRIVING ON THE FREEWAY I NEEDED TO ACCELERATE TO PASS A VEHICLE AND WHEN I DID A EXHAUST SMELL ENTERED THE CAB IT TOOK ABOUT 5-10 SECONDS AFTER ACCELERATING OVER 3500 RPMS. I HAVE TESTED THIS AGAIN AND AGAIN AND IT HAPPENS EVERY TIME UNDER THESE CONDITIONS. SITTING STILL THERE IS NO EFFECT AT ALL. FIVE STAR FORD OF PLANO TEXAS HAS TRIED A "TSB" THAT WAS ISSUED TO INSTALL A VENT ADJUSTMENT. THEY ALSO CHANGED OUT THE CABIN FILTER. STILL NO LUCK. THANK YOU *TR
NHTSA ODI #10637147
2,500 miles · Sep 12, 2014
EngineUnknown Or Other
UPON HEAVY ACCELERATION (TO ENTER THE FREEWAY, FOR EXAMPLE) A STRONG ODOR OF EXHAUST FUMES ENTERS THE CABIN. IT IS NECESSARY TO OPEN A WINDOW IN ORDER TO BREATH AGAIN! THIS OCCURS EVERY TIME UPON ENTERING THE FREEWAY, AND IF/WHEN PASSING ANOTHER VEHICLE ON THE HIGHWAY. *TR
NHTSA ODI #10632709
Official recalls
6Jan 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.
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.
Nov 10, 2020
Ford Motor Company (Ford) is recalling certain 2014-2016 Explorer, 2014-2015 Taurus and 2014 Edge vehicles equipped with 2.0L or 2.3L engines and front wheel drive. The support bracket for the front drive axle halfshaft may fail.
Consequence & remedy
Consequence: The failed bracket could result in a loss of park function which can cause unintended vehicle movement, and loss of motive power while driving which increases the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the link shaft bracket, free of charge. Parts are not currently available. Owners received an interim notification detailing safety risk December 8, 2020. A second letter will be mailed when parts become available in January 2021. The recall began February 2, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S63.
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.
Apr 26, 2016
Ford Motor Company (Ford) is recalling certain model year 2014-2015 Ford Explorer vehicles manufactured January 17, 2014 to May 31, 2014. The affected vehicles may have improperly welded rear suspension toe links that may fracture.
Consequence & remedy
Consequence: A fracture of the rear suspension toe link may result in a loss of steering control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, free of charge. The recall began on November 18, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S18.
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
4PE23001 · 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.
Illustration