NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
2,449 reportsMileage unknown · Jun 22, 2026
SteeringSuspensionWheels
2016 Ford Explorer, VIN [XXX]. Filing against Planet Ford Dallas regarding incomplete Regional Program 21R01 (Rear Toe Link Replacement), tied to Federal Safety Recall 21V537. May 11, 2026: Vehicle presented for 21R01 service. May 15: Returned with recall marked complete in Ford's system. 21R01 mandates replacement of both rear …
Read full complaint
2016 Ford Explorer, VIN [XXX]. Filing against Planet Ford Dallas regarding incomplete Regional Program 21R01 (Rear Toe Link Replacement), tied to Federal Safety Recall 21V537. May 11, 2026: Vehicle presented for 21R01 service. May 15: Returned with recall marked complete in Ford's system. 21R01 mandates replacement of both rear toe links, alignment check, and rear toe adjustment. None of these steps were correctly completed. Dealer has since acknowledged to me that the toe link was not replaced correctly, but instead with the incorrect part and that rear suspension hardware was left loose upon vehicle release. The vehicle was driven approximately one month in this condition. Progressive symptoms followed: steering pull, steering wheel offset, tire screeching, and vehicle instability. Rear toe was subsequently found approximately 3 degrees out of specification — consistent with loose hardware shifting during normal driving. Dealer is attributing front suspension wear to natural causes while providing no investigation demonstrating the incomplete recall did not contribute to or accelerate that damage. Ford Motor Company Head Office has confirmed 21R01 as applicable (Corporate Case [XXX]). Dealer has declined to accept responsibility. The recall was marked complete in Ford's system despite mandatory work not being performed. I am requesting NHTSA investigate dealer compliance with 21R01/21V537 and whether a reimbursement claim was submitted to Ford for work not performed. This matter may also be referred to the Texas AG Consumer Protection Division and FTC. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11745716
Mileage unknown · Jun 19, 2026
Electrical System
I have a 2016 ford explorer limited and it has 2 separate recalls on it one being the exterior a pillar applique trim clip attachments are not properly engaged due to improper assembly which borders the right and left side of the windshield, may be loose missing or become detached. also, the driver and front passenger door b-pil…
Read full complaint
I have a 2016 ford explorer limited and it has 2 separate recalls on it one being the exterior a pillar applique trim clip attachments are not properly engaged due to improper assembly which borders the right and left side of the windshield, may be loose missing or become detached. also, the driver and front passenger door b-pillar trim appliques may become partially or fully detached. which I can hear wind noise and a rattling noise with also water pouring inside my truck when it rains, which has now caused damage to my wiring in the seats where the heat and cold does not work, nor does my sunroof/moonroof work anymore bc the water comes in from the top also
NHTSA ODI #11745291
Mileage unknown · Jun 19, 2026
Visibility/wiper
one fell of window right side when driving on right side of window i tried to glue it back on don't think it will hold don't drive it much now went to ford dealer several time always told part is not available why it is a 2016 after 10 years should replacement parts not be available
NHTSA ODI #11745266
246,000 miles · Jun 18, 2026
Structure
The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that while driving approximately 70 MPH, the front passenger’s side A-pillar trim became loose and was vibrating against the…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that while driving approximately 70 MPH, the front passenger’s side A-pillar trim became loose and was vibrating against the passenger’s side window. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 246,000.
NHTSA ODI #11745042
Mileage unknown · Jun 18, 2026
Structure
Multiple Ford dealerships in my service area have been contacted for recall dated Jan 19,2024, Manufacturer Recall Number24S02, NHTSA Recall Number24V031 but indicate Ford manufacturing does not have parts available. It has been over 2 years. What recourse do consumers have? Summary IN SOME OF THE AFFECTED VEHICLES, IT MAY BE PO…
Read full complaint
Multiple Ford dealerships in my service area have been contacted for recall dated Jan 19,2024, Manufacturer Recall Number24S02, NHTSA Recall Number24V031 but indicate Ford manufacturing does not have parts available. It has been over 2 years. What recourse do consumers have? Summary IN SOME OF THE AFFECTED VEHICLES, IT MAY BE POSSIBLE THAT SOME OF THE EXTERIOR A-PILLAR APPLIQUE TRIM CLIP ATTACHMENTS ARE NOT PROPERLY ENGAGED DUE TO IMPROPER ASSEMBLY OR REPAIR. IF THIS OCCURS, THE A-PILLAR APPLIQUE TRIM, WHICH BORDERS THE RIGHT AND LEFT SIDE OF THE WINDSHIELD, MAY BE LOOSE, MISSING OR BECOME DETACHED. Safety Risk AN EXTERIOR A-PILLAR TRIM PART THAT DETACHES WHILE DRIVING CAN CREATE A ROAD HAZARD FOR OTHER ROAD USERS, INCREASING THE RISK OF A CRASH. Remedy FORD MOTOR COMPANY HAS AUTHORIZED YOUR DEALER TO INSPECT AND REPAIR ANY LOOSE OR MISSING EXTERIOR A-PILLAR TRIM MOLDINGS FREE OF CHARGE PARTS AND LABOR. A TEMPORARY REPAIR MAY ALSO BE COMPLETED AS NEEDED.
NHTSA ODI #11744978
Mileage unknown · Jun 13, 2026
Steering
The electronic power steering failed Yes its available for inspection My child and my safety were put at risk when I warning came up and said "steering loss, stop safely" and the steering wheel was locked. The problem was still there when it was brought into Ford service center Nothing prior to the warning
NHTSA ODI #11743933
Mileage unknown · Jun 11, 2026
Unknown Or OtherInjury
I am filing a complaint regarding a safety recall on my 2016 Ford Explorer that remains unrepaired despite repeated attempts to have it fixed. I purchased this vehicle from a dealership in 2024. At the time of purchase, the dealership did not disclose any outstanding safety recalls. Within a few weeks of purchasing the vehicle,…
Read full complaint
I am filing a complaint regarding a safety recall on my 2016 Ford Explorer that remains unrepaired despite repeated attempts to have it fixed. I purchased this vehicle from a dealership in 2024. At the time of purchase, the dealership did not disclose any outstanding safety recalls. Within a few weeks of purchasing the vehicle, I noticed the exterior trim panels were loose and beginning to separate from the vehicle. I returned to the dealership, where I was told that replacement parts were not yet available but should be available soon. Ford’s recall notice stated that parts were anticipated to be available toward the latter half of 2024. However, that representation has proven inaccurate. I have now been waiting more than two years for this safety recall to be repaired. During that time, I have contacted the dealership regularly, often weekly, seeking updates and a resolution. No repair has been offered, and no meaningful timeline has been provided. The unrepaired condition has created significant safety hazards. Because of the loose trim panels, my windshield frequently fogs on the inside, making it extremely difficult or impossible to properly defrost during cold weather. This severely limits visibility while driving. I have experienced multiple near-collisions while transporting my children because I could not adequately clear the windshield. More recently, the situation escalated when a trim panel from the driver’s side door detached while I was driving. The panel flew off the vehicle and struck my daughter in the face while she was seated in the rear seat with the window down. Fortunately, her injuries were not more severe, but the incident demonstrates the serious danger posed by this unresolved recall. As a single mother of four children, I rely on this vehicle for daily transportation and cannot simply replace it. I have made every reasonable effort to obtain the recall repair, yet I continue to drive a vehicle with a known safety defect that has alrea
NHTSA ODI #11743417
Mileage unknown · Jun 6, 2026
Electrical System
I was driving on the highway and the driver side trim piece on the window flew off onto ongoing traffic. This is the second piece that flew off. The passenger side also flew off but was fixed. But now since this piece flew off I can’t even open my trunk. I did some research and it does say that the piece that flew off is connec…
Read full complaint
I was driving on the highway and the driver side trim piece on the window flew off onto ongoing traffic. This is the second piece that flew off. The passenger side also flew off but was fixed. But now since this piece flew off I can’t even open my trunk. I did some research and it does say that the piece that flew off is connected to the trunk and a wire might have snapped when the piece flew off and now won’t allow the trunk to open. I took it to ford and they told me they can’t do anything about it until I get the recall paper and they get the piece in stock. This has been a year now that I’ve been having to drive around like this and with trunk not opening. Please help!
NHTSA ODI #11742477
120,000 miles · Jun 4, 2026
Structure
The contact owns 2016 Ford Explorer. The contact recieved notice of NHTSA Campaign Number: 24V031000 (Structure). The contact stated that while driving at unknowns speeds, she observed something hitting the vehicle. The vehicle was stopped and when she observed the vehicle the lower passenger windshield had a missing trim piece.…
Read full complaint
The contact owns 2016 Ford Explorer. The contact recieved notice of NHTSA Campaign Number: 24V031000 (Structure). The contact stated that while driving at unknowns speeds, she observed something hitting the vehicle. The vehicle was stopped and when she observed the vehicle the lower passenger windshield had a missing trim piece. The contact added on another occasion while parked and examining the windshield she noticed that additional pieces were missing. The mechanic from the dealer made a house call to her residence where it was diagnosed that the pillar trim needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 120,000.
NHTSA ODI #11742111
90,686 miles · Jun 3, 2026
Back Over Prevention
The contact owns a 2016 Ford Explorer. The contact stated that distorted image would appear on rear view camera every time contact would go in reverse with his vehicle. The contact stated that distortion on camera started happening today, 06/03/2026. Contact stated they contacted dealer but has not contacted manufacturer. The v…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that distorted image would appear on rear view camera every time contact would go in reverse with his vehicle. The contact stated that distortion on camera started happening today, 06/03/2026. Contact stated they contacted dealer but has not contacted manufacturer. The vehicle failure damage regarding rear view camera distortion was 90,686 miles.
NHTSA ODI #11741765
Official recalls
14Jul 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
2PE23001 · 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
Illustration