NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
62 reportsClear category filter50 miles · Sep 28, 2016
EngineFuel/propulsion SystemUnknown Or Other
THERE IS AN OVERBEARING ALMOST INTOXICATING SULFUR/ROTTEN EGG SMELL COMING IN THE CABIN OF THE CAR ANY TIME ACCELERATING. I GOT THIS VEHICLE NEW IN 2014 AND IT HAS BEEN DOING IT SINCE DAY ONE. AT FIRST I WROTE IT OFF AS NEW CAR OR POSSIBLY THE TURBO. BUT NOW AFTER READING THE THOUSANDS OTHERS WITH SAME PROBLEM I AM EXTREMELY …
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THERE IS AN OVERBEARING ALMOST INTOXICATING SULFUR/ROTTEN EGG SMELL COMING IN THE CABIN OF THE CAR ANY TIME ACCELERATING. I GOT THIS VEHICLE NEW IN 2014 AND IT HAS BEEN DOING IT SINCE DAY ONE. AT FIRST I WROTE IT OFF AS NEW CAR OR POSSIBLY THE TURBO. BUT NOW AFTER READING THE THOUSANDS OTHERS WITH SAME PROBLEM I AM EXTREMELY CONCERNED FOR MY FAMILY'S WELL BEING. I HAVE BEEN DRIVING MY INFANT IN THIS CAR FOR TWO YEARS AND I AM VERY UPSET THAT I COULD HAVE PUT HER HEALTH AT RISK.
NHTSA ODI #10910224
53,000 miles · Sep 19, 2016
Fuel/propulsion System
I HAVE SEEN MANY COMPLAINTS ABOUT THE FUEL VALVE ON FORD VEHICLES WITH THE CAPLESS FUEL SYSTEMS. I RECENTLY HAD A CHECK ENGINE LIGHT GO ON IN MY CAR FOR PO456 WHICH I TOOK TO THE DEALER TO HAVE THEM CHECK IT OUT BECAUSE I HAVE AN EXTENDED WARRANTY. TURNS OUT THAT THE FUEL VAPOR VALVE HAS STUCK OPEN AND NEEDS TO BE REPLACED. SADL…
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I HAVE SEEN MANY COMPLAINTS ABOUT THE FUEL VALVE ON FORD VEHICLES WITH THE CAPLESS FUEL SYSTEMS. I RECENTLY HAD A CHECK ENGINE LIGHT GO ON IN MY CAR FOR PO456 WHICH I TOOK TO THE DEALER TO HAVE THEM CHECK IT OUT BECAUSE I HAVE AN EXTENDED WARRANTY. TURNS OUT THAT THE FUEL VAPOR VALVE HAS STUCK OPEN AND NEEDS TO BE REPLACED. SADLY THIS IS AN EMISSIONS ISSUE AND NOT COVERED UNDER MY WARRANTY. I LOOKED UP ONLINE AND NOTICED THAT THIS HAPPENS A LOT TO FORD WITH THE CAPLESS FUELING SYSTEM. I BELIEVE THIS IS A MAJOR ISSUE AND THEY ARE CHARGING $250 FOR A PART THAT GOES OUT IN LESS THAN 50K MILES.
NHTSA ODI #10907649
Mileage unknown · Aug 22, 2016
Fuel/propulsion System
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE VEHICLE WAS REPAIRED ACCORDING TO TECHNICAL SERVICE BULLETINS 12-12-4 AND 14-0130, AND NHTSA ACTION NUMBER: PE16008 (FUEL SYSTEM). THE CONTACT SMELLED A FUEL ODOR AFTER THE REPAIRS. THE CONTACT WAS REFERRED TO THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE VIN AND FAILURE MILEA…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE VEHICLE WAS REPAIRED ACCORDING TO TECHNICAL SERVICE BULLETINS 12-12-4 AND 14-0130, AND NHTSA ACTION NUMBER: PE16008 (FUEL SYSTEM). THE CONTACT SMELLED A FUEL ODOR AFTER THE REPAIRS. THE CONTACT WAS REFERRED TO THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE VIN AND FAILURE MILEAGE WERE UNKNOWN.
NHTSA ODI #10897740
Mileage unknown · Jul 28, 2016
EngineFuel/propulsion SystemUnknown Or Other
WE HAVE A 2014 FORD EXPLORER THAT HAS A SMELL INSIDE WHILE ACCELERATING. WE HAVE TAKEN IT TO THE DEALER TO HAVE THE PROBLEM CORRECTED. OUR CONCERN IS THAT EXHAUST HAS BEEN COMING INTO THE VEHICLE. WE AREN'T SURE IF THE CURRENT SOLUTIONS IN PLACE TO FIX THE VEHICLE ARE ENOUGH. WELL KNOWING AND OUR FAMILY IS GETTING SICK FROM THIS…
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WE HAVE A 2014 FORD EXPLORER THAT HAS A SMELL INSIDE WHILE ACCELERATING. WE HAVE TAKEN IT TO THE DEALER TO HAVE THE PROBLEM CORRECTED. OUR CONCERN IS THAT EXHAUST HAS BEEN COMING INTO THE VEHICLE. WE AREN'T SURE IF THE CURRENT SOLUTIONS IN PLACE TO FIX THE VEHICLE ARE ENOUGH. WELL KNOWING AND OUR FAMILY IS GETTING SICK FROM THIS CURRENT ISSUE WE JUST AREN'T SURE WHAT WE'RE BREATHING INSIDE THE VEHICLE IS SAFE. THE SMELL COMES WHEN YOU ACCELERATE HARD EITHER TOWING OR MERGING ONTO THE HIGHWAY OR EVEN FROM A RED LIGHT. THE SMELL IS A SULFUR SMELL OR ROTTEN EGG SMELL THAT SEEMS TO DISSIPATE QUICKLY BUT IS NOTICEABLE.
NHTSA ODI #10889250
1,500 miles · Jul 20, 2016
Fuel/propulsion SystemUnknown Or Other
EACH TIME AFTER DRIVING OUR FORD EXPLORER FOR A LENGTH OF TIME WITH THE AIR CONDITIONING ON, MY WIFE AND I BEGIN TO FEEL LIGHT HEADED, TIRED AND SICK. MY WIFE IS PREGNANT AND WE HAVE SEVERE CONCERNS ABOUT THE SAFETY OF DRIVING OUR EXPLORER DUE TO THE HEALTH RISK OF CARBON MONOXIDE LEAKING INTO THE CABIN. WE ARE NOW AWARE OF THIS…
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EACH TIME AFTER DRIVING OUR FORD EXPLORER FOR A LENGTH OF TIME WITH THE AIR CONDITIONING ON, MY WIFE AND I BEGIN TO FEEL LIGHT HEADED, TIRED AND SICK. MY WIFE IS PREGNANT AND WE HAVE SEVERE CONCERNS ABOUT THE SAFETY OF DRIVING OUR EXPLORER DUE TO THE HEALTH RISK OF CARBON MONOXIDE LEAKING INTO THE CABIN. WE ARE NOW AWARE OF THIS PROBLEM WITH OTHER EXPLORERS AND ARE DEEPLY CONCERNED FOR OUR HEALTH AND THE HEALTH OF OUR BABIES.
NHTSA ODI #10886037
Mileage unknown · Dec 18, 2015
Fuel/propulsion SystemUnknown Or Other
I HAVE HAD A PROBLEM SINCE I GOT MY LEASED 2014 EXPLORER, WHEN I HIT THE GAS HARD IT WOULD SMELL OF EXHAUST FUMES, AT FIRST I THOUGHT IT WAS BECAUSE IT WAS NEW AND WOULD GO AWAY SO I USED TO OPEN THE WINDOWS TO LET THE SMELL OUT BUT IT WAS QUITE BAD SO I HAD TO PULL AWAY MORE SLOWLY TO AVOID IT OR HAVE A BAD SMELL OF FUMES IN TH…
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I HAVE HAD A PROBLEM SINCE I GOT MY LEASED 2014 EXPLORER, WHEN I HIT THE GAS HARD IT WOULD SMELL OF EXHAUST FUMES, AT FIRST I THOUGHT IT WAS BECAUSE IT WAS NEW AND WOULD GO AWAY SO I USED TO OPEN THE WINDOWS TO LET THE SMELL OUT BUT IT WAS QUITE BAD SO I HAD TO PULL AWAY MORE SLOWLY TO AVOID IT OR HAVE A BAD SMELL OF FUMES IN THE CAR, I WOULD OPEN THE WINDOWS BUT ITS SO HOT IN FLORIDA AND IT LETS ALL THE A/C OUT, MY GIRLFRIEND KEPT TELLING ME THERE IS SOMETHING WRONG BUT I KEPT SAYING IT WILL PROBABLY GO AWAY, I WORKED AT A FORD DEALERSHIP AND I ASKED THE SERVICE DEPARTMENT IF THEY HAVE HAD OTHER COMPLAINTS TOO THEY SAID THERE WAS NOTHING WRONG, HOWEVER SHE WAS RIGHT THERE IS A PROBLEM AND IT HAS NOT GONE AWAY I WILL TAKE IT IN ON MONDAY AGAIN AND HAVE THEM DRIVE IN THE CAR WITH ME TO SMELL THE FUMES TOO THEN THEY MAY BE ABLE TO FIX IT. FORD HAVE KNOW ABOUT THIS PROBLEM FOR QUITE SOME TIME AND THEY ACTED NEGLIGIBLE IN MY HONEST OPINION BECAUSE THEY HAVE KNOW ABOUT THIS COMPLAINT WHY WOULD THEY NOT INFORM CUSTOMERS WHO HAVE PURCHASED THESE VEHICLES TO GET THEM CHECKED OUT FOR THEIR SAFETY AND THE LONG TERM EFFECTS FROM CARBON MONOXIDE FUMES IT COULD LEAD TO CANCER OR RESPIRATORY ISSUES AND MUCH MORE, THERE SHOULD BE A RECALL FOR SAFETY SAKE.
NHTSA ODI #10811079
18,000 miles · Oct 15, 2015
Fuel/propulsion System
NASTY EXHAUST SMELL ENTERING THE CABIN WHEN MERGING ON THE INTERSTATE, DRIVING UP A LONG HILL, OR PASSING VEHICLES. THIS OCCURS WHEN HAVING TO ACCELERATE QUICKLY -- HIGH RPMS FOR EXTENDED PERIODS. SMELL APPEARS TO COME FROM BACK TO FRONT AND IS DIFFICULT TO GET RID OF. AT FIRST I THOUGHT IT MAY BE OTHER VEHICLE'S EXHAUST ENTE…
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NASTY EXHAUST SMELL ENTERING THE CABIN WHEN MERGING ON THE INTERSTATE, DRIVING UP A LONG HILL, OR PASSING VEHICLES. THIS OCCURS WHEN HAVING TO ACCELERATE QUICKLY -- HIGH RPMS FOR EXTENDED PERIODS. SMELL APPEARS TO COME FROM BACK TO FRONT AND IS DIFFICULT TO GET RID OF. AT FIRST I THOUGHT IT MAY BE OTHER VEHICLE'S EXHAUST ENTERING THE CABIN, HOWEVER, AFTER DRIVING LONG PERIODS IN AREAS WITH NO OTHER VEHICLES AROUND THE EXHAUST STENCH CONTINUES. NOTED METALLIC TASTE IN MOUTH AFTER SMELLING ODOR VEHICLE.
NHTSA ODI #10782265
Mileage unknown · Sep 29, 2015
Fuel/propulsion System
WHEN HARD ACCELERATION OCCURS, SUCH AS ENTERING A FREEWAY OR GOING INTO PASSING GEAR TO PASS ANOTHER VEHICLE, THERE IS AN EXTREME ODOR - VERY SIMILAR TO ROTTEN EGG SMELL. THIS HAS OCCURRED SINCE THE VEHICLE WAS ORDERED AND PURCHASED NEW. THE VEHICLE WAS RETURNED TO THE DEALERSHIP FOR THIS PROBLEM, BUT AFTER BEING ON A WAITING …
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WHEN HARD ACCELERATION OCCURS, SUCH AS ENTERING A FREEWAY OR GOING INTO PASSING GEAR TO PASS ANOTHER VEHICLE, THERE IS AN EXTREME ODOR - VERY SIMILAR TO ROTTEN EGG SMELL. THIS HAS OCCURRED SINCE THE VEHICLE WAS ORDERED AND PURCHASED NEW. THE VEHICLE WAS RETURNED TO THE DEALERSHIP FOR THIS PROBLEM, BUT AFTER BEING ON A WAITING LIST FOR OVER 4 MONTHS, WE WERE ADVISED THAT THERE WERE NO PROBLEMS FOUND. THIS VEHICLE WAS PREVIOUSLY DRIVEN ON A DAILY BASIS, TO AND FROM WORK 37 MILES EACH WAY - IN TRAFFIC. I HAD CONTINUAL PROBLEMS WITH SMELL AND TASTE (EXACTLY THAT OF THE FUMES IN THE CABIN) UNTIL SUCH TIME THAT I BEGAN WORKING FROM HOME AND NO LONGER FORCED TO DRIVE THIS VEHICLE ON A DAILY BASIS. THIS PROMPTED MY RESEARCH AND THIS COMPLAINT OF THE KNOWN ISSUE. I FIRST REPORTED THIS SHORTLY AFTER PURCHASE AROUND JULY OF 2014. I DID ALSO SEND A COMPLAINT LETTER TO FORD - MORE TO THE SERVICE OF THE DEALERSHIP - HOWEVER I BELIEVE THIS ISSUE WAS IN THAT LETTER.
NHTSA ODI #10778491
27,700 miles · Aug 31, 2015
Fuel/propulsion SystemStructureSuspension
MY GRANDSON WENT OFF THE ROAD AT 70MPH INTO SOME PINE TREES AND COMPLETLE SEVERED THE PASSAGENS WHEEL OFF AND WINDSHIELD COMPLETLE DESTROYES ROOF DAMAGE AND BODY DAMAGE AND NO AIR BAGS DEPLOYED. I TALKE TO A CUSTOMER WHO ALSO HAD A 2014 EXPLORER THAT WAS INVOLVED IN A COLLISION AND THEIR AIR BAGS DIDN'T DEPLOY EITHER .THE DAMAGE…
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MY GRANDSON WENT OFF THE ROAD AT 70MPH INTO SOME PINE TREES AND COMPLETLE SEVERED THE PASSAGENS WHEEL OFF AND WINDSHIELD COMPLETLE DESTROYES ROOF DAMAGE AND BODY DAMAGE AND NO AIR BAGS DEPLOYED. I TALKE TO A CUSTOMER WHO ALSO HAD A 2014 EXPLORER THAT WAS INVOLVED IN A COLLISION AND THEIR AIR BAGS DIDN'T DEPLOY EITHER .THE DAMAGE TO MY VEHICLE WAS ON THE FRONT AND THE SIDE YET NO AIRBAGE DEPLOYED. SOMETHING IS WRONG !!! ITS A MIRACLE MY GRANDSON IS ALIVE I HAVE PICTURES.
NHTSA ODI #10760473
150 miles · Aug 10, 2015
Fuel/propulsion SystemFire
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING AT APPROXIMATELY 60 MPH WHENATTEMPTING TO ACCELERATE OR GOING UP AN INCLINE, THE VEHICLE EMITTED A BURNING ODOR. THE CONTACT STATED THAT THIS WAS A RECURRING FAILURE. THE VEHICLE WAS DRIVEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THAT THAT THE FUMES LEA…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING AT APPROXIMATELY 60 MPH WHENATTEMPTING TO ACCELERATE OR GOING UP AN INCLINE, THE VEHICLE EMITTED A BURNING ODOR. THE CONTACT STATED THAT THIS WAS A RECURRING FAILURE. THE VEHICLE WAS DRIVEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THAT THAT THE FUMES LEAKING INTO THE VEHICLE MIGHT BE CAUSED BY CRACKS IN THE REAR OF THE VEHICLE. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 150.
NHTSA ODI #10747632
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.
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