NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
237 reportsClear category filterMileage unknown · Feb 27, 2025
Engine
I was driving my 2017 Ford Explorer on 10/14/22 and the engine started shaking aggressively randomly. So, I took it to our local Mechanic shop . They said that from the engine shaking, it had broken the engine mounts, and it had an internal problem. I had paid $200 to fix the engine mount. So, they had a service bulletin and sa…
Read full complaint
I was driving my 2017 Ford Explorer on 10/14/22 and the engine started shaking aggressively randomly. So, I took it to our local Mechanic shop . They said that from the engine shaking, it had broken the engine mounts, and it had an internal problem. I had paid $200 to fix the engine mount. So, they had a service bulletin and said Ford should fix it for free because it’s a known problem. They had provided me with the service bulletin 22-2287. My husband took the copy of the bulletin to ford, and brought the car. Explained that it already had other recalls on it that needed to be fixed and showed him the service bulletin. He asked if it would be covered and the guy said “It should be”. Then, we proceed to get a call the next day that it’s not covered because it hasn’t “officially” been recalled and it would be$4200 to fix. Even though the engine is going to ruin the parts in a few years because it’s the engine causing the other parts to overheat. So, I told them I wanted to get a second opinon, and they charged me “diagnostic fee” of $213.76, even tho they told my husband the diagnostic fee if it wasn’t covered would be $80. So, after months of fighting ford to make things right,I had the car towed to a local transmission shop , and had them repair it for 4,655.. I go to pick it up, and it’s still shaking. So bring it back, and they fix it again, Well, it’ still not fixed. Then, they fix it again, and I pick it up, the transmission isn’t running correctly.I have been without a working car since 10/14/22. So, now they are fixing it again and putting another brand new transmission in. Ford needs to be held responsible. This is a known issue, and could lead to someone getting into a terrible accident when the engine falls through the car, and could kill someone. The engine itself it heating up other components of the car, and ruining it. As of today, 02/27/2025 the transmission is starting to have problems again! When I am driving and come to a stop it wont accelerate
NHTSA ODI #11645367
Mileage unknown · Feb 22, 2025
Engine
Check engine light came on while driving on highway. I had a OBD reader with me and plugged it in. Came back with a cylinder misfire. Took it to a local mechanic to get new plugs and coils. Mechanic cleared the code but the light came back on. I took it to another mechanic that I trust who found coolant in the oil due to cracked…
Read full complaint
Check engine light came on while driving on highway. I had a OBD reader with me and plugged it in. Came back with a cylinder misfire. Took it to a local mechanic to get new plugs and coils. Mechanic cleared the code but the light came back on. I took it to another mechanic that I trust who found coolant in the oil due to cracked heads. Mechanic gave me information about this 3.5l motor being known to have this problem to take back to dealer. 3 months of waiting and having to argue that despite being out of warranty, they knew this motor was bad and should replace it. Ford finally put a new motor in. Drove for 6 more months and just had the check engine light come back. Cylinder misfire again. They shouldn't be allowed to sell this motor knowing that it can leave people stranded. This is criminal. Will never buy a Ford again. They KNOW this motor is trash but keep letting unsuspecting consumers foot the bill be cause they assume it's a one off. Shame!
NHTSA ODI #11644312
Mileage unknown · Feb 15, 2025
Engine
1. The cylinder head gasket (2.3L Eng Standard EJ7Z-6079-F) had cracked due to a problem that my mechanic said was common for engines of this make / year. 2. If this had not been fixed could have damaged the cylinder head and totaled the vehicle, is my understanding. 3. Yes 4. No 5. I noticed the engine felt different and …
Read full complaint
1. The cylinder head gasket (2.3L Eng Standard EJ7Z-6079-F) had cracked due to a problem that my mechanic said was common for engines of this make / year. 2. If this had not been fixed could have damaged the cylinder head and totaled the vehicle, is my understanding. 3. Yes 4. No 5. I noticed the engine felt different and the check engine light was sporadically on and off. First occurred Nov, 2024.
NHTSA ODI #11642891
Mileage unknown · Jan 27, 2025
Engine
Was driving my vehicle on the highway when it start chugging and died. Had to act Fast to get off the highway as there was no shoulder nor warning. I had the vehicle towed to my shop and they confirmed the engine was done. The water pump gave out while driving with no warning and took the engine out. It appears after doing s…
Read full complaint
Was driving my vehicle on the highway when it start chugging and died. Had to act Fast to get off the highway as there was no shoulder nor warning. I had the vehicle towed to my shop and they confirmed the engine was done. The water pump gave out while driving with no warning and took the engine out. It appears after doing some research Ford has 2 years of Explorers (2016 & 2017) that they did an internal water pump. So when the water pump goes out it dumps all the antifreeze into the oil pan. There are many complaints out online about this same exact thing and Ford will do nothing about it. I was stuck with a $12,500.00 bill for a vehicle that has 73,989 yes that is right not even 75K on the car. Ford is a joke and this definitely a safety concern as it just dies with no warning and takes the engine out. Something needs to be done before people get hurt as all these 2 years worth of Explorers will have this same issue. Whomever designed a waterpump on the inside of the engine should be investigated. I will upload the estimate as that is what I have on me. Be I do have the repair bill at home as we just got it back after 5 weeks
NHTSA ODI #11638743
Mileage unknown · Jan 20, 2025
Engine
Car was misfiring, oil in the spark plugs. Took it to our mechanic and basically told us we need a new engine. The car in a 2017 with 143,000 miles. There was coolant in cylinder 1 of the engine. Mechanic said cylinder walls are not properly sealed causing the head gasket to fail repeatedly even after replacement.
NHTSA ODI #11637118
Mileage unknown · Jan 16, 2025
EnginePower TrainVehicle Speed Control
Transmission is not shifting correcting. Will be traveling down the road and loses power, loses it's acceleration. When trying to proceed after making a stop at a light, car will not go. Bucks hard when putting in reverse. I heard there was a recall on the torque converter's awhile back, but I never received any notification abo…
Read full complaint
Transmission is not shifting correcting. Will be traveling down the road and loses power, loses it's acceleration. When trying to proceed after making a stop at a light, car will not go. Bucks hard when putting in reverse. I heard there was a recall on the torque converter's awhile back, but I never received any notification about it. Now that I know, the ford dealerships are telling me there are no recalls for this.
NHTSA ODI #11636279
Mileage unknown · Dec 2, 2024
Engine
Brought car in for 100,000 mile tune up on 11/21. On 11/30, used the heater for the first time since having tune up done and the heater was blowing only cold air. Brought into ford today and was told that the water pump has a leak and needs to be replaced at a cost of $5,000. Car has 100,550 miles on it, mostly only driven on ci…
Read full complaint
Brought car in for 100,000 mile tune up on 11/21. On 11/30, used the heater for the first time since having tune up done and the heater was blowing only cold air. Brought into ford today and was told that the water pump has a leak and needs to be replaced at a cost of $5,000. Car has 100,550 miles on it, mostly only driven on city roads and not freeway.
NHTSA ODI #11628446
Mileage unknown · Dec 2, 2024
Engine
Water pump defect with my 2017 Ford Explorer XLT V6. This vehicle has a significant design flaw related to the water pump, which is located inside the engine cover. Recently, the water pump in my vehicle failed, the signal warning light turned on and indicated that the thermostat reaching high engine temperatures and warning the…
Read full complaint
Water pump defect with my 2017 Ford Explorer XLT V6. This vehicle has a significant design flaw related to the water pump, which is located inside the engine cover. Recently, the water pump in my vehicle failed, the signal warning light turned on and indicated that the thermostat reaching high engine temperatures and warning the engine could overheat. The failure of the water pump can lead to engine overheating, which could cause the vehicle to break down unexpectedly, putting my safety and the safety of others at risk, especially while driving at high speeds or in heavy traffic. The problem has been reproduced and confirmed by both a Ford dealer and an independent service center. Ford acknowledges this issue and that the water pump is prone to failure approximately every 100,000 miles. The repair costs amount to over $4,000. This exorbitant cost is due to the labor-intensive process required to access the water pump, owing to its placement within the engine cover. The cost of the repair is disproportionately high and places an undue financial burden on consumers.
NHTSA ODI #11628300
Mileage unknown · Dec 2, 2024
EnginePower Train
I have a 2017 Ford Explorer with a water pump that needs replacing per a Ford dealership. It has 59K. It should last at least 150k. There should be a recall as there are thousands of these vehicles with the internal water pump. Apparently it's a problem if they are no longer making them internal. I want to file a complaint and w…
Read full complaint
I have a 2017 Ford Explorer with a water pump that needs replacing per a Ford dealership. It has 59K. It should last at least 150k. There should be a recall as there are thousands of these vehicles with the internal water pump. Apparently it's a problem if they are no longer making them internal. I want to file a complaint and would like some type of compensation.
NHTSA ODI #11628265
Mileage unknown · Nov 19, 2024
Engine
2.3L 4 cylinder engine has coolant intrusion causing a blown head gasket and requiring a super expensive repair that should be falling to Ford not the consumer. This is a design flaw and should be fixed ASAP. Coolant should not be intruding and leaking. This engine has around 76,000 miles and has only been owned for 1 year. Very…
Read full complaint
2.3L 4 cylinder engine has coolant intrusion causing a blown head gasket and requiring a super expensive repair that should be falling to Ford not the consumer. This is a design flaw and should be fixed ASAP. Coolant should not be intruding and leaking. This engine has around 76,000 miles and has only been owned for 1 year. Very disappointed in this.
NHTSA ODI #11626257
Official recalls
13Jul 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.
Feb 20, 2026
Ford Motor Company (Ford) is recalling certain 2017-2019 Explorer vehicles. The rear suspension toe links 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: Dealers will replace the toe links, free of charge. Owner notification letters were mailed on March 16, 2026. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 26S08. This recall is an expansion of previous NHTSA recall number 21V537. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning February 25, 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.
Sep 11, 2019
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer vehicles equipped with power front seats. The seat frames may have sharp edges.
Consequence & remedy
Consequence: Occupants my contact the sharp edges when reaching between the power front seat and center console, increasing their risk of injury.
Remedy: Ford will notify owners, and dealers will install protective tape on the exposed inside edge and tab of the power seat frames, free of charge. The recall began November 8, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S29.
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.
Aug 28, 2017
Ford Motor Company (Ford) is recalling certain 2017 Explorer, Taurus and Police Interceptor Utility and Sedan vehicles. The steering gear heat shield fasteners may corrode, allowing the heat shield to detach.
Consequence & remedy
Consequence: If the heat shield detaches, the steering gear may overheat, increasing the steering effort required by the driver, especially at lower speeds, and increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers to inspect and replace the heat shield fasteners as needed, free of charge. The recall began on September 13, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S23.
May 22, 2017
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence & remedy
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Additional source detail variants (2)
Seats:front Assembly:recliner
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Seats
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Dec 22, 2016
Ford Motor Company (Ford) is recalling certain model year 2016 Ford Taurus, 2016-2017 Ford Flex, Lincoln MKT, 2017 Ford Explorer and Ford Explorer Police Interceptor Utility vehicles equipped with 3.5L GTDI engines. Improperly brazed turbocharger oil supply tubes may leak oil on engine components.
Consequence & remedy
Consequence: An oil leak, in the presence of an ignition source, increases the risk of a fire.
Remedy: Ford will notify owners, and dealers will inspect, and if necessary, replace the turbocharger oil supply tubes, free of charge. The recall began on January 31, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S46.
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