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NHTSA owner reports · September 18, 2026 snapshot.

32 crash reports6 fire reports29 injury reports

Unknown Or Other complaints

335 reports

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Mileage unknown · Feb 16, 2016

Unknown Or Other

WHILE DRIVING WITH THE AIR CONDITIONING OR HEAT ON THE VEHICLE HAS A STRONG ODOR OF BURNING PLASTIC OR SULFUR TYPE SMELL.

NHTSA ODI #10836534

Mileage unknown · Dec 18, 2015

Fuel/propulsion SystemUnknown Or Other

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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

8 miles · Dec 1, 2015

Unknown Or Other

VEHICLE IS EMITTING CARBON MONOXIDE AND OTHER DANGEROUS FUMES INTO CABIN AFTER ACCELERATION. CAUSING MY ASTHMA TO FLAIR. MY WIFE AND KIDS HAVE HEADACH WHEN IN CAR WITH ME. I BEEN HAVING BREATHING ISSUE SINCE I PURCHASED THE CAR.

NHTSA ODI #10807664

Mileage unknown · Nov 15, 2015

Unknown Or Other

VEHICLE IS EMITTING CARBON MONOXIDE AND OTHER DANGEROUS FUMES INTO CABIN WHILE IN OPERATION

NHTSA ODI #10790476

5,000 miles · Aug 23, 2015

EngineUnknown Or Other

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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

500 miles · Aug 21, 2015

Unknown Or Other

EXHAUST FUMES ENTERING CABIN UPON ACCELERATION, SUCH AS ENTERING INTERSTATE OR PASSING ANOTHER VEHICLE.

NHTSA ODI #10750387

45,000 miles · Aug 17, 2015

Unknown Or Other

WHEN ACCELERATING ONTO HIGHWAY, THERE IS A STRONG EXHAUST-LIKE ODOR COMING FROM THE VENTS. I HAVE TAKEN THE VEHICLE BACK TO THE DEALERSHIP AND THEY CANNOT FIND ANY REASON WHY THE ODOR WOULD BE COMING INSIDE THE VEHICLE. THIS IS EXTREMELY DISTURBING AS I ALSO HAVE MY 4 YEAR OLD INHALING THESE FUMES WHICH I BELIEVE IS CARBON MONOX…

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NHTSA ODI #10749264

25 miles · Aug 10, 2015

Unknown Or OtherInjury

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I AM NOTICING A SMELL COMING OUT OF AIR VENTS. OCCURRING SINCE AS FAR BACK AS I REMEMBER BUT DON'T RECALL EXACT DATE WHEN I STARTED QUESTIONING THE SMELL.. THE SMELL IS A BURNING SMELL - NOT ELECTRICAL BUT ALMOST LIKE HAIR/HAIR DRYER WHEN IT GETS HOT. I NOTICE WHEN I ACCELERATE TO GET ON EXPRESSWAYS AND/OR IF I'M GOING UP A HILL (BASICALLY WHEN I GO INTO HIGH GEAR). MY HUSBAND WAS IN THE CAR AT A TIME RECENTLY AND SO I ASKED HIM IF HE COULD SMELL IT AND HE IMMEDIATELY SAID IT WAS EXHAUST COMING IN THROUGH THE AIR VENTS. I'M NOT SURE IF I CAN SMELL IT MORE WHEN THE AIR IS ON AND THE WINDOWS CLOSED BUT DUE TO ALLERGIES AND RESPIRATORY ISSUES I MORE TIMES THAN NOT DRIVE WITH WINDOWS CLOSED AND THEREFORE SMELL IT QUITE OFTEN THROUGHOUT THE YEAR. I AM NOT SURE IF DIRECTLY RELATED OR NOT BUT LAST TWO YEARS I DROVE 12 HOURS TO FLORIDA AND BY THE TIME I GO THERE I HAD HEADACHE AND BREATHING PROBLEMS AND CONTINUE TO STRUGGLE WITH THAT MORE OFTEN THAN I EVER HAVE BEFORE. I'M WORRIED THAT THIS EXHAUST INTO MY CAR IS MAGNIFYING MY HEALTH ISSUES. REGARDLESS, IT IS A DANGER TO HAVE THIS EXHAUST COMING IN THROUGH THE CAR. I AM TAKING TO FORD THIS COMING FRIDAY. I STOPPED IN TO TALK TO THEM AND THEY SAID THEY WERE NOT AWARE OF ISSUES LIKE THIS. I GOOGLED THE ISSUE MERELY AS "FORD EXPLORE EXHAUST ISSUES" AND WAS SHOCKED AND HORRIFIED BY THE FACT THAT IT APPEARS VERY COMMON AND THAT A CIVIL SUIT WAS FILED IN FLORIDA. RIGHT NOW THEY ARE SAYING WARRANTIES SHOULD COVER THE FIX BUT I'VE READ WHERE THE FIX ISN'T WORKING EITHER. I WILL SEE WHAT THEY SAY ONCE THEY HAVE MY CAR BUT ANYONE HAVING THIS PROBLEM NEEDS TO REPORT IT SO THAT IT CAN BE RECTIFIED BY EVERYONE HAVING THIS VEHICLE DURING THE YEARS NOTED IN THE CLAIMS! IN JUST COMING TO THIS SITE ALONE I SEE THAT SEVERAL OTHERS ARE HAVING SAME ISSUES. I DON'T PAY THIS MUCH FOR A VEHICLE FOR IT TO MAKE ME SICK!

NHTSA ODI #10747611

2,000 miles · Aug 3, 2015

Unknown Or Other

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WHEN ACCELERATING HARD, EXHAUST FUMES BLOW INTO THE CABIN FROM THE AC. CALLED THE DEALERSHIP WITHIN A MONTH AFTER BUYING THE VEHICLE AND WAS TOLD THAT IT WAS BECAUSE THE CAR/ENGINE WAS NEW. I'D NEVER OWNED A NEW CAR BEFORE SO I TOOK THEIR WORD FOR IT. HOWEVER, AFTER THE ISSUE KEPT REOCCURING FOR 8+ MONTHS, I BROUGHT THE EXPLORER TO THE DEALERSHIP AND TOLD THEM I WANTED IT CHECKED OUT. I WAS INFORMED THAT NOTHING WAS WRONG AND I COULD TRY USING A FUEL ADDITIVE TO HELP CLEAN THE ENGINE. ANY TIME I ACCELERATE HARD, I PRETTY MUCH JUST HAVE TO ROLL DOWN THE WINDOW OR I'LL START GETTING LIGHT HEADED. IT HAS REACHED THE POINT THAT I'M NOW LOOKING TO GET A NEW VEHICLE. I'M AMAZED THAT DESPITE MULTIPLE LAWSUITS AGAINST FORD, THESE EXPLORERS HAVE YET TO BE RECALLED.

NHTSA ODI #10745747

200 miles · Jul 27, 2015

Unknown Or Other

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BOUGHT THIS 2014 FORD EXPLORER NEW THE LAST OF MAY, 2014. IMMEDIATELY UPON ACCELERATION SMELLED EXHAUST. THOUGHT IT WAS COMING FROM OUTSIDE AIR. THE SMELL STOPPED WHEN WE QUIT USING THE AIR CONDITIONER. THE SMELL STARTED AGAIN THIS SUMMER WHEN WE STARTED USING THE AIR CONDITIONER.. WE FINALLY REALIZED THAT IT WAS OUR VEHICLE AND NOT OUTSIDE AIR. TOOK CAR ON VACATION AND IT WAS SO BAD IT MADE US ALL SICK. HAVE HAD IT TO THE DEALER TWO TIMES. THE FIRST TIME THEY SAID THEY COULD NOT FIND ANYTHING WRONG. TODAY, WE TOOK IT BACK AS IT IS SO BAD I AM SICK. THEY ADMITTED THERE WAS A KNOWN PROBLEM BUT NO FIX. SAID THERE WILL BE A FIX IN THE NEAR FUTURE. THE CARBON MONOXIDE IS SO STRONG AT RANDOM TIMES THAT WE ARE GETTING AFRAID TO DRIVE IT. IT SEEMS TO BE THE WORSE ON SUDDEN ACCELERATION, SUCH AS PULLING OUT INTO TRAFFIC. SOMETHING NEEDS TO BE DONE AS THIS IS VERY DANGEROUS. WE WERE SICK DURING VACATION AS WELL AS THE LADY WHO WAS WITH US....UPDATED 11/04/15 *BF

NHTSA ODI #10743755

Official recalls

24V031000 · Structure:body:roof And Pillars

Jan 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.

21V537000 · Suspension:rear

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.

20V675000 · Suspension:rear

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.

20V692000 · Power Train:axle Assembly:axle Shaft

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.

19V435000 · Suspension:rear

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.

16V245000 · Suspension:rear

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

PE23001 · 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

Structure:body

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

Structure:body

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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