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NHTSA owner reports · September 18, 2026 snapshot.

44 crash reports11 fire reports42 injury reports

Power Train complaints

119 reports

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Mileage unknown · Feb 5, 2023

Power Train

Faulty water pumps causing leakage and eventually seize the engine

NHTSA ODI #11505652

Mileage unknown · Jan 17, 2023

Fuel/propulsion SystemPower TrainSuspension

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This winter I began starting my vehicle and letting it warm up before driving it. After letting it run approximately 10 to 15 minutes, I opened my door and to get in and there was a very strong exhaust smell inside. I would have to roll my windows down to clear the cabin of the fumes. This happened every single time I would let it sit and warm up. There is also something happening with what I believe is my drive-train. There is a lot of different noises (squealing/whining, grinding (metal to metal), clanking and thumping) when I give it gas after sitting at a light. As soon as I step on the gas pedal it makes all the above noises and jerks, then acts like it doesn't want to go. It finally kicks in then goes. Once it kicks in, it drives just fine. The noise sounds like its coming from the undercarriage and sometimes the rear end. I am not driving the vehicle now, it is parked in my driveway, so I am currently without transportation. There is also a very loud popping noise coming from the front end. I was told this could be ball joints or possibly stabilizers.

NHTSA ODI #11502298

Mileage unknown · Nov 22, 2022

Power Train

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The PTU (Power Transfer Unit) was engineered without a drain plug and described by Ford as "Maintenance Free" for the life of the vehicle. Due to the close proximity of the PTU to hot exhaust components, small fluid capacity, and no recommendation by Ford to be serviced for the life of the vehicle, my PTU started failing within warranty under 50,000 miles. The propane smell within the cab of the vehicle is a tell tale of the PTU fluid breaking down under severe heat conditions, spewing out of the vent and flashing on the surrounding exhaust components. This was not diagnosed at that time by my local Ford dealer, so the problem continued until the PTU finally failed out of warranty at approximately 71,000 miles. Research confirmed that this PTU design failure has been recognized by Ford and that it can lead to a complete failure while the vehicle is in motion, causing loss of control and risk to lives. Recognition by Ford of this problem in the 2013 model year Explorer is self evident, as later model years incorporated air dams to direct air to flow over the PTU to help with cooling, and incorporated drain plugs and recommended service intervals to properly service the PTU. There have been thousands of premature PTU failures in Ford vehicles, but Ford has not yet issued a recall or replacement PUT's with a drain plug for serviceability for my 2013 model year. My PTU had to be replaced at my cost with another non-serviceable PTU, that will no doubt fail prematurely. I am concerned that my vehicle could pose risk to my family's safety in the future, because the repair that was done by my Ford dealer is not a long term, complete solution.

NHTSA ODI #11494620

Mileage unknown · Sep 16, 2022

Electrical SystemEnginePower Train

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As stated in the 2 of the articles in this year make and model range 2013-2018 Ford explorer. The car has been up to date with maintenance, after a couple thousand miles after the oil changed was. I then took the car to a mechanic shop and was told the water pump and thermostat were failing. I stopped driving the car and decided to take it to a ford dealer. After visiting Palmetto Ford in Miami. I was told the car did not have an open recall for this vin and they did not cover it. It is evident that the problem has been present in many ford explorers in this year and has been a safety concern since the car overheats while on the road. I will need to have a recall placed on my vin number so that i can take this to a ford dealer and get it resolved asap so that i can get back to my normal living as I do not have a transportation and happen to be losing time from work and spending money in rides. My vin number is provided in this report Vin: [XXX] 2013 Ford Explorer Limited Recall 16v925000 (engine and engine cooling) https://www.bing.com/search?q=2013+ford+explorer+water+pump+recall&cvid=744c57e549d049c2bbcd35d89655cedd&aqs=edge.0.0l3.8405j0j1&pglt=41&FORM=ANNTA1&PC=U531 https://www.carproblemzoo.com/ford/explorer/water-pump-problems.php#:~:text=The%20contact%20reference%20manufacturer%20recall%20number%3A%2016s46%20campaign,not%20assist.%20The%20failure%20mileage%20was%20approximately%2065%2C000. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI #11484748

Mileage unknown · Jul 26, 2022

Power TrainCrash

I pulled into a parking spot. I shifted to park, turned off my engine. My vehicle rolled backward and hit a parked car while I was still sitting in it.

NHTSA ODI #11476027

Mileage unknown · Jun 14, 2022

Power Train

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The contact owns a 2013 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormally loud sound. Upon inspection underneath the vehicle, the contact noticed that the link shaft bracket and CV axle had broken in half. Additionally, the vehicle rolled away while the gear shifter was in park(P). The contact activated the parking brake to stop the vehicle from rolling away. The vehicle was not diagnosed nor repaired by an independent mechanic or the dealer. The manufacturer was not made aware of the failure. The contact related the failure to NHTSA Campaign Number: 20V692000 (Power Train) however, the VIN was not included in the recall. The failure mileage was unknown. Consumer was left with loss of power and a loud metal hitting metal sound the tripod spider joint/ bearing had broke because it was not properly supported due to bracket failure the recall for this part is for models starting with 2014 Ford Explorer mine is a 2013 mine was built at the same plant as the recall for 2014 and up the exact problems the recall list is what happened even down to the roll away even through its in park it will still roll unless the parking brake is applied.

NHTSA ODI #11469112

Mileage unknown · Jul 20, 2021

Power Train

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I was driving on the interstate and all of a sudden the vehicle lost power. It slowed down and I had to pull off the interstate. I thought it was because I broke for the speed limit change to fast. This was before July. It happened another time and I noticed the dashboard and it showed a big wrench symbol. Pryor to the mishap I saw nothing on the dashboard, no warning at all. I checked the internet and it was stating that there were a recall on this problem. I have not received any paperwork.

NHTSA ODI #11425663

200,000 miles · Jun 25, 2021

Power TrainSteering

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The contact owns a 2013 Ford Explorer. The contact stated while driving 10 mph, the vehicle lost power steering functionality while driving. The vehicle was turned off and restarted and regained normal steering functionality. The failure recurred. The vehicle was towed to the dealer and diagnosed that the battery, alternator, and transmission needed to be replaced. The battery and alternator were replaced. The dealer also performed three recall repairs for the door, rear toe link, and exhaust. and the battery and alternator were replaced. The failure recurred and the vehicle was towed to an independent mechanic for transmission repair. The vehicle remained at the mechanic's. The manufacturer was made aware of the failure but informed the contact that the VIN was not included in NHTSA Campaign Number: 14V286000 (Steering). The failure mileage was 200,000.

NHTSA ODI #11422346

189,000 miles · Feb 4, 2021

Electrical SystemPower TrainSteering

I STARTED MY CAR AFTER WORK (THIS IS AFTER A 12 HR SIT TIME) AND SEEN I HAD A FAULT ON MY DASHBOARD, POWER STEERING ASSIST AND SERVICE ADVANCE FAULTS. SO IN SHORT, I DO NOT HAVE POWER STEERING, NOR DO I HAVE MY 4WD, AND FOR SOME REASON MY TURN SIGNAL DOES NOT WORK FOR STEADY ON. THE TURN SIGNAL WORKS FOR LANE CHANGES BUT NOT FOR…

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NHTSA ODI #11394597

100,000 miles · Nov 23, 2020

EnginePower Train

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FOUR 2013 FORD EXPLORER RAN HOT WHILE I WAS OPERATING THE VEHICLE. WE THOUGHT IT WAS LOW ON ANTIFREEZE SO WE ADDED SOME. OUT OF PRECAUTION, WE BEGAN MONITORING THE ANTIFREEZE LEVEL AND NOTICE THAT THE LEVEL WOULD DROP, OVER A COUPLE OF WEEKS, ENOUGH WHICH REQUIRED US TO HAVE TO ADD MORE ANTIFREEZE. MY WIFE CALLED FORD'S SERVICE DEPARTMENT TO SCHEDULE AN APPOINTMENT TO DETERMINE/CONFIRM THE PROBLEM. WE WERE TOLD THAT IT SOUNDS LIKE THE WATER PUMP WAS MAY BE DEFECTIVE. ON OUR WAY TO THE APPOINTMENT, THE VEHICLE SHUT DOWN AND HAD TO BE TOWED THE REST OF THE WAY. UPON INSPECTION, WE WERE TOLD THAT ANTIFREEZE HAD LEAKED INTO THE ENGINE, AND FURTHER, THE ENGINE WAS DAMAGED BECAUSE OF A BROKEN TIMING CHAIN.

NHTSA ODI #11376033

Official recalls

24V031000 · Structure:body:roof And Pillars

Jan 19, 2024

Ford Motor Company (Ford) is recalling certain 2011-2019 Explorer vehicles. The A-pillar trim retention clips may not be properly engaged, allowing the trim to detach.

Consequence & remedy

Consequence: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.

Remedy: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model years. Owner notification letters were mailed between July 18, 2024 and December 16, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.

21V746000 · Suspension:rear

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.

21V537000 · Suspension:rear

Jul 15, 2021

Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin, and the District of Columbia. Exposure to road salt can cause the cross-axis ball joint to corrode and seize, resulting in a fracture of the outboard section of the rear suspension toe link.

Consequence & remedy

Consequence: A rear toe-link fracture can result in a loss of steering control, increasing the risk of a crash.

Remedy: Dealers will inspect and replace as necessary, the cross-axis ball joint (CABJ) knuckle, and replace the rear suspension toe links, free of charge. This recall is an expansion of previous NHTSA recall numbers 16V-245, 19V-435, and 20V-675. Certain vehicles previously repaired will need to return for the new remedy. An interim notification letter notifying owners of the safety risk were mailed on September 10, 2021. Owner notification letters were mailed on March 16, 2022. Owners may contact Ford's customer service at 1-866-436-7332. Ford's number for this recall is 21S32.

20V675000 · Suspension:rear

Mar 12, 2021

Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin that were previously repaired under a prior recall numbers 16V-245 or 19V-435. The outboard section of a rear suspension toe link may fracture.

Consequence & remedy

Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.

Remedy: Ford will notify owners, and dealers will inspect the cross-axis ball joint (CABJ) knuckle attached to the rear suspension toe link and replace it as necessary, free of charge. The recall began November 27, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S62.

19V435000 · Suspension:rear

Jun 10, 2019

Ford Motor Company (Ford) is recalling certain 2011-2017 Explorer vehicles. The rear suspension toe links may fracture due to stress on the rear suspension.

Consequence & remedy

Consequence: A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.

Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, and inspect both rear toe link ball joints, replacing the rear wheel knuckle(s), if necessary, free of charge. The recall began June 26, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S17.

15V812000 · Fuel System, Gasoline

Dec 2, 2015

Ford Motor Company (Ford) is recalling certain model year 2013 Explorer, Explorer Police Utility, Taurus, Taurus Police Interceptor, Flex, Lincoln MKS, and Lincoln MKT vehicles. In the affected vehicles, the fuel delivery module may crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source may result in a fire.

Remedy: Ford will notify owners, and dealers will replace the fuel delivery module, free of charge. The recall began on December 21, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 13S04-S1.

15V171000 · Structure:body:door

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.

14V286000 · Steering:electric Power Assist System

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.

13V270000 · Latches/locks/linkages

Jun 26, 2013

Ford Motor Company (Ford) is recalling certain model year 2013 Ford Explorer, Taurus, and Lincoln MKS vehicles manufactured November 29, 2012, through December 12, 2012. In the affected vehicles, with sufficient door openings and closings, the child safety locks may change from an activated position to a deactivated position without notice.

Consequence & remedy

Consequence: If the child lock is deactivated, the door could be unlocked and opened from the inside which could lead to personal injury to an unrestrained child.

Remedy: Ford will notify owners, and dealers will test the safety locks. If necessary, the locks will be replaced free of charge. The recall began on August 2, 2013. Ford's recall number is 13S07. Owners may contact the Ford customer relationship center at 1-866-436-7332.

13V227000 · Fuel System, Gasoline

May 31, 2013

Ford is recalling certain model year 2013 Explorer, Taurus, Flex, Fusion, Police Interceptor Sedan and Police Interceptor Utility vehicles; and certain model year 2013 Lincoln MKS, MKT, and MKZ vehicles. In the affected vehicles, the fuel delivery module may develop a crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source may result in a fire.

Remedy: Ford will notify owners, and dealers will replace the fuel delivery module, free of charge. The recall began on July 20, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332. Ford's recall campaign number is 13S04.

13V109000 · Fuel System, Gasoline:storage:tank Assembly

Mar 27, 2013

Ford is recalling certain model year 2012 Taurus, Lincoln MKS, and model year 2013 Explorer vehicles manufactured July 19, 2011, through March 15, 2012. In the affected vehicles, the fuel tanks may have a marginally sealed seam in the side of the tank. As a result, the fuel tanks may not provide the expected strength in the event of an impact. The tanks may also leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source may result in a fire.

Remedy: Ford will notify owners, and dealers will inspect the fuel tanks and replace them as necessary, free of charge. The recall began on May 9, 2013. Ford's recall campaign number is 13S03. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

PE23001 · Windshield Trim Molding Item Detachment

Opened Jan 27, 2023 · Closed Feb 8, 2024

Status: closed (inferred from source dates) · Structure:body:roof And Pillars

On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this failure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injuries. Some consumers have reported that the failure occurred while they were driving at highway speeds, with the detached trim panel entering the path of travel of the vehicle behind them, requiring the driver of the following vehicle to take evasive action. It is noteworthy that motorists who experience this type of road hazard are less likely to accurately identify the subject vehicle the item detached from and report the event to the NHTSA. In its April 17, 2023 response to ODI’s information request, Ford provided 175 consumer complaints (including field reports) and 14,162 warranty claims related to A-pillar trim panel detachment. Ford relayed that the subject vehicles utilize a plastic A-pillar bracket, which is bolted to the vehicle structure during assembly. The A-pillar trim panel is attached to the bracket utilizing 7 plastic clips. Contributory factors which have been identified by Ford as leading to the subject defect include incomplete installation at the assembly plant, inadequate part stack up, damage to fasteners during installation, and failure to follow proper repair procedure during windshield replacements or other services. On January 19, 2024, Ford filed safety recall 24V-031 for MY 2011-2019 Ford Explorer vehicles to address the subject defect. In the Part 573 Safety Recall Report, Ford identified that a detached A-pillar trim panel can create a road hazard for other road users, increasing the risk of a crash. The recall remedy includes an inspection of the existing A-pillar trim panel and, if necessary, the replacement of the component. The remedy A-pillar trim panels will be installed with an additional adhesive for robustness and utilize an inspection procedure to ensure full engagement of all the retention clips during installation. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

EA17002 · Exhaust Odor In Passenger Cab

Opened Jul 27, 2017 · Closed Jan 17, 2023

Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe; Structure:body

During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inve

Additional source detail variants (2)

Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe

Structure:body

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

Structure:body

EA15005 · Front Brake Hose Failure

Opened Sep 28, 2015 · Closed Nov 2, 2018

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings

On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate a report alleging incidents of front brake hose failure in model year (MY) 2015 Ford Explorer Police Interceptor vehicles used by the Sacramento Police Department in its pursuit driving training program (VOQ 10705832).On September 28, 2015, ODI upgraded the investigation to an Engineering Analysis (EA15-005) to assess maximum front caliper crimp temperatures under various test conditions, test hose assemblies removed from police interceptor service for any signs of thermal degradation, and further assess field data for evidence of a defect trend related to the alleged defect.The alleged defect results from exposure to extremely high heat at the caliper-side hose crimp. NHTSA?s vehicle testing suggests that the conditions necessary to produce the critical temperatures in the subject components result from drive-soak intervals that can occur during the Sacramento training program.NHTSA's testing of hose assemblies returned from police interceptor service did not identify any evidence of thermal degradation.NHTSA has not confirmed any incidents of caliper crimp failures due to overheating in vehicles not subjected to the Sacramento training course driving.The low number of hose assembly failure reports and the absence of any verified incidents of heat related front brake hose crimp failures since 2015 suggests that the Sacramento PD incidents resulted from conditions unique to the training program.A safety related defect trend has not been identified at this time and further use of Agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The Agency will take further action if warranted by the circumstances.For additional information, see the Closing Report in the document file for EA15-005 on www.nhtsa.gov.

PE14027 · Front Brake Hose Failure

Opened Aug 22, 2014 · Closed Feb 3, 2015

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings

The Office of Defects Investigation (ODI) opened PE14-027 based on a report of 13 front brake hose (jounce hose) failures in 11 vehicles in the District of Columbia Metropolitan Police Department (DCMPD) fleet of 46 model year (MY) 2013 Ford Explorer Police Interceptor (PI) vehicles (VOQ 10621634).The DCMPD fleet provided Ford with 71 jounce hoses for analysis, including 4 of the 13 failed hoses.Inspection of each of the failed hoses identified a small tear in the outer cover on the body end of the hoses on the outboard side. Ford?s lab analysis of these hoses identified splits in the inner liners 1.5-2.0mm from the end of the nipple (outside of the crimped ferrule joint).Ford conducted pressure testing of 10 randomly selected samples of the remaining 67 hoses that had not experienced leaks and 9 of the samples leaked at 6,000 psi.Ford?s examination of the 9 hoses that leaked in the pressure tests found 4 that failed on the outboard side of the hose (similar to the 4 leaking field parts) and 5 that failed on the body end of the hose on the inboard side.Four additional non-leaking hoses were sent to the hose supplier, Hitachi, for analysis.Broken yarn was observed in scanning electron microscope examinations at both the body side and caliper side hose to ferrule crimps, indicating severe bending stress had occurred at these locations. Hitachi supplied an additional set of non-leaking field return hoses and a brand new set of hoses to an outside laboratory (Element Materials Technology) for analysis.The lab did not identify any manufacturing or material deficiencies in the hoses and concluded that the hose failures were caused by excessive bending stresses.Based on the examinations of the returned jounce hoses, Ford conducted durability testing on new hoses that were the same design as those found on the subject vehicles.Ford first determined the worst case conditions for the hoses; jounce bumpers removed, internal rebound stops fully compressed, and shock absorbers attached. With the jounce hose installed, the steering was rotated to the maximum turn angle while the suspension was translated from full jounce to full rebound.This determined the maximum hose length of 13.0in (331mm) and a minimum hose bending radius of 1.6in (40mm).Using these conditions hoses tested on a Suspension Motion Simulator far surpassed Ford?s performance specifications. Twenty (20) complaints of front brake jounce hose failure were identified on a total of 18 Explorer PI vehicles, including the 13 hose failures in 11 vehicles from the DCMPD fleet that prompted PE14-027.The remaining 7 complaints included 3 from one fleet that reportedly occurred on the banjo block end of the hose assembly and single complaints from 4 other fleets.Only two brake hose assemblies were used in the subject and peer Explorer vehicles, with the BB53 level hose used until June 20, 2012, and an updated DB53 level hose used thereafter.No pattern of failures was observed by hose assembly, with 15 of failures involving the BB53 hose assembly (including the 13 from DCMPD manufactured in March 2012) and 5 the DB53 hose assembly built after June 20, 2012. No root cause was determined for the reported Explorer PI jounce hose failures, but Ford identified improper service repair procedures (e.g., hanging the brake caliper from the brake hose during brake pad replacement) as a possible contributor to higher than expected rate of front brake jounce hose leaks. ODI?s analysis of field data, hose inspection and test data did not identify evidence of any defects in hose material, manufacture or vehicle installation.The closing of this invest

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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