NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
827 reportsMileage unknown · Dec 1, 2014
Wheels
WE HAVE 74000 MILES ON OUR 2012 FORD EXPLORER. I WAS DOING THE 6000 MILE SERVICE, CHANGE OIL AND FILTER, ROTATE TIRES, CHECK FLUIDS, BRAKE INSPECTION, AND DO INSPECT OTHER AREAS. I WAS IN THE PROCESS TORQUEING THE LUG NUTS AFTER THE TIRE ROTATION. I USE A CRAFTSMAN TORQUE 1/2" DRIVE RATCHET FOR THIS. ON THE DRIVER SIDE FRONT AND…
Read full complaint
WE HAVE 74000 MILES ON OUR 2012 FORD EXPLORER. I WAS DOING THE 6000 MILE SERVICE, CHANGE OIL AND FILTER, ROTATE TIRES, CHECK FLUIDS, BRAKE INSPECTION, AND DO INSPECT OTHER AREAS. I WAS IN THE PROCESS TORQUEING THE LUG NUTS AFTER THE TIRE ROTATION. I USE A CRAFTSMAN TORQUE 1/2" DRIVE RATCHET FOR THIS. ON THE DRIVER SIDE FRONT AND REAR WHEEL 1 OUT OF THE 5 WHEEL STUDS WOULD NOT TORQUE TOO THE 100 FT. POUNDS. THE STUDS ON EACH WHEEL STRETCH AND ARE READY TO BREAK. WHY WOULD FORD USE INFERIOR MEDAL IN SOMETHING SO IMPORTANT. WE RECENTLY OWNED A 2001 DODGE DURANGO AND BOUGHT IT NEW. WE HAD OVER 200,000 MILES ON THIS VEHICLE AND I NEVER HAD THIS PROBLEM. AND TO REPLACE THESE FORD DIDN'T ALLOW ENOUGH ROOM. YOU HAVE TO REMOVE THE WHEEL HUB AND BEARING. WHICH I TRIED AFTER REMOVING THE 4 BOLTS AND AXLE NUT. IT WOULD NOT COME OUT. I BELIEVE IT'S BECAUSE OF THE 2 DIFFERENT MEDALS. THE ALUMINUM HOUSING AND THE STEEL BEARING HUB WAS FIND WHEN IT'S NEW BUT GIVE TIME IN THE ELEMENTS AND CORROSION SETS IN. I HAVE NO OTHER CHOICE BUT TAKE IT BACK TO FORD DEALER FOR THE REPAIRS. I DON'T TRUST THE OTHER WHEEL STUDS AND WANT ALL REPLACE FOR SAFETY CONCERNS. PLEASE HELP ON THIS PROBLEM. I BELIEVE THE MEDAL IS TO SOFT FOR WHEEL STUDS. THANK YOU. *JS
NHTSA ODI #10661374
40,000 miles · Nov 30, 2014
EnginePower Train
WHILE I WAS DRIVING MY 2012 FORD EXPLORER XLT, IT LOST ALL POWER FOR THE 4TH TIME. WHEN I PRESSED THE THROTTLE THERE WAS NO RESPONSE. INDICATOR LIGHTS SAID AWD OFF AND DISPLAYED A WRENCH ICON. I COASTED TO THE SIDE OF THE ROAD. WHEN THIS HAPPENED THE FIRST THREE TIMES I TURNED THE CAR OFF, RESTARTED IT AND ALL WAS FINE FOR A FEW…
Read full complaint
WHILE I WAS DRIVING MY 2012 FORD EXPLORER XLT, IT LOST ALL POWER FOR THE 4TH TIME. WHEN I PRESSED THE THROTTLE THERE WAS NO RESPONSE. INDICATOR LIGHTS SAID AWD OFF AND DISPLAYED A WRENCH ICON. I COASTED TO THE SIDE OF THE ROAD. WHEN THIS HAPPENED THE FIRST THREE TIMES I TURNED THE CAR OFF, RESTARTED IT AND ALL WAS FINE FOR A FEW MINUTES, BEFORE THIS HAPPENED AGAIN. THIS IS QUITE A DANGEROUS SITUATION TO BE IN. I HAVE ALSO SEEN SEVERAL COMPLAINTS OF THE SAME PROBLEM FROM SEVERAL OTHER FORD AND LINCOLN OWNERS. I BELIEVE THIS IS A SERIOUS SAFETY ISSUE, SINCE STALLING IN THE MIDDLE OF ANYWHERE IS NOT SAFE AND CAN LEAD TO ACCIDENTS WITHOUT WARNING. ALSO MY CHECK ENGINE LIGHT IS NOW LIGHT AND I WILL BE TAKING IT TO THE FORD DEALER TO GET IT FIXED. IT IS GOING TO COST ME AN ARM AND LEG, BUT HOPEFULLY IT ENDS UP BEING A SAFETY RECALL AND FORD REIMBURSES DOWN THE LINE. *TR
NHTSA ODI #10661311
52,000 miles · Nov 18, 2014
Engine And Engine Cooling
INVESTIGATION OF INTERMITTENT "SERVICE ENGINE" LIGHT EVENTUALLY LED TO A DETERMINATION OF A FAULTY EVAP PURGE VALVE PULLING FUEL INTO THE EVAP CANISTER. TECHNICIAN SAID HE WOULD NOT DRIVE THE CAR, AS THIS IS A FUEL LEAK AND UNSAFE CONDITION. DEALER ACKNOWLEDGED SAFETY ISSUE, CITES 1ST TIME THIS HAS BEEN SEEN, AND NOT COVERED B…
Read full complaint
INVESTIGATION OF INTERMITTENT "SERVICE ENGINE" LIGHT EVENTUALLY LED TO A DETERMINATION OF A FAULTY EVAP PURGE VALVE PULLING FUEL INTO THE EVAP CANISTER. TECHNICIAN SAID HE WOULD NOT DRIVE THE CAR, AS THIS IS A FUEL LEAK AND UNSAFE CONDITION. DEALER ACKNOWLEDGED SAFETY ISSUE, CITES 1ST TIME THIS HAS BEEN SEEN, AND NOT COVERED BY ANY EXTENDED WARRANTY OR MAINTENANCE PROGRAM. PAPERWORK PROVIDED CITES "A FAULTY EVAP PURGE VALVE CAN CAUSE EXCESSIVE ENGINE VACUUM TO BE PLACED ON FUEL TANK, DRAWING FUEL/AIR FROM THE FUEL TANK THROUGH THE EVAP SYSTEM AND INTO ENGINE. THIS CAN CAUSE DRIVABILITY CONCERNS AS WELL AS RICH/LEAN CONCERN." *TR
NHTSA ODI #10658792
Mileage unknown · Nov 10, 2014
EngineFuel/propulsion System
AFTER A MONTH OF OWNING THE 2012 FORD EXPLORER WE NOTICED A VERY FOUL EXHAUST SMELL FROM INSIDE THE CABIN OF THE EXPLORER. WE WOULD SMELL THE ODOR UNDER ACCELERATION, ESPECIALLY WHEN RPMS REACHED 3,000 PLUS. THIS PARTICULAR ODOR SMELL UNDER THE ABOVE CONDITIONS HAVE BEEN OBSERVED EVER SINCE. WE DID NOT THINK ANYTHING OF THE…
Read full complaint
AFTER A MONTH OF OWNING THE 2012 FORD EXPLORER WE NOTICED A VERY FOUL EXHAUST SMELL FROM INSIDE THE CABIN OF THE EXPLORER. WE WOULD SMELL THE ODOR UNDER ACCELERATION, ESPECIALLY WHEN RPMS REACHED 3,000 PLUS. THIS PARTICULAR ODOR SMELL UNDER THE ABOVE CONDITIONS HAVE BEEN OBSERVED EVER SINCE. WE DID NOT THINK ANYTHING OF THE SMELL UNTIL WE BEGAN RESEARCHING IT RECENTLY AND CAME ACROSS SEVERAL SOURCES INDICATING THIS COULD BE HARMFUL TO OUR HEALTH. *TR
NHTSA ODI #10654067
62,000 miles · Nov 5, 2014
Steering
POWER STEERING ASSIST FAILURE LIGHT CAME ON AND VEHICLE STEERING LOCKED UP. WAS TOLD BY FORD DEALER IT IS UNSAFE TO DRIVE THIS VEHICLE YET THEY WANT ME TO DRIVE IT TO THEM TO BE REPAIRED WHICH THEY ARE GOING TO CHARGE ME FOR. I FEEL THIS SHOULD BE COVERED BY FORD IN FULL. *TR
NHTSA ODI #10652906
Mileage unknown · Nov 3, 2014
Structure
WE OWN A 2012 FORD EXPLORER XLT AND ARE VERY PLEASED WITH IT OVERALL. HOWEVER, WE HAVE RECENTLY DISCOVERED THAT OUR INTERIOR DOOR PANEL ON BOTH THE DRIVER AND PASSENGER SIDES IS SPLITTING ON THE VINYL SEAM JUST BELOW THE ARM REST. OUR VEHICLE CURRENTLY HAS 55K ON IT FOR MILEAGE, SO ANY HOPE OF THIS BEING COVERED UNDER WARRANTY I…
Read full complaint
WE OWN A 2012 FORD EXPLORER XLT AND ARE VERY PLEASED WITH IT OVERALL. HOWEVER, WE HAVE RECENTLY DISCOVERED THAT OUR INTERIOR DOOR PANEL ON BOTH THE DRIVER AND PASSENGER SIDES IS SPLITTING ON THE VINYL SEAM JUST BELOW THE ARM REST. OUR VEHICLE CURRENTLY HAS 55K ON IT FOR MILEAGE, SO ANY HOPE OF THIS BEING COVERED UNDER WARRANTY IS GONE. I HAVE CONTACTED AN UPHOLSTERY REPAIR SERVICE AND THEY STATED THAT IT CANNOT BE REPAIRED BECAUSE IT IS VINYL, BUT WILL INSTEAD NEED TO BE REPLACED. I RECENTLY GOT AN ESTIMATE AND FOR PARTS AND LABOR IT WOULD COST US ALMOST $600 TO REPAIR BOTH SIDES. BECAUSE IT IS HAPPENING IN THE EXACT SAME LOCATION ON BOTH INTERIOR DOORS, I FEEL THAT THIS IS FAULTY DESIGN AND SHOULD BE SUBJECT TO RECALL. *TR
NHTSA ODI #10652113
28,000 miles · Nov 3, 2014
StructureVisibility
I WAS DRIVING AT 55 MILES PER HOUR AND THE MOLDING FROM AROUND THE RIGHT SIDE WINDSHIELD FLEW OFF AFTER DRIVING ANOTHER 10-15 MILES THE LEFT HAND MOLDING ON THE WINDSHIELD ALSO BLEW OFF THIS COULD HAVE BEEN TROUBLE FOR ANY ONE BEHIND ME OR TO THE SIDE OF ME. *TR
NHTSA ODI #10651997
33,000 miles · Oct 18, 2014
Steering
POWER STEERING LOSS WHILE DRIVING. STEERING BECOMES DIFFICULT. MUST SHUT OFF CAR AND RESTART TO RECOVER POWER STEERING. HAPPENS OFTEN. TAKEN IN FOR SERVICE AND SOURCE OF PROBLEM WAS NOT ISOLATED OR FIXED. *TR
NHTSA ODI #10648610
47,000 miles · Oct 7, 2014
EngineFuel/propulsion SystemPower Train
THE THROTTLE BOX HAS GONE BAD. THE CAR STALLS RANDOMLY WHEN TAKING OFF FROM A START AND REQUIRES A NEW THROTTLE BODY AT ONLY 47K MILES. THIS IS PART OF THE POWERTRAIN, BUT NOT COVERED BY THE WARRANTY. FORD HAD LOTS OF PROBLEMS WITH THROTTLE BODIES IN EARLIER MODELS AND IT SEEMS THEY HAVEN'T FIXED IT YET. *TR
NHTSA ODI #10643166
34,000 miles · Oct 7, 2014
EnginePower TrainVehicle Speed Control
I WAS DRIVING APPROX. 35MPH AND ALL OF A SUDDEN THE WRENCH LIGHT ON THE ENGINE CAME ON I LOST ALL POWER TO THE ACCELERATOR. I HAD TO COAST TO STOP, TURN OFF THE VEHICLE, START IT BACK UP AND PROCEED. IT HAS HAPPENED 4 MORE TIMES SINCE THE ORIGINAL DATE. ONE OF THOSE TIMES WAS WHEN I WAS CROSSING AN INTERSECTION AND WAS ALMOST BR…
Read full complaint
I WAS DRIVING APPROX. 35MPH AND ALL OF A SUDDEN THE WRENCH LIGHT ON THE ENGINE CAME ON I LOST ALL POWER TO THE ACCELERATOR. I HAD TO COAST TO STOP, TURN OFF THE VEHICLE, START IT BACK UP AND PROCEED. IT HAS HAPPENED 4 MORE TIMES SINCE THE ORIGINAL DATE. ONE OF THOSE TIMES WAS WHEN I WAS CROSSING AN INTERSECTION AND WAS ALMOST BROADSIDED. THIS IS VERY DANGEROUS AND IS HAPPENING WITH NO WARNING OR PATTERN. I HAVE LOOKED ONLINE AND IT SEEMS TO HAVE HAPPENED WITH MANY FORD EXPLORER OWNERS. I AM READING IT HAS TO DO WITH THE POWERTRAIN CONTROL MODULE. *TR
NHTSA ODI #10643084
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.
Illustration