NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
100 reportsClear category filter10,000 miles · Jun 6, 2017
Electrical SystemFuel/propulsion SystemSeats
BOUGHT MY 2014 EXPLORER BRAND NEW FROM KOONS FORD AND RIGHT OFF THE BAT, THE DRIVER SEATS STARTED SQUEAKING AT ABOUT 5K MILES. THEY REPLACED THE LOWER LUMBAR BAR, WHICH FIXED IT FOR ANOTHER 2K MILES AND THE SEAT STARTED SQUEAKING AGAIN. I GAVE UP ON THIS ISSUE AFTER A FEW MORE ATTEMPTS TO GET IT FIXED. THEN ABOUT 6 MONTHS LATER,…
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BOUGHT MY 2014 EXPLORER BRAND NEW FROM KOONS FORD AND RIGHT OFF THE BAT, THE DRIVER SEATS STARTED SQUEAKING AT ABOUT 5K MILES. THEY REPLACED THE LOWER LUMBAR BAR, WHICH FIXED IT FOR ANOTHER 2K MILES AND THE SEAT STARTED SQUEAKING AGAIN. I GAVE UP ON THIS ISSUE AFTER A FEW MORE ATTEMPTS TO GET IT FIXED. THEN ABOUT 6 MONTHS LATER, THE LCD ON MY DASH WOULD STAY ON EVERY NOW AND THEN WHEN I SHUT OFF AND LOCK THE CAR. TOOK IT BACK TO KOONS AND THEY CLAIM THEY CAN'T REGENERATE THE ISSUE AND CAN'T FIX IT. AFTER 2 YEARS, STARTED HEARING WHINNING/SQUEALING NOISES FROM THE REAR WHEELS, KOONS ALSO COULD NOT DIAGNOSE/FIX. I GAVE UP ON KOONS AND TOOK IT TO TED BRITT, WHO ALSO COULD NOT DIAGNOSE/FIX. HAD MY 45K SERVICE AND TOLD THEM ABOUT BAD ODOR SMELL IN THE CAR AT TED BRITT AND THEY SAID EVERYTHING IS IN GREAT CONDITION, 5K MILES LATER, REAR WHEELS HAS GRINDING NOISES WHEN DRIVING AT LOW OR HIGH SPEEDS AND THE BAD ODOR IS STILL AROUND, MY 8 YEAR OLD SON COMPLAINS ABOUT THE CAR GIVING HIM HEADACHES. I TOOK IT BACK TO FORD AND THEY SAID THERE IS ONLY A TSB SO, THE OWNERS DO NOT GET NOTIFIED, WHICH I THINK, WE AS OWNERS SHOULD BE NOTIFIED BY THE MANUFACTURE OF ANY HARMFUL SUBSTANCE LINGERING INSIDE THE CAR CABIN AND SHOULD BE RECALLED AND FIXED AT NOT COST TO THE OWNERS. THIS IS VERY UNPROFESSIONAL OF THE MANUFACTURE.
NHTSA ODI #10993363
Mileage unknown · May 27, 2017
Electrical SystemService BrakesWheels
I HAVE HAD MULTIPLE ELECTRICAL PROBLEMS WITH THIS VEHICLE AND SAFETY ISSUES. ELECTRICAL- AUDIO OUTPUT FAILS INTERMITTENTLY, POWER OUTLETS SHORT OUT, INSTRUMENT CLUSTER FAILS (WHILE MOVING AND IN PARK) EXHAUST- FUMES COMING INSIDE VEHICLE (IN MOTION AND PARK) BRAKES- HAD TO HAVE ENTIRE SYSTEM REPLACED AFTER COMPLETE FAILURE O…
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I HAVE HAD MULTIPLE ELECTRICAL PROBLEMS WITH THIS VEHICLE AND SAFETY ISSUES. ELECTRICAL- AUDIO OUTPUT FAILS INTERMITTENTLY, POWER OUTLETS SHORT OUT, INSTRUMENT CLUSTER FAILS (WHILE MOVING AND IN PARK) EXHAUST- FUMES COMING INSIDE VEHICLE (IN MOTION AND PARK) BRAKES- HAD TO HAVE ENTIRE SYSTEM REPLACED AFTER COMPLETE FAILURE OF ABS SYSTEM (HAPPENED MULTIPLE TIMES WHILE IN MOTION, ONCE ON EXPRESSWAY, ALL REPORTED TO FORD CORPORATE) WHEELS - LUG NUTS HAVE BEEN REPORTED MULTIPLE TIMES FOR MOISTURE COLLECTING INSIDE THE LUG NUTS AND CAUSING CORROSION SEAT BELTS - HOUSING CASE OF SAFETY BELTS POP OFF IDLE - WHEN IDLING WITH BRAKE DEPRESSED AND A DOOR OPENED AND CLOSED THE IDLE SKIPS AND MAKES NOISE WASHER FLUID SENSOR - FAILED AT 70, 000 MILES AC SYSTEM DRAINS POWER HORRIBLY VEHICLE WAS LEASED JANUARY 2014 PROBLEMS HAVE BEEN CONSISTEN SINCE THAT DATE, ALL RECORDS ARE IN FORD'S SYSTEM.
NHTSA ODI #10991903
Mileage unknown · May 2, 2017
Electrical System
DOOR AJAR INDICATOR STAY ON ALTHOUGH THE DOORS ARE CLOSED.
NHTSA ODI #10983058
51,400 miles · Apr 24, 2017
Electrical System
DRIVER'S DOOR AJAR WARNING IS ACTIVATED AND NO DOOR IS AJAR. THIS VEHICLE IS EQUIPPED WITH AUTOMATIC LOCKING DOORS, WHICH DO NOT LOCK AS A RESULT. I AM AWARE THAT FORD HAS BEEN GIVEN A PASS ON RECALLS FOR THIS BUT THIS IS A PROBLEM KNOWN TO FORD SINCE 2011. I BELIEVE FORD SHOULD BE REQUIRED TO MAKE REPAIRS, EVEN AFTER THE NEW CA…
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DRIVER'S DOOR AJAR WARNING IS ACTIVATED AND NO DOOR IS AJAR. THIS VEHICLE IS EQUIPPED WITH AUTOMATIC LOCKING DOORS, WHICH DO NOT LOCK AS A RESULT. I AM AWARE THAT FORD HAS BEEN GIVEN A PASS ON RECALLS FOR THIS BUT THIS IS A PROBLEM KNOWN TO FORD SINCE 2011. I BELIEVE FORD SHOULD BE REQUIRED TO MAKE REPAIRS, EVEN AFTER THE NEW CAR WARRANTY IS EXPIRED.THIS IS AN OBVIOUS MFG DEFECT, AND THE MFG SHOULD BE ACCOUNTABLE FOR THE LIFE OF THE VEHICLE. I IMAGINE FORD HAS BEEN GIVEN A PASS ON RECALLS BECAUSE THEY NEGOTIATED A DEAL, AND PROBABLY INDICATED THEY WOULD REPAIR ALL REPORTED DEFECTS RATHER THAN HAVE A COMPLETE RECALL OF ALL MODELS USING THIS SAME WARNING SYSTEM, WITH THE SAME PARTS. THE LOCAL DEALER TOLD ME FORD WILL REPAIR AS NECESSARY FOR CARS UNDER WARRANTY, BUT NOT AFTER WARRANTY PERIOD. THIS DEFECT AFFECTS SEVERAL MODELS OF FORD VEHICLES, FOR SEVERAL KNOWN YEARS, AND FORD SHOULD BE REQUIRED TO REPLACE THE DEFECT, FOR ALL MODELS, FOR ALL YEARS, AS LONG AS THE PROBLEM MANIFESTS ITSELF IN OPERATING VEHICLES MANUFACTURED BY FORD.TO MY KNOWLEDGE, THERE HAVE BEEN MORE THAN 2700 SIMILAR COMPLAINTS, AND MORE THAN 33,000 WARRANTY CLAIMS.THAT'S OVER 35,000 KNOWN DEFECTIVE VEHICLES, WHICH DOES NOT INCLUDE THOS THAT OWNERS HAVE SIMPLY HAD REPAIRED WITHPOUT COMPLAINT.
NHTSA ODI #10980129
61,500 miles · Apr 24, 2017
Electrical System
THE ELECTRIC MOONROOF STOPPED WORKING AND WOULD NOT OPEN. THE SUN SHADE WOULD PARTIALLY CLOSE. WE CHANGED THE FUSE BUT THE MOONROOF STILL WOULD NOT WORK. SO WERE LEAVING IT ALONE UNTIL THE WEATHER WARMED UP. THIS MORNING I WENT OUT TO GO TO WORK AND MY MOONROOF WAS STANDING OPEN AND MY CAR WAS STANDING IN WATER AND LEAVES. NO ON…
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THE ELECTRIC MOONROOF STOPPED WORKING AND WOULD NOT OPEN. THE SUN SHADE WOULD PARTIALLY CLOSE. WE CHANGED THE FUSE BUT THE MOONROOF STILL WOULD NOT WORK. SO WERE LEAVING IT ALONE UNTIL THE WEATHER WARMED UP. THIS MORNING I WENT OUT TO GO TO WORK AND MY MOONROOF WAS STANDING OPEN AND MY CAR WAS STANDING IN WATER AND LEAVES. NO ONE HAD DRIVEN THE CAR IN 3 DAYS. I AM A 50+ YEAR OLD FEMALE AND TRY TO BE VERY PARTICULAR WITH MY VEHICLE. I RARELY USE THE MOONROOF ITSELF, BUT I DO OPEN THE SUN SHIELD AT TIMES IN THE PAST. I DO NOT KNOW HOW THE MOONROOF OPENED, IF THERE WAS A POWER SURGE OR WHAT??? I HAVE SEARCHED THE INTERNET THIS MORNING AND FOUND THIS HAD HAPPENED TO OTHER INDIVIDUALS.
NHTSA ODI #10980070
90,000 miles · Apr 17, 2017
Electrical SystemEngine
WHEN THERE IS A HEAVY RAIN THE SERPENTINE BELT SQUEALS AT VARIOUS MOMENTS, FOR SHORT PERIODS OF TIME. THIS HAS BEEN GOING ON SINCE I PURCHASED THE VEHICLE IN 2014 , BUT DEALERSHIP SAID IT WAS A KNOWN ISSUE AND THERE WAS NOTHING THEY COULD DO ABOUT IT. THEY SAID IT WAS DUE TO THE BELT GETTING WET AND FORD DIDN'T KNOW HOW TO PRE…
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WHEN THERE IS A HEAVY RAIN THE SERPENTINE BELT SQUEALS AT VARIOUS MOMENTS, FOR SHORT PERIODS OF TIME. THIS HAS BEEN GOING ON SINCE I PURCHASED THE VEHICLE IN 2014 , BUT DEALERSHIP SAID IT WAS A KNOWN ISSUE AND THERE WAS NOTHING THEY COULD DO ABOUT IT. THEY SAID IT WAS DUE TO THE BELT GETTING WET AND FORD DIDN'T KNOW HOW TO PREVENT IT FROM HAPPENING, AND THAT IT OCCURS ON OTHER FORD TRUCKS TOO. MY OTHER ISSUE HAS STARTED RECENTLY HAPPENING TO WHEN IT RAINS HEAVILY, THE "LOW BATTERY FEATURES TEMPOR. TURNED OFF" NOTIFICATION COMES ON AND MY STEERING WHEEL LOCKS UP BRIEFLY WHILE DRIVING. I CHECKED MY BATTERY CONNECTS AS THE MANUAL SAYS TO DO AND THEY ARE FINE. THIS ONLY OCCURS DURING HEAVY RAIN AND IT HAPPENS AT VARIOUS TIMES DURING DRIVING. IT NEVER JUST STAYS ON, BUT WILL TURN ON AND GO OFF AT DIFFERENT TIMES DURING THE DRIVE IN THE HEAVY RAIN. SEEMS LIKE SOMETHING IS GETTING WET CAUSING A SHORTAGE, BUT EITHER WAY ITS DANGEROUS WHEN MY STEERING WHEEL LOCKS UP.
NHTSA ODI #10978786
47,412 miles · Jan 6, 2017
Electrical SystemEngineTraction Control System
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE FAILED TO START AND STALLED INTERMITTENTLY. THE VEHICLE STARTED ONLY AFTER THE BATTERY WAS CHARGED. THE CONTACT ALSO STATED THAT THE HEATING SYSTEM BECAME INOPERABLE AND THE CHECK ENGINE, SERVICE TRACTION, AND BATTERY WARNING INDICATORS ILLUMINATED. T…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE FAILED TO START AND STALLED INTERMITTENTLY. THE VEHICLE STARTED ONLY AFTER THE BATTERY WAS CHARGED. THE CONTACT ALSO STATED THAT THE HEATING SYSTEM BECAME INOPERABLE AND THE CHECK ENGINE, SERVICE TRACTION, AND BATTERY WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, BUT WAS UNABLE TO BE STARTED OR DIAGNOSED. THE DEALER DIAGNOSED THAT THE BATTERY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE THROTTLE BODY FAILED. THE THROTTLE BODY WAS REPLACED AND REPROGRAMMED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 47,412. *TR
NHTSA ODI #10940085
32,640 miles · Dec 2, 2016
Electrical SystemEngineVehicle Speed Control
I BOUGHT MY 2014 FORD EXPLORER IN NOVEMBER OF 2015. I NOTICED A ROTTEN EGG/ EXHAUST SMELL AS THE WEATHER BECAME WARMER. ANYTIME I WOULD ACCELERATE UP A HILL OR ACCELERATE ON A FLAT STRETCH OF ROAD DURING THE SUMMER MONTHS WAS WHEN THE SMELL IS THE WORST. I HAVE TO ROLL DOWN ALL OF THE WINDOWS. I NO LONGER ALLOW MY CHILDREN TO RI…
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I BOUGHT MY 2014 FORD EXPLORER IN NOVEMBER OF 2015. I NOTICED A ROTTEN EGG/ EXHAUST SMELL AS THE WEATHER BECAME WARMER. ANYTIME I WOULD ACCELERATE UP A HILL OR ACCELERATE ON A FLAT STRETCH OF ROAD DURING THE SUMMER MONTHS WAS WHEN THE SMELL IS THE WORST. I HAVE TO ROLL DOWN ALL OF THE WINDOWS. I NO LONGER ALLOW MY CHILDREN TO RIDE IN THE THIRD ROW BECAUSE THEY WOULD COMPLAIN ON THE LONGER CAR RIDES OF HAVING A HEADACHE. I HAVE TAKEN THIS TO THE DEALERSHIP ON 3 OCCASIONS NOW. THEY HAVE TOLD ME THEY HAVE TRIED TO REPRODUCE MY COMPLAINT, AND HAVE FAILED TO DO SO. I AM CURRENTLY GOING TO THAT THE SERVICE MANAGER ON A RIDE TOMORROW TO REPRODUCE THIS SMELL. THE SMELL HAS BEEN SO BAD AT TIMES THAT I PERSONALLY HAVE FELT LIKE I WAS GOING TO BE SICK. THERE IS SOMETHING SERIOUSLY WRONG WITH THE EXPLORERS HAVING THIS SMELL. SOMETHING NEEDS TO BE DONE. I AM AT THE POINT THAT I DO NOT PUT MY KIDS IN MY CAR ANYMORE THEN I HAVE TO. I HAVE HAD TO APOLOGIZE ON SEVERAL OCCASIONS TO MY FRIENDS ABOUT THE SMELL. FORD NEEDS TO FIGURE THIS OUT!! *TR
NHTSA ODI #10929575
31,000 miles · Aug 7, 2016
Electrical System
DRIVERS DOOR AJAR LIGHT STAYS ON. TOOK TO FORD DEALER, WAS TOLD THAT FMCO REQUIRES THEY CLEAN CONTACTS FIRST, BEFORE REPLACING. THIS WAS DONE AND SOLVED THE PROBLEM FOR A WHILE. I TOOK BACK TO DEALER WHEN PROBLEM STARTED AGAIN. NOW THEY SAY THE DOOR LATCH IS BROKEN AND WANT $366.00 TO FIX IT, AND THEY HAVE TO ORDER THE PART. …
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DRIVERS DOOR AJAR LIGHT STAYS ON. TOOK TO FORD DEALER, WAS TOLD THAT FMCO REQUIRES THEY CLEAN CONTACTS FIRST, BEFORE REPLACING. THIS WAS DONE AND SOLVED THE PROBLEM FOR A WHILE. I TOOK BACK TO DEALER WHEN PROBLEM STARTED AGAIN. NOW THEY SAY THE DOOR LATCH IS BROKEN AND WANT $366.00 TO FIX IT, AND THEY HAVE TO ORDER THE PART. THIS IS AN ONGOING PROBLEM WITH FORD PRODUCTS AND THEY HAVE IN FACT RECALLED SEVERAL MODELS. I WAS GIVEN THE IMPRESSION TO START WITH THAT IF THE CONTACT CLEANING PROCEDURE DIDN'T WORK THEN IT WOULD BE REPLACED. NOW THEY WANT TO CHARGE FOR THIS.
NHTSA ODI #10893834
37,000 miles · Jun 22, 2016
Electrical System
THE DRIVER DOOR CONTINUES TO SOUND ALARM OF DOOR AJAR, SLAM THE DOOR AND STILL THE SAME, VERY ANNOYING WHEN DRIVING BECAUSE IT WON'T STOP
NHTSA ODI #10875873
Official recalls
6Jan 19, 2024
Ford Motor Company (Ford) is recalling certain 2011-2019 Explorer vehicles. The A-pillar trim retention clips may not be properly engaged, allowing the trim to detach.
Consequence & remedy
Consequence: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.
Remedy: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model years. Owner notification letters were mailed between July 18, 2024 and December 16, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.
Jul 15, 2021
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin, and the District of Columbia. Exposure to road salt can cause the cross-axis ball joint to corrode and seize, resulting in a fracture of the outboard section of the rear suspension toe link.
Consequence & remedy
Consequence: A rear toe-link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Dealers will inspect and replace as necessary, the cross-axis ball joint (CABJ) knuckle, and replace the rear suspension toe links, free of charge. This recall is an expansion of previous NHTSA recall numbers 16V-245, 19V-435, and 20V-675. Certain vehicles previously repaired will need to return for the new remedy. An interim notification letter notifying owners of the safety risk were mailed on September 10, 2021. Owner notification letters were mailed on March 16, 2022. Owners may contact Ford's customer service at 1-866-436-7332. Ford's number for this recall is 21S32.
Mar 12, 2021
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin that were previously repaired under a prior recall numbers 16V-245 or 19V-435. The outboard section of a rear suspension toe link may fracture.
Consequence & remedy
Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will inspect the cross-axis ball joint (CABJ) knuckle attached to the rear suspension toe link and replace it as necessary, free of charge. The recall began November 27, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S62.
Nov 10, 2020
Ford Motor Company (Ford) is recalling certain 2014-2016 Explorer, 2014-2015 Taurus and 2014 Edge vehicles equipped with 2.0L or 2.3L engines and front wheel drive. The support bracket for the front drive axle halfshaft may fail.
Consequence & remedy
Consequence: The failed bracket could result in a loss of park function which can cause unintended vehicle movement, and loss of motive power while driving which increases the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the link shaft bracket, free of charge. Parts are not currently available. Owners received an interim notification detailing safety risk December 8, 2020. A second letter will be mailed when parts become available in January 2021. The recall began February 2, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S63.
Jun 10, 2019
Ford Motor Company (Ford) is recalling certain 2011-2017 Explorer vehicles. The rear suspension toe links may fracture due to stress on the rear suspension.
Consequence & remedy
Consequence: A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, and inspect both rear toe link ball joints, replacing the rear wheel knuckle(s), if necessary, free of charge. The recall began June 26, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S17.
Apr 26, 2016
Ford Motor Company (Ford) is recalling certain model year 2014-2015 Ford Explorer vehicles manufactured January 17, 2014 to May 31, 2014. The affected vehicles may have improperly welded rear suspension toe links that may fracture.
Consequence & remedy
Consequence: A fracture of the rear suspension toe link may result in a loss of steering control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, free of charge. The recall began on November 18, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S18.
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).
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.
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