NHTSA owner reports · September 18, 2026 snapshot.
Suspension complaints
102 reportsClear category filter58,000 miles · Jul 7, 2016
Suspension
RECENTLY HAD TO REPLACE A FAILED POWER STEERING ISSUE, AND I AM READING THAT MANY OTHERS ARE HAVING THE SAME ISSUE. FORD HAS INDICATED THAT MY VEHICLE IS NOT CURRENTLY UNDER A RECALL, BUT OBVIOUSLY IT IS EFFECTING MORE VEHICLES THAN JUST THE ONES THEY HAVE RECALLED. MY VEHICLE LOST THE ABILITY TO STEER ON THE FREEWAY, PUTTIN…
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RECENTLY HAD TO REPLACE A FAILED POWER STEERING ISSUE, AND I AM READING THAT MANY OTHERS ARE HAVING THE SAME ISSUE. FORD HAS INDICATED THAT MY VEHICLE IS NOT CURRENTLY UNDER A RECALL, BUT OBVIOUSLY IT IS EFFECTING MORE VEHICLES THAN JUST THE ONES THEY HAVE RECALLED. MY VEHICLE LOST THE ABILITY TO STEER ON THE FREEWAY, PUTTING MYSELF AND MY CHILDRENS' LIVES AT RISK. THIS IS DISGRACEFUL THAT FORD WILL NOT RECOGNIZE THIS ISSUE FOR MORE THAN JUST THE SELECTED VEHICLES.
NHTSA ODI #10883380
Mileage unknown · Jun 20, 2016
Suspension
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION); HOWEVER, THE PARTS FOR THE RECALL REPAIR WERE NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE CONTACT HAD NOT EXPERIENCED A FAILURE…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION); HOWEVER, THE PARTS FOR THE RECALL REPAIR WERE NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE CONTACT HAD NOT EXPERIENCED A FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. PARTS DISTRIBUTION DISCONNECT. UPDATED 08/05/16*LJ UPDATED 09/29/16.*JB
NHTSA ODI #10875302
Mileage unknown · Jun 17, 2016
Suspension
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS A MANUFACTURER RECALL ON THE SUSPENSION. THERE WAS NO PERMANENT REPAIR SOLUTION YET AND THE PART WAS NOT AVAILABLE FOR THE SUSPENSION RECALL. THE CONTACT WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE MANUFACTURER WAS UNABLE TO P…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS A MANUFACTURER RECALL ON THE SUSPENSION. THERE WAS NO PERMANENT REPAIR SOLUTION YET AND THE PART WAS NOT AVAILABLE FOR THE SUSPENSION RECALL. THE CONTACT WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE MANUFACTURER WAS UNABLE TO PROVIDE A REPAIR SOLUTION TO REFER THE CONTACT TO THE DEALER FOR INSPECTION AND REPAIR. THE CONTACT HAD NOT EXPERIENCED A FAILURE.
NHTSA ODI #10874775
44,000 miles · Jun 14, 2016
SteeringSuspension
I AM HAVING A MAJOR CONCERN OVER THIS RECALL GIVEN THE FACT THAT NOTHING CAN BE DONE TO RESOLVE THIS ISSUE UNTIL THE THIRD QUARTER OF 2016. HOW CAN FORD ALLOW 75K+ DRIVERS TO DRIVE WILLINGLY KNOWING THERE MAY BE A POTENTIAL ISSUE WITH THEIR STEERING. THIS IS EVEN MORE SO OF A CONCERN FOR ME SINCE MY FAMILY AND I ARE SCHEDULED TO…
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I AM HAVING A MAJOR CONCERN OVER THIS RECALL GIVEN THE FACT THAT NOTHING CAN BE DONE TO RESOLVE THIS ISSUE UNTIL THE THIRD QUARTER OF 2016. HOW CAN FORD ALLOW 75K+ DRIVERS TO DRIVE WILLINGLY KNOWING THERE MAY BE A POTENTIAL ISSUE WITH THEIR STEERING. THIS IS EVEN MORE SO OF A CONCERN FOR ME SINCE MY FAMILY AND I ARE SCHEDULED TO TRAVEL NORTH 16 HOURS TOMORROW. HEAVEN FORBID BUT WHO WILL BE RESPONSIBLE FOR DAMAGES TO MY VEHICLE OR MY FAMILY BECAUSE FORD WAS NOT PROACTIVELY PREPARED TO REMEDY THIS ISSUE? WHO WILL REIMBURSE ME FOR A RENTAL SINCE I CANNOT RELY ON MY VEHICLE I PAY GOOD MONEY FOR AND ON TIME EVERY MONTH? THIS IS MY VERY FIRST FORD VEHICLE I HAVE HAD FOR 6 MONTHS AND THIS IS THE 2ND STEERING ISSUE IVE ENCOUNTERED AND AM VERY DISAPPOINTED AND CONCERNED. JUST THREE WEEKS AGO I HAD TO HAVE MY STEERING RACK REPLACED. THIS IS JUST UNACCEPTABLE!
NHTSA ODI #10874124
18,500 miles · Dec 18, 2015
Air BagsSteeringSuspensionCrashInjury
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 5 MPH, THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER WITHOUT WARNING. AS THE CONTACT APPLIED FORCE TO THE STEERING WHEEL IN ORDER TO STEER THE VEHICLE, THE VEHICLE SUDDENLY JERKED TO THE SIDE. AS A RESULT, THE CONTACT CRASHED INTO…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 5 MPH, THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER WITHOUT WARNING. AS THE CONTACT APPLIED FORCE TO THE STEERING WHEEL IN ORDER TO STEER THE VEHICLE, THE VEHICLE SUDDENLY JERKED TO THE SIDE. AS A RESULT, THE CONTACT CRASHED INTO THE REAR END OF ANOTHER VEHICLE. THE AIR BAGS FAILED TO DEPLOY. UPON INSPECTION, THE CONTACT NOTICED THAT THE LOWER CONTROL ARM IN THE FRONT OF THE VEHICLE HAD FRACTURED. THE CONTACT SUSTAINED MINOR BRUISES AND THE REAR PASSENGER SUSTAINED MINOR NECK BRUISES THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE CONTROL ARM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 18,500.
NHTSA ODI #10811166
18,500 miles · Dec 18, 2015
SuspensionCrash
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 5 MPH, THE LOWER CONTROL ARM FRACTURED CAUSING THE CONTACT TO CRASH INTO ANOTHER VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. NO FURTHER DETAILS WERE AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE …
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 5 MPH, THE LOWER CONTROL ARM FRACTURED CAUSING THE CONTACT TO CRASH INTO ANOTHER VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. NO FURTHER DETAILS WERE AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 18,500.
NHTSA ODI #10811158
21,600 miles · Sep 24, 2015
Suspension
ON SEPTEMBER 17, 2015 PICKED MY DAUGHTER UP FROM SWIM PRACTICE AT 5:50 PM THEN WE WENT TO PICK HER FRIEND UP AND WENT ON 220 TOWARDS MILL HALL TO DROP THEM OFF AT A FOOTBALL GAME, WHILE ON HIGH WAY SMELLED AN AWFUL SMELL, THOUGHT IT WAS CAR IN FRONT OF ME, WE PROCEEDED TO MILL HALL EXIT WHERE WE GOT OFF AND TOOK THEM TO CENTRAL …
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ON SEPTEMBER 17, 2015 PICKED MY DAUGHTER UP FROM SWIM PRACTICE AT 5:50 PM THEN WE WENT TO PICK HER FRIEND UP AND WENT ON 220 TOWARDS MILL HALL TO DROP THEM OFF AT A FOOTBALL GAME, WHILE ON HIGH WAY SMELLED AN AWFUL SMELL, THOUGHT IT WAS CAR IN FRONT OF ME, WE PROCEEDED TO MILL HALL EXIT WHERE WE GOT OFF AND TOOK THEM TO CENTRAL MOUNTAIN MIDDLE SCHOOL DROPPED THEM OFF TO A FOOTBALL GAME AND PROCEEDED THROUGH PARKING LOT WHICH IS 5 MPH OR LESS AND AT APPROXIMATELY 6:16 PM MY CAR LOCKED UP SKIDDED OVER TO CURB AND HIT THAT A COUPLE TIMES AND THEN ACROSS THE PARKING LOT WHERE IT STOPPED HALF IN MIDDLE OF ROAD. I WAITED 4 HOURS FOR A TOW TRUCK WHICH AS TOWED TO FORD GARAGE, NEXT DAY STATE POLICE LOOKED AT MY CAR BEFORE ANYONE ELSE AND DEFINITELY A FAULTY LOWER CONTROL ARM WHICH SNAPPED OFF.. ON SEPTEMBER 23, 2015 FORD GARAGE CALLED SAID FORD IS NOT GOING TO PAY FOR MY CAR OR LOOK AT IT AND I NEED TO CALL INTO MY INSURANCE COMPANY. ...UPDATED 12/29/15 *BF AFTER INSPECTING THE LOWER CONTROL ARM, IT APPEARED TO BE WEAK IN THE AREA OF THE BREAK. THERE WAS DAMAGE TO THE VEHICLE AS A RESULT OF THE BREAK, BUT NO EVIDENCE TO INDICATE ANY DAMAGE PRIOR TO THE BREAK.
NHTSA ODI #10776247
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
39,000 miles · Jul 13, 2015
SteeringStructureSuspension
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT AREA OF THE VEHICLE NEAR THE BUMPER. THE NOISE WAS PRESENT WHEN THE STEERING WHEEL WAS TURNED TO THE LEFT OR RIGHT. THE DEALER COULD NOT DUPLICATE THE FAILURE INITIALLY. THE CONTACT TOOK THE VEHICLE TO THE DEALER …
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT AREA OF THE VEHICLE NEAR THE BUMPER. THE NOISE WAS PRESENT WHEN THE STEERING WHEEL WAS TURNED TO THE LEFT OR RIGHT. THE DEALER COULD NOT DUPLICATE THE FAILURE INITIALLY. THE CONTACT TOOK THE VEHICLE TO THE DEALER A SECOND TIME AND THEY REPLACED THE HALF SHAFT THRUST WASHER. ON A THIRD VISIT TO THE DEALER, THEY PROVIDED A TEST DRIVE, REPLACED THE PASSENGER SIDE STRUTS, AND INSPECTED THE NUTS AND BOLTS; HOWEVER, THE NOISE CONTINUED. THE VEHICLE WAS TAKEN TO THE DEALER'S BODY SHOP. THE TECHNICIAN MOVED THE FRONT BUMPER AND REPLACED THE FRONT PASSENGER SIDE BODY APRON PANEL ALONG WITH NEW BOLTS, BUT THE NOISE CONTINUED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 39,000.
NHTSA ODI #10733783
10,000 miles · May 17, 2015
StructureSuspension
VEHICLE WAS TRAVELING APPROXIMATELY 30-35 MPH DOWN A ROAD WITH NO POT HOLES WHEN THE FRONT RIGHT LOWER CONTROL ARM BROKE IN HALF. VEHICLE LOST CONTROL AND PULLED TO THE RIGHT BRINGING THE VEHICLE INTO THE STREET CURB. DAMAGE TO THE FENDER, TIRE, WHEEL, CV JOINT, AND OTHER ASSOCIATED PARTS REPORTED. FORD DENIES WARRANTY CLAIM.…
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VEHICLE WAS TRAVELING APPROXIMATELY 30-35 MPH DOWN A ROAD WITH NO POT HOLES WHEN THE FRONT RIGHT LOWER CONTROL ARM BROKE IN HALF. VEHICLE LOST CONTROL AND PULLED TO THE RIGHT BRINGING THE VEHICLE INTO THE STREET CURB. DAMAGE TO THE FENDER, TIRE, WHEEL, CV JOINT, AND OTHER ASSOCIATED PARTS REPORTED. FORD DENIES WARRANTY CLAIM....05-27-15 *BF UPDATED 10/17/2017*CN
NHTSA ODI #10716939
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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