Structure. Review the 584 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Steering. Review the 530 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine. Review the 381 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

39 crash reports14 fire reports43 injury reports

Unknown Or Other complaints

427 reports

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Mileage unknown · Nov 1, 2019

Unknown Or Other

WHEN I TURN THE HEAT ON A HORRIBLE SMELL LIKE ROTTEN EGGS COMES IN THE VEHICLE. THE ODOR IS SO STRONG IT HAS CAUSED HEADACHES AND HAS MADE ME AND FAMILY FEEL SICK TO OUR STOMACHS

NHTSA ODI #11277637

16,000 miles · Oct 17, 2019

Unknown Or Other

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THERE IS AN EXHAUST SMELL PERMEATING THE CABIN IN CITY DRIVING CAUSING DIZZINESS AND THE CABIN GETS FLOODED WITH EXHAUST FUMES UNDER HEAVY ACCELERATION DUE TO MERGING INTO TRAFFIC ON INTERSTATE ON RAMPS OR WHILE PASSING IN ANY DRIVING CONDITION ALL CONTRIBUTING TO DIZZINESS, HEADACHES AND SOMETIMES NAUSEA. EVEN WITH THE AIR CONDITIONER ON AND THE RECIRCULATING AIR FEATURE ENGAGED. SEVERAL TIMES DURING MY DRIVE I NEED TO OPEN THE WINDOW TO AIR OUT MY VEHICLE TO AVOID BECOMING ILL. I'VE HAD IT TO THE DEALER SEVERAL TIMES WITH NO RESOLUTION OF THIS ISSUE AND FORD'S REPLY IS SORRY BUT YOU EXPERIENCE NO MORE THAN WHAT IS ACCEPTABLE LEVELS OF EXHAUST FUMES. THIS IS THE FIRST VEHICLE I'VE OWNED THAT FLOODS THE CABIN WITH EXHAUST FUMES EVEN WITH THE A/C RECIRCULATING THE AIR. THIS IS AN ONGOING ISSUE SINCE I'VE OWNED THE VEHICLE FEBRUARY 2017.

NHTSA ODI #11269185

47,000 miles · Oct 9, 2019

EngineFuel/propulsion SystemUnknown Or Other

WAS DRIVING DOWN 95 @ 65 MPH WHEN ALL OF A SUDDEN, THE CAR JERKED AND LOST ALL POWER. WRENCH LIGHT, CHECK ENGINE, AND AIRBAG LIGHT ALL CAME ON. NO POWER. NO GAS, LIMP MODE. CODE READER DETERMINED THROTTLE BODY ISSUE. LOOKED ONLINE, APPEARS TO BE KNOWN ISSUE IGNORED BY FORD. I COULD HAVE BEEN KILLED

NHTSA ODI #11267269

Mileage unknown · Oct 5, 2019

Unknown Or Other

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HAVE A 2016 EXPLORER XLT. LAST SUMMER AND THIS SUMMER (MAINLY WHILE AC IS ON) THE WIERD NOISE OF WHOOP, WHOOP OR SLIDE WHISTLE OR POLICE SIRENS EMITTS FROM THE REAR OF THE VEHICLE. THINGS I KNOW 1) MAKES NOISE INTERMITTENTLY DURING DRIVING AT ALL SPEEDS. 2) CANT REPRODUCE SOUND FOR DEALER 3) MAKE NOISE MAINLY WHILE AC IS ON 4) WILL MAKE NOISE WHILE IDLING IN PARK 5) NOISE COMES FROM REAR OF VEHICLE, UNKNOWING OF A CERTAIN SIDE LEFT OR RIGHT 6) ONLY 2 POSTS I CAN FIND THAT SOMEWHAT DESCRIBES THIS NOISE ON THE INTERNET, NIETHER APPLY ANY HELP OR EXPERIENCES WOULD BE APPRECIATED, OTHERWISE A GREAT VEHICLE

NHTSA ODI #11266550

1 miles · Sep 18, 2019

Unknown Or Other

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THE EXHAUST FUMES AND CARBON MONOXIDE ARE PRESENT IN THE VEHICLE'S CABIN WHILE DRIVING. THE CAR WAS SERVICED AT THE FORD DEALER TWICE FOR THIS PROBLEM. FIRST TIME WAS AFTER FORD ISSUED AN OFFICIAL " CUSTOMER SATISFACTION PROGRAM" RELATED TO THIS ISSUE. SINCE I WAS CONSTANTLY DEALING WITH DIZZINESS, NAUSEA, AND OTHER SYMPTOMS CONSISTENT WITH CARBON MONOXIDE POISONING I TOOK THE CAR TO THE DEALER AGAIN. I WAS TOLD THAT THE PREVIOUS "REPAIR" WAS NOT DONE PROPERLY AND NEEDED TO BE CORRECTED. THE "CORRECTION" DID NOT HELP. THE CARBON MONOXIDE METER I KEEP IN THE CAR FREQUENTLY SOUNDS THE ALARM AND SHOWS ELEVATED LEVELS OF CO. THE HIGHEST LEVEL I HAVE SEEN WAS 52 PPM BEFORE OPENING ALL WIDOWS. I HAVE MULTIPLE VIDEO RECORDING OF THE METER READING GOING UP WHILE DRIVING. NOW I'M DRIVING WITH WINDOWS OPENED AND AC OFF TO AVOID GETTING SICK. I CONTACTED THE DEALER, THEY PROMISED TO CONTACT FORD FOR SOME SUGGESTIONS. I MADE MULTIPLE ATTEMPTS TO FOLLOW UP AND EVERY TIME I HEARD THAT FORD DID NOT ANSWER YET.

NHTSA ODI #11256347

48,000 miles · Jul 27, 2019

Unknown Or Other

I HAVE HAD AN ISSUE IN THE TRANSMISSION OR SHIFTING AND WON'T GO INTO GEAR OR DRIVE UNTIL YOU TAKE IT AND PUT BACK TO PARK. THEN SOMETIMES IT WILL AND SOMETIMES IT WON'T. I TOOK IT TO THE DEALER AND THEY HAD A FORD ENGINEER THAT THOUGHT THEY FIGURED IT OUT AFTER SHELLING SOMETHING AND REPAIRING IT. IT WORKED FOR A MONTH AND NOW…

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NHTSA ODI #11235297

65,000 miles · Jul 27, 2019

Unknown Or Other

SMELL OF SULFUR OR NATURAL GAS IN THE CABIN, CAUSING HEADACHES AND DIZZINESS. THE ISSUE SEEMS TO BE WORSENED IF CLIMATE CONTROL FANS ARE BLOWING. THE ISSUE OCCURS WHILE DRIVING OR IDLING.

NHTSA ODI #11235291

95,000 miles · Jul 23, 2019

Unknown Or Other

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CARBON MONOXIDE IN CAR. I DRIVE UP TO 8 HOURS A DAY FRO MY JOB. OVER THE PAST SEVERAL MONTHS I'VE EXPERIENCE DIZZINESS AND NAUSEA THOUGHT OUT THE DAY AND RECENTLY LEARNED OF CO ISSUES WITH FORD EXPLORERS. I PURCHASED A CO DETECTOR LAST WEEK TO TEST MY CAR OVER THE PAST 3 DAYS THE ALARM HAS GONE OFF INDICATING HIGH LEVELS OF CO IN THE CABIN WHILE THE CAR WAS IN MOTION AND STOPPED. SPECIFICALLY, WITH THE AIR CONDITIONER ON "AUTO" AT APPROXIMATELY 3500RPM THE DETECTOR REGISTERED CO IN THE CABIN, AT 4500 RPM THE LEVEL OF CO DOUBLED.

NHTSA ODI #11234296

20,000 miles · Jul 16, 2019

Unknown Or Other

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TIRES - ALL 4 HANOOK TIRES DOT # 5MNC 1A H (0216) 255/50/R20 TREADS HAVE BEEN CHIPPING AND PEELING UP RESULTING IN UNSAFE CONDITIONS AND EXCESSIVE WEAR. THESE TIRES ARE CLEARLY PROBLEMATIC TIRES AND COMPLETELY WORN OUT AT 20,000 MILES. MANUFACTURER IS AWARE IF THIS RESULTING FROM NEW COMPOUNDS (MATERIALS) USED IN MANUFACTURING. HIGH SPEED BLOWOUTS HAVE BEEN REPORTED FOR THIS PARTICULAR TIRE YET NO RECALL HAS BEEN ISSUED FOR THIS TIRE DESPITE ITS DEFECTS AND SAFETY CONCERNS. I FIRST NOTICED IT ON THE TWO FRONT TIRES. IT IS SHOCKING THAT FORD WOULD USE THESE TIRES.

NHTSA ODI #11232259

33,000 miles · Jun 25, 2019

SteeringUnknown Or Other

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I BROUGHT MY 2016 FORD EXPLORER SPORT INTO LHM DRAPER ON APRIL 29TH WITH SOME SERVICE CONCERNS. THE MOST IMPORTANT PROBLEM WAS A CLUNKING/KNOCKING/BUCKLING NOISE IN THE FRONT END WHEN TURNING THE WHEEL. AFTER LEAVING THE CAR FOR 12 DAYS I DISCOVERED THEY DID NOT FIX ANYTHING. FOR THE NEXT 9 DAYS AS I DROVE THE CAR I NOTICED THAT THE CLUNKING NOISE WAS STILL VERY MUCH PRESENT AND HAPPENING EVERY SINGLE DAY. THERE WASN'T A SINGLE DAY THAT I DIDN'T HEAR THIS NOISE. I TOOK THE CAR BACK IN ON MAY 24TH AGAIN FOR A CLUNKING/KNOCKING NOISE IN FRONT END WHEN THE WHEEL IS TURNED. ALSO A WHINING/WINDING NOISE FROM THE STEERING WHEEL. I PICKED THE CAR UP ON JUNE 4TH ONLY TO DISCOVER IT STILL WASN'T FIXED. I HAVE SENT SEVERAL MESSAGES TO THE DEALER WITH NO RESPONSE. THE CAR MAKES THIS NOISE DAILY. TO MY DISMAY, I DID SOME GOOGLE SEARCHES ON THE INTERNET YESTERDAY FOR POTENTIAL CAUSES OF THIS KNOCKING NOISE AND DISCOVERED THIS IS A HUGE PROBLEM WITH FORD EXPLORERS!!! THERE ARE HUNDREDS AND HUNDREDS OF COMPLAINTS!!! I ALSO UNDERSTAND FORD RECALLED EARLIER MODEL YEAR EXPLORERS WITH POWER STEERING PROBLEMS WITH THIS SAME KNOCKING NOISE. I AM CONCERNED THAT I AM NOW OUTSIDE OF MY WARRANTY PERIOD. I KNOW ALL TOO WELL ABOUT THAT. WE HAVE A 2006 FORD F350 WITH ONLY 55,000 MILES SITTING ON THE SIDE OF OUR HOUSE THAT HASN'T BEEN DRIVABLE FOR YEARS. ABOUT A YEAR AFTER WE BOUGHT THE TRUCK, WE BEGAN HAVING PROBLEMS WITH OVERHEATING AND ONE DAY IT STARTED BLOWING WHITE SMOKE. WE IMMEDIATELY TOOK IT TO THE DEALER AND WERE TOLD THAT THIS PARTICULAR TRUCK HAS PROBLEMS WITH THE EGR COOLER. THE VEHICLE WAS SERVICED, BUT SOMETIME AFTER THE WARRANTY EXPIRED IT BEGAN EXPERIENCING THE SAME PROBLEMS AND FORD WASHED THEIR HANDS OF IT. WE'VE BEEN TOLD THAT IT WILL COST OVER $10K TO GET IT FIXED. SO THERE IT SITS! THIS VEHICLE IS ONLY 3 YEARS OLD WITH 33,000 MILES.

NHTSA ODI #11222511

Official recalls

26V448000 · Structure:body

Jul 14, 2026

Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The roof rail covers may come loose and detach from the vehicle.

Consequence & remedy

Consequence: A detached roof rail cover can create a road hazard, increasing the risk of a crash.

Remedy: Dealers will inspect the roof rail covers and as necessary, repair or replace the push-pins, rail clips, or roof rail covers, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 28, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S54. This recall expands previous NHTSA recall number 21V316. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.

25V685000 · Equipment:electrical:engine Block Heater

Oct 10, 2025

Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.

Consequence & remedy

Consequence: An electrical short circuit can increase the risk of a fire.

Remedy: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.

25V347000 · Structure:body

May 23, 2025

Ford Motor Company (Ford) is recalling certain 2016-2017 Explorer vehicles. The driver and front passenger B-Pillar door trim may detach while driving.

Consequence & remedy

Consequence: Door trim that detaches while driving can create a road hazard, increasing the risk of a crash.

Remedy: Dealers will repair the B-pillar trim, free of charge. Interim letters, notifying owners of the safety risk, were mailed June 5, 2025. A second notice will be sent once the final remedy is available, anticipated November 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S53.

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.

21V316000 · Structure:body

May 5, 2021

Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The retention pins could loosen and allow the roof rail covers to detach from the vehicle.

Consequence & remedy

Consequence: A detached roof rail cover can create a road hazard, increasing the risk of a crash.

Remedy: Dealers will install push-pins and replace any damaged rail clips and roof rail covers, as necessary, free of charge. The interim owner notification letter was mailed on June 22, 2021. Owner notification letters (remedy available) were mailed on October 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S22.

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.

17V767000 · Seats

Nov 29, 2017

Ford Motor Company (Ford) is recalling certain 2016 F-150 and Explorer vehicles. Loose power seat adjuster pivot bolts may cause the front seat cushions to detach and not properly restrain the seat occupant in the event of a crash.

Consequence & remedy

Consequence: In the event of a crash, a seat occupant that is not properly restrained has an increased risk of injury.

Remedy: Ford will notify owners, and dealers will inspect the tightness of the power seat track upper pivot link bolt, either applying threadlocker or replacing the lift link and hardware, free of charge. Interim letters are expected to go out January 15, 2018. Owners will receive a second notice when the remedy becomes available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S40.

16V475000 · Seats:front Assembly:recliner

Jun 28, 2016

Ford Motor Company (Ford) is recalling certain model year 2016 Ford Explorer and F-150 vehicles equipped with a manual recline driver's seat. The seat back frame may have insufficient welds which may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202, "Head Restraints" and 207, "Seating Systems."

Consequence & remedy

Consequence: The seat back may not adequately restrain the occupant during a crash, increasing the risk of injury.

Remedy: Ford will notify owners, and dealers will inspect and, if necessary, replace the seat back frame, free of charge. The recall begin on August 18, 2016. Owners may contact Ford at 1-800-392-3673. Ford's number for this recall is 16C11.

16V183000 · Engine And Engine Cooling:engine

Mar 31, 2016

Ford Motor Company (Ford) is recalling certain model year 2015-2016 Lincoln MKC vehicles manufactured November 25, 2013, to January 25, 2016, and 2016 Ford Explorer vehicles manufactured October 20, 2014, to January 28, 2016. The affected vehicles are equipped with 2.3L GTDI engines and engine block heaters. These engine block heaters have elements that may overheat while plugged in.

Consequence & remedy

Consequence: Overheating of the engine block increase the risk of a fire.

Remedy: Ford will notify owners, and dealers will replace the engine block heater, free of charge. Dealers will also inspect and replace the electrical cord, as necessary. The recall began on May 18, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S14. Note: Owners should not use the engine block heater until the vehicle has been remedied.

15V605000 · Fuel System, Gasoline:storage:tank Assembly:mounting

Sep 28, 2015

Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Lincoln MKS, and 2016 Ford Explorer vehicles manufactured on July 24, 2015. During vehicle production, the fuel tank attachment bolts may not have been properly tightened. As a result, the fuel tank straps may fracture and the fuel tank could separate from the vehicle.

Consequence & remedy

Consequence: If the fuel tank separates from the vehicle, a fuel leak may occur, increasing the risk of a fire.

Remedy: Ford will notify owners, and dealers will tighten the fuel tank attachment bolts, as necessary, free of charge. The recall began on October 19, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S26.

15V464000 · Parking Brake

Jul 24, 2015

Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Ford Flex, and Lincoln MKS vehicles manufactured May 4, 2015, to May 23, 2015, Lincoln MKT vehicles manufactured May 4, 2015, to May 21, 2015, and 2015-2016 Ford Explorer vehicles manufactured May 4, 2015, to May 23, 2015. The affected vehicles have a parking brake that may not fully engage when applied. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 135, "Light Vehicle Brake Systems."

Consequence & remedy

Consequence: If the parking brake does not fully engage and the transmission is left in a gear other than 'Park' while on a slope, the vehicle may roll away, increasing the risk of a crash.

Remedy: Ford will notify owners, and dealers will test the operation of the parking brake system, and if necessary, replace the parking brake control assembly, free of charge. The recall began on September 4, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15C07.

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

Go deeper into Ford Explorer problems

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