NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
27 reportsClear category filter100,000 miles · Feb 14, 2017
EngineFuel/propulsion System
TL* THE CONTACT OWNS A 2012 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL FUEL ODOR WHILE OPERATING THE VEHICLE. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL ODOR COULD NOT BE DIAGNOSED; HOWEVER, THE CHECK ENGINE INDICATOR FAILURE WAS DIAG…
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TL* THE CONTACT OWNS A 2012 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL FUEL ODOR WHILE OPERATING THE VEHICLE. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL ODOR COULD NOT BE DIAGNOSED; HOWEVER, THE CHECK ENGINE INDICATOR FAILURE WAS DIAGNOSED AS AN AIR FILTER NEEDING TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000.
NHTSA ODI #10954436
Mileage unknown · Dec 6, 2016
Fuel/propulsion SystemUnknown Or Other
FUMES ENTERING THE CABIN MAKING THE PASSENGERS NAUSEOUS AND RESULTING IN HEADACHES. WE NOTICED THAT ONLY WHEN WE ARE IN MY HUSBAND'S CAR THAT MY CHILDREN AND I BECOME SICK WITH HEADACHES AND NAUSEA. MY HUSBAND DRIVES TO WORK IN THIS VEHICLE AND USUALLY ARRIVES TO WORK WITH A HEADACHE. HE DIDN'T REALIZE THAT THE CAR WAS MAKING HI…
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FUMES ENTERING THE CABIN MAKING THE PASSENGERS NAUSEOUS AND RESULTING IN HEADACHES. WE NOTICED THAT ONLY WHEN WE ARE IN MY HUSBAND'S CAR THAT MY CHILDREN AND I BECOME SICK WITH HEADACHES AND NAUSEA. MY HUSBAND DRIVES TO WORK IN THIS VEHICLE AND USUALLY ARRIVES TO WORK WITH A HEADACHE. HE DIDN'T REALIZE THAT THE CAR WAS MAKING HIM SICK. HE TRUSTED THE SERVICE PEOPLE WHEN THEY TOLD HIM THE CAR WAS FINE. HE TYPICALLY DIVES ON HIGHWAYS. THE FUMES ARE COMING THROUGH THE VENTS.
NHTSA ODI #10930124
55,128 miles · Nov 4, 2016
EngineFuel/propulsion System
TL* THE CONTACT OWNS A 2012 FORD EXPLORER. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE PURGE VALVE WAS LEAKING AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS …
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TL* THE CONTACT OWNS A 2012 FORD EXPLORER. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE PURGE VALVE WAS LEAKING AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 53,128.
NHTSA ODI #10924249
40,000 miles · Sep 13, 2016
EngineFuel/propulsion SystemUnknown Or Other
FOR ABOUT THE LAST YEAR, I WOULD SMELL SOMETHING BURNING INSIDE MY VEHICLE WHEN ENTERING THE FREEWAY. I WAS NEVER ABLE TO IDENTIFY THE SOURCE OF THE SMELL, EVEN AFTER REPEATEDLY STOPPING TO SNIFF THE ENGINE COMPARTMENT AND AROUND THE TIRES AND EXHAUST. I COULD NOT DETECT THE SMELL OUTSIDE OF THE CAR, NOR DID I FIND ANY EVIDENCE …
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FOR ABOUT THE LAST YEAR, I WOULD SMELL SOMETHING BURNING INSIDE MY VEHICLE WHEN ENTERING THE FREEWAY. I WAS NEVER ABLE TO IDENTIFY THE SOURCE OF THE SMELL, EVEN AFTER REPEATEDLY STOPPING TO SNIFF THE ENGINE COMPARTMENT AND AROUND THE TIRES AND EXHAUST. I COULD NOT DETECT THE SMELL OUTSIDE OF THE CAR, NOR DID I FIND ANY EVIDENCE OF ANYTHING BURNING (NO SMOKE, CHARRED AREAS, STUCK BRAKES, MELTED RUBBER, ETC). THERE DIDN'T APPEAR TO BE ANY PATTERN, AS I WOULD SMELL SOMETHING BURNING AT DIFFERENT POINTS IN MY COMMUTE, WITH THE ONLY TIME I CONSISTENTLY EXPERIENCED IT BEING MERGING ONTO THE FREEWAY. ON JUNE 20, 2016 AT 1:38 PM CENTRAL TIME, I SENT MY HUSBAND THE FOLLOWING TEXT: "IS THE FIRE EXTINGUISHER STILL IN THE CAR?" DUE TO THE OVERPOWERING SMELL OF SMOKE IN THE PASSENGER COMPARTMENT SHORTLY AFTER GETTING ON THE FREEWAY. I ROLLED DOWN THE WINDOWS AND EXITED THE FREEWAY, STOPPING AT THE FAR END OF A PARKING LOT. THERE WAS NO SMOKE NOR ODOR EMANATING FROM THE EXTERIOR OF THE VEHICLE. DUE TO THE HEAT, WE DRIVE WITH THE AIR RECIRCULATING MOST OF THE YEAR. MUCH OF OUR DRIVING IS IN THE CITY, WITH LIGHT ACCELERATION. TYPICALLY, THE ONLY TIME WE RAPIDLY ACCELERATE IS WHEN ENTERING THE FREEWAY. ON THIS OCCASION, I ACCELERATED MORE THAN NORMAL DUE TO A SEMI'S POSITION IN THE RIGHT LANE. AT TIMES, MY 7 YEAR OLD HAS COMPLAINED ABOUT NOT BEING ABLE TO BREATHE WITH THE WINDOWS ROLLED UP.
NHTSA ODI #10906152
51,000 miles · Aug 17, 2016
Fuel/propulsion System
AWD OFF ERROR AND WRENCH SYMBOL - ISSUE HAS OCCURRED MULTIPLE TIMES, UNDER DIFFERENT CONDITIONS. WITHOUT WARNING, THE VEHICLE LOSES ACCELERATION AND THE WRENCH ICON AND AWD ERRORS DISPLAY. THE THROTTLE BECOMES UNRESPONSIVE, BUT ALL OTHER SYSTEMS REMAIN FUNCTIONING. IF YOU LEAVE IT IN GEAR WITHOUT THE BRAKES ENGAGED, IT WILL MOV…
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AWD OFF ERROR AND WRENCH SYMBOL - ISSUE HAS OCCURRED MULTIPLE TIMES, UNDER DIFFERENT CONDITIONS. WITHOUT WARNING, THE VEHICLE LOSES ACCELERATION AND THE WRENCH ICON AND AWD ERRORS DISPLAY. THE THROTTLE BECOMES UNRESPONSIVE, BUT ALL OTHER SYSTEMS REMAIN FUNCTIONING. IF YOU LEAVE IT IN GEAR WITHOUT THE BRAKES ENGAGED, IT WILL MOVE AT IDLE SPEED ON FLAT GROUND, BUT IS UNABLE TO NAVIGATE INCLINES. WHEN SLOWING TO A STOP, THE WHOLE VEHICLE SHUDDERS. STOPPING AND RESTARTING NORMALLY RETURNS THE VEHICLE TO NORMAL OPERATION. THIS HAS ACCURED OVER A DOZEN TIMES. DEALER HAS SAID THAT THERE ARE NO CODES REPORTING THE PROBLEM. RECOMMENDED WE REPLACE TIRES. REPLACED TIRES AND ISSUE IS STILL PRESENT. HAVE FILED A COMPLAINT WITH FORD TO BRING IN OTHER RESOURCES TO TRIAGE/DIAGNOSE ISSUE WITHOUT SUCCESS. THIS IS A VERY DANGEROUS ISSUE AS WHEN TO ISSUE PRESENTS ITSELF, THE CAR STOPS UNEXPECTEDLY AND MUST BE SHIFTED INTO PARK IN ORDER TO CLEAR THE PROBLEM. ON ROADS WITHOUT SHOULDERS OR MULTIPLE LANES, THIS IS A VERY DANGEROUS AS THE CAR IS SOMETIMES NOT ABLE TO MAKE IT TO THE SIDE OF THE ROAD AND MUST BE PUT INTO PARK WHERE IT STOPS. THE CAR IS TO DANGEROUS TO DRIVE AND THERE ARE NO KNOW FIXES RIGHT NOW.
NHTSA ODI #10896657
51,426 miles · Aug 16, 2016
Fuel/propulsion System
I/WE HAVE HAD MULTIPLE OCCASIONS OF THE ENGINE FAILURE TO ACCELERATE WHILE IN A REGULAR DRIVING MODE. THE ENGINE WILL NOT CONTINUE TO RESPOND TO THE ACCELERATOR. THE VEHICLE WAS DRIVEN TO THE LOCAL FORD DEALER AND THEY WERE UNABLE TO DUPLICATE THE PROBLEM. TODAY I WAS ABLE TO PULL A CODE P2111 AND TOOK THAT IN. I WAS TOLD IT…
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I/WE HAVE HAD MULTIPLE OCCASIONS OF THE ENGINE FAILURE TO ACCELERATE WHILE IN A REGULAR DRIVING MODE. THE ENGINE WILL NOT CONTINUE TO RESPOND TO THE ACCELERATOR. THE VEHICLE WAS DRIVEN TO THE LOCAL FORD DEALER AND THEY WERE UNABLE TO DUPLICATE THE PROBLEM. TODAY I WAS ABLE TO PULL A CODE P2111 AND TOOK THAT IN. I WAS TOLD IT WAS A MALFUNCTIONING THROTTLE BODY. THIS APPEARS TO BE A PROBLEM THAT IS OCCURRING IN THIS AND SIMILAR VEHICLES. FORD HAS SAID THEY WILL NOT CORRECT THE PROBLEM. THE VEHICLE WAS BEING DRIVEN ON A LOCAL ROAD AT THE TIME OF THE CONDITION OCCURRED. WE PULLED INTO A PARKING LOT TO GET IT OFF THE STREET. AFTER PULLING THE CODE THE VEHICLE STILL WOULD NOT RESPOND TO ACCELERATION ATTEMPTS. THE VEHICLE WAS TURNED OFF AND RESTARTED. UPON RESTART IT RAN CORRECTLY.
NHTSA ODI #10896460
61,500 miles · Jul 20, 2016
EngineFuel/propulsion System
WHILE DRIVING DOWN THE HIGHWAY MY EXPLORER MADE A LOUD CLUNK SOUND AND THEN THE WRENCH SYMBOL APPEARED ON MY DASHBOARD. THEN THE GAS PEDAL QUIT WORKING, AND WE HAD TO ROLL OFF THE HIGHWAY AVOIDING BEING HIT BY OTHER TRAFFIC. I HAD TO STOP AND RESTART MY CAR 5-6 TIMES BEFORE THE GAS PEDAL WOULD WORK AGAIN. THIS HAS HAPPENED 5 TIM…
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WHILE DRIVING DOWN THE HIGHWAY MY EXPLORER MADE A LOUD CLUNK SOUND AND THEN THE WRENCH SYMBOL APPEARED ON MY DASHBOARD. THEN THE GAS PEDAL QUIT WORKING, AND WE HAD TO ROLL OFF THE HIGHWAY AVOIDING BEING HIT BY OTHER TRAFFIC. I HAD TO STOP AND RESTART MY CAR 5-6 TIMES BEFORE THE GAS PEDAL WOULD WORK AGAIN. THIS HAS HAPPENED 5 TIMES IN THE PAST TWO MONTHS, AND WHEN I CALLED TO HAVE IT SERVICED THEY TOLD ME THE WRENCH LIGHT HAD TO BE ON FOR THEM TO IDENTIFY THE PROBLEM. BUT I CANT GO ANYWHERE WHEN THE WRENCH LIGHT COMES ON AND A TOW TRUCK WILL NOT TOW A CAR WITH IT RUNNING FOR ME TO GET IT TO THE DEALERSHIP TO BE TESTED. THIS IS A SAFETY ISSUE THAT OTHER PEOPLE ARE HAVING. THE THROTTLE BODY IS GOING OUT ON MANY EXPLORERS AFTER 55,000 MILES. IS IT GOING TO TAKE DEATHS BEFORE THIS IS A RECALL?
NHTSA ODI #10886107
28,000 miles · Jul 7, 2016
Fuel/propulsion SystemUnknown Or Other
SMELL OF EXHAUST GAS INSIDE THE VEHICLE WHILE IN MOTION OR ACCELERATION.
NHTSA ODI #10883326
35,000 miles · Jul 2, 2016
Fuel/propulsion System
THROTTLE BODY ELECTRONICS, VEHICLE WILL SUDDENLY STOP. I WAS DRIVING IN TRAFFIC AT 55MPH AND SUDDENLY STOPPED MOVING WHEN FAILURE OCCURRED. DASHBOARD INDICATED A 4 WHEEL DRIVE OR ENGINE CHECK. I WAS SLOWED TO 2MPH LUCKILY NO OTHER VEHICLES WERE BEHIND ME. THIS IS VERY DANGEROUS IN TRAFFIC, NO WARNING. FORD KNOWS ABOUT THIS PROB…
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THROTTLE BODY ELECTRONICS, VEHICLE WILL SUDDENLY STOP. I WAS DRIVING IN TRAFFIC AT 55MPH AND SUDDENLY STOPPED MOVING WHEN FAILURE OCCURRED. DASHBOARD INDICATED A 4 WHEEL DRIVE OR ENGINE CHECK. I WAS SLOWED TO 2MPH LUCKILY NO OTHER VEHICLES WERE BEHIND ME. THIS IS VERY DANGEROUS IN TRAFFIC, NO WARNING. FORD KNOWS ABOUT THIS PROBLEM AND IS NOT RECALLING VEHICLES WHY, THE PARTS ARE IN SHORT SUPPLY MY SUV WAS IN THE GARAGE FOR 10 DAYS WAITING FOR PART, THIS ISSUE SHOULD BE A RECALL. FORD REPAIRED MY EXPLORER BUT MANY DRIVERS ARE ON THE ROAD AND HAVE NO IDEA THIS COULD HAPPEN TO THEM. SAFETY FIRST PLEASE
NHTSA ODI #10882309
50,000 miles · Oct 18, 2015
Fuel/propulsion System
THIS HAPPENED THREE TIMES AT SPEEDS OF 40, 50 AND 60 MPH, ON HIGHWAY, VEH. ENGINE LIGHT COMES ON AND VEH. COMES TO A STOP. THE ENGINE IS STILL IDLING BUT THE GAS PETAL DOES NOT WORK. THERE IS NO WARNING, THE VEH. JUST COMES TO A STOP.I WAS LUCKY TO HAVE BEEN ON RURAL TWO LANE ROADS SO I COULD PULL OF ROAD. IF YOU WERE ON A MULT…
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THIS HAPPENED THREE TIMES AT SPEEDS OF 40, 50 AND 60 MPH, ON HIGHWAY, VEH. ENGINE LIGHT COMES ON AND VEH. COMES TO A STOP. THE ENGINE IS STILL IDLING BUT THE GAS PETAL DOES NOT WORK. THERE IS NO WARNING, THE VEH. JUST COMES TO A STOP.I WAS LUCKY TO HAVE BEEN ON RURAL TWO LANE ROADS SO I COULD PULL OF ROAD. IF YOU WERE ON A MULTI LANE HIGHWAY YOU WOULD BE IN BIG TROUBLE, BECAUSE VEH. COMES TO A STOP AND YOU HAVE NO CONTROL OF THE SPEED. THE FIRST PROBLEM, SWITCHED OFF VEH. RESTATED, NO ENGINE LIGHT AND EVERYTHING WORKED, TOOK VEH. TO FORD, THEY CHECK IT OUT, COULD NOT FIND ANY PROBLEM. THE VEH. WORKED FINE FOR ABOUT 6000 MORE THOUSAND MILES, THEN AT 60 MPH IT CUT OFF AGAIN, I GOT OFF ROAD, RESTARTED VEH. ENGINE LIGHT STAYED ON BUT GAS PETAL WORKED. I DROVE ABOUT TWO MORE MILES AND VEH. CUT OF AGAIN, ENGINE IDLING GAS PETAL NOT WORKING. RESTARTED VEH. ENGINE LIGHT STAYED ON BUT GAS PETAL WAS WORKING. I DROVE VEH. TO FORD DEALER, THEY NOW SAID THE PROBLEM WAS THE THROTTLE MODULE. FORD SAID THERE WAS NO RECALL ON THIS MODULE, SO I PAID OVER $600 FOR THE REPAIR WORK. THIS IS A VERY SERIOUS SAFETY PROBLEM THERE SHOULD BE A RECALL OR SOMETHING TO WARN FORD EXPLORER OWNERS THIS COULD HAPPEN TO THEM. I WOULD THINK, I AM NOT THE ONLY EXPLORER OWNERS TO HAVE HAD THIS PROBLEM.
NHTSA ODI #10783168
Official recalls
5Jan 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.
Sep 22, 2021
Ford Motor Company (Ford) is recalling certain 2011-2013 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. These vehicles may be equipped with a cross-axis ball joint (CABJ) replacement part that could seize, and result 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: Dealer will inspect for the presence of a CABJ. If a CABJ of any design is found, the dealer will inspect the tightness of the CABJ, and replace the CABJ, knuckle, and/or toe link as necessary, free of charge. Interim notification letters were mailed November 10, 2021. Owner notification letters were mailed on March 17, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S43.
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.
Mar 24, 2015
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Explorer vehicles. In the affected vehicles, the interior door handle return spring may unseat, resulting in interior door handle that does not return to the fully stowed position after actuation.
Consequence & remedy
Consequence: If the interior door handle return spring is unseated, the door may unlatch in the event of a side impact crash, increasing the risk of personal injury.
Remedy: Ford will notify owners, and dealers will inspect all four of the interior door handles and either repair or replace them, free of charge. The recall began on July 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S11.
May 29, 2014
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Ford Explorer vehicles manufactured May 17, 2010, through February 28, 2012. The affected vehicles may experience an intermittent connection in the electric power steering gear, which can cause a loss of the motor position sensor signal resulting in a shut down of the power steering assist.
Consequence & remedy
Consequence: If the vehicle experiences a loss of power steering assist it will require extra steering effort at lower speeds, increasing the risk of a vehicle crash.
Remedy: Ford will notify owners, and dealers will update the Power Steering Control Module (PSCM) software, free of charge. If a vehicle shows a history of a loss of motor position sensor signal when the vehicle is brought in for the recall remedy, its steering rack assembly will be replaced, free of charge. The recall began on July 23, 2014. Owners may contact Ford customer service at 1-800-392-3673. Ford's number for this recall is 14S06.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4PE23001 · Windshield Trim Molding Item Detachment
Opened Jan 27, 2023 · Closed Feb 8, 2024
Status: closed (inferred from source dates) · Structure:body:roof And Pillars
On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this failure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injuries. Some consumers have reported that the failure occurred while they were driving at highway speeds, with the detached trim panel entering the path of travel of the vehicle behind them, requiring the driver of the following vehicle to take evasive action. It is noteworthy that motorists who experience this type of road hazard are less likely to accurately identify the subject vehicle the item detached from and report the event to the NHTSA. In its April 17, 2023 response to ODI’s information request, Ford provided 175 consumer complaints (including field reports) and 14,162 warranty claims related to A-pillar trim panel detachment. Ford relayed that the subject vehicles utilize a plastic A-pillar bracket, which is bolted to the vehicle structure during assembly. The A-pillar trim panel is attached to the bracket utilizing 7 plastic clips. Contributory factors which have been identified by Ford as leading to the subject defect include incomplete installation at the assembly plant, inadequate part stack up, damage to fasteners during installation, and failure to follow proper repair procedure during windshield replacements or other services. On January 19, 2024, Ford filed safety recall 24V-031 for MY 2011-2019 Ford Explorer vehicles to address the subject defect. In the Part 573 Safety Recall Report, Ford identified that a detached A-pillar trim panel can create a road hazard for other road users, increasing the risk of a crash. The recall remedy includes an inspection of the existing A-pillar trim panel and, if necessary, the replacement of the component. The remedy A-pillar trim panels will be installed with an additional adhesive for robustness and utilize an inspection procedure to ensure full engagement of all the retention clips during installation. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
EA17002 · Exhaust Odor In Passenger Cab
Opened Jul 27, 2017 · Closed Jan 17, 2023
Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe; Structure:body
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
Additional source detail variants (2)
Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
Structure:body
During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve
PE16008 · Ford Explorer Exhaust Odor
Opened Jul 1, 2016 · Closed Sep 12, 2017
Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System; Structure:body
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
Additional source detail variants (2)
Engine And Engine Cooling:exhaust System
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
Structure:body
During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).
PE12017 · Electric Power Steering Failure
Opened Jun 19, 2012 · Closed Jun 12, 2014
Status: closed (inferred from source dates) · Steering:electric Power Assist System
On May 27, 2014 and amended June 2, 2014, Ford Motor Company (Ford) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 179,027 model year (MY) 2011 through 2013 Ford Explorer vehicles equipped with electric power assisted steering (EPAS), including 82,328 MY 2011 Explorersthat are the subject of PE12-017.Ford has assigned the recall number 14S06.The NHTSA recall number is 14V-286.Ford's DIR indicates that loss of power steering assist while driving would require higher steering effort at lower vehicle speeds, which may result in an increased risk of a crash.Sudden loss of power steering assist while driving can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe mode, which removes power from the EPAS motor and defaults to manual steering.Ford's DIR indicates that the majority of steering assist failures in the recalled vehicles have been caused by an intermittent electrical connection in the Power Steering Control Module (PSCM) that can lead to a loss of the motor position sensor signal.Ford's remedy instructs dealers to check the PSCM for diagnostic trouble codes (DTC).If upon initial inspection a loss of steering assist DTC is present, dealers will replace the steering gear at no charge to the owner and update the PSCM with revised software.Following detection of a motor position sensor signal fault, the revised software will provide audible and visual warnings to the driver that a power steering system fault has been detected and will maintain steering assist for the remainder of that drive cycle.If no DTC is present, dealers will reprogram the PSCM with the revised software. Analysis of information from all sources identified a total of 969 complaints and 4,059 warranty claims related to loss of power steering assist while driving in the MY 2011 through 2012 Explorer vehicles, resulting in a complaint rate of 5.4 incidents per thousand vehicles and a warranty claim rate of 2.3 percent.ODI identified 15 crashes with evidence indicating loss of power steering assist may have been a factor.All 15 crashes involved low-speed impacts with roadside objects during turning maneuvers, resulting in minor vehicle damage or no damage.In one incident that occurred in a low-speed curve, the driver attempted to brake in response to the sudden increase in steering effort and inadvertently applied the accelerator pedal instead.This caused the vehicle to run off the side of the road and strike a wooden pole at approximately 15 mph.Another incident occurred when the driver was unable to to negotiate a left-turn at an intersection and ran off the road into a shallow ditch, resulting in moderate front-end damage to the vehicle and minor injuries to the driver that did not require medical treatment. This investigation is closed.All ODI complaints associated with this closing resume are listed in the Attachment 1.
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