NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
196 reportsClear category filter5,000 miles · Jun 21, 2014
EngineVehicle Speed Control
EVERY TIME THE SUV IS ACCELERATING OVER 3.4K RPMS FOR A DURATION OF GREATER THAN 3-5 SECONDS, THE AC SYSTEM FILLS THE CABIN WITH NAUSEATING GAS. THE SMELL HAS CHANGED OVER THE COURSE OF OWNERSHIP FROM BURNT HAIR SMELL, NOW TO A EXHAUST, ROTTEN EGG/CARBON SMELL. OCCURS WITH AC SYSTEM OFF, OR ON INDEPENDENT OF FRESH AIR OR RECIRCU…
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EVERY TIME THE SUV IS ACCELERATING OVER 3.4K RPMS FOR A DURATION OF GREATER THAN 3-5 SECONDS, THE AC SYSTEM FILLS THE CABIN WITH NAUSEATING GAS. THE SMELL HAS CHANGED OVER THE COURSE OF OWNERSHIP FROM BURNT HAIR SMELL, NOW TO A EXHAUST, ROTTEN EGG/CARBON SMELL. OCCURS WITH AC SYSTEM OFF, OR ON INDEPENDENT OF FRESH AIR OR RECIRCULATE MODE. SMELL LINGERS FOR MINUTES AFTERWARDS. TAKEN TO DEALER BUT UNABLE TO REPLICATE PROBLEM. ALSO, THEY SAID THAT THE TSB FOR THE ISSUE DID NOT APPLY TO 2014 MODELS. I AM VERY CONCERNED THAT EXHAUST (CO) IS ENTERING THE VEHICLE AT HAZARDOUS LEVELS. *TR
NHTSA ODI #10604940
Mileage unknown · Jun 2, 2014
EngineVehicle Speed Control
EXHAUST GAS IS GETTING INTO THE CABIN WHEN THE CAR ACCELERATES OVER 3200 TO 3500 RPM. FORD SAYS THAT THE GAS IS NOT EXHAUST GAS, BUT A STRONG ORDER THAT IS NOT HARMFUL. THEY WILL NOT TELL US WHAT CHEMICAL THE ORDER IS. WHEN I DROVE THE CAR I WAS EXPERIENCING ASTHMA AND HEART PALPITATIONS. THE DEALERSHIP FOUND THAT IT HAD THE…
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EXHAUST GAS IS GETTING INTO THE CABIN WHEN THE CAR ACCELERATES OVER 3200 TO 3500 RPM. FORD SAYS THAT THE GAS IS NOT EXHAUST GAS, BUT A STRONG ORDER THAT IS NOT HARMFUL. THEY WILL NOT TELL US WHAT CHEMICAL THE ORDER IS. WHEN I DROVE THE CAR I WAS EXPERIENCING ASTHMA AND HEART PALPITATIONS. THE DEALERSHIP FOUND THAT IT HAD THE 2013 EXPLORER PARTS IN IT AND CHANGED THEM OUT PER THE TSB 12-12-4. IT STILL DID NOT HELP. ANOTHER POST SAID THAT THEY DID USE A MONITOR IN THEIR CAR AND IT WAS EXHAUST. WHEN WE PASS A CAR OR FARM MACHINERY OR ENTER ONTO A FREEWAY, THE EXHAUST SMELL IS SUFFOCATING WHEN IT ENTERS THE CAR CABIN. MY FEAR IS THAT THE EXHAUST COULD BE COMING INTO THE CABIN ALL THE TIME, BUT WE CAN'T SMELL IT UNTIL IT GETS TO A CONCENTRATED LEVEL. FORD SAID THAT THE ENGINEERS ARE WORKING ON IT. SO I HAVE PURCHASED A $45,000 VEHICLE THAT I CAN'T DRIVE. *TR
NHTSA ODI #10595494
5,600 miles · Apr 30, 2014
EngineFuel/propulsion System
IT WAS RAINING QUITE HEAVILY ALL DAY AND WAS RAINING WHEN THE MISFIRE OCCURRED. THE VEHICLE WOULD BUCK AND JERK WHEN I TRIED TO ACCELERATE. I HAD TO PULL OVER AND RESTART THE CAR AND THEN FINALLY THE BLINKING ENGINE WENT AWAY. THE ENGINE ON THIS CAR IS A TWIN TURBO 3.5L ECOBOOST. *JS
NHTSA ODI #10585780
3,400 miles · Apr 2, 2014
EnginePower Train
I AM PASTING FROM A PARTS OF A POST THAT I MADE ON 4/2/2014 @ 11:06AM AT WWW.BLUEOVALFORUMS.COM WITH THE TOPIC BEING: "MAJOR CONCERN/ISSUE WITH 2014 FORD EXPLORER SPORT": THIS FOR THE 2014 FORD EXPLORER SPORT WITH V6 3.5L ECOBOOST (TWIN TURBO) MOTOR. ABOUT A MONTH AFTER OWNING IT, I WAS TRAVELING ON THE HIGHWAY....I WAS TRA…
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I AM PASTING FROM A PARTS OF A POST THAT I MADE ON 4/2/2014 @ 11:06AM AT WWW.BLUEOVALFORUMS.COM WITH THE TOPIC BEING: "MAJOR CONCERN/ISSUE WITH 2014 FORD EXPLORER SPORT": THIS FOR THE 2014 FORD EXPLORER SPORT WITH V6 3.5L ECOBOOST (TWIN TURBO) MOTOR. ABOUT A MONTH AFTER OWNING IT, I WAS TRAVELING ON THE HIGHWAY....I WAS TRAVELING ABOUT 60MPH ....I SIGNALED TO GET OVER AND GAVE IT GAS TO SPEED UP MODERATELY TO ABOUT 75MPH OR SO. WHEN I PRESSED ON THE GAS THE CAR BASICALLY ALMOST STALLED ON ME...IT WASN'T A TRANSMISSION TRYING TO THINK WHICH GEAR TO SHIFT INTO ISSUE, IT WAS A STRAIGHT CHOKING OF THE GAS AND STUTTERING/HESITATING UNTIL I LET OFF THE GAS 2 TIMES OR SO AND THEN PRESS DOWN ON THE GAS AGAIN AND IT TAKES OFF, BUT IT A NOTICEABLE LOSE OF POWER.THIS HAS HAPPENED NOW 4 TIMES WITH THIS PAST WEEKEND 3/30/2014 BEING THE MOST RECENT. HOWEVER THE HIGHWAY SPEED WAS THE ONLY HIGH SPEED INCIDENT. THE OTHER 3 TIMES THAT IT OCCURRED WERE ALL IN TOWN, ON ONE OF THEM I WAS MAKING A SIMPLE U-TURN FROM A STOP AND WHEN I PRESSED THE GAS (NOT HEAVILY) TO GET UP AND OUT OF THE TURN IT STALLED. THE OTHER TIME WAS PASSING TO ANOTHER LANE AND GIVING IT SOME GAS TO SPEED UP. THIS PAST SUNDAY I WAS TRAVELING ON A 2 LANE ROAD THEN CHANGES TO A 1 LANE ROAD APPROX. 100 YARDS AFTER THE STOP LIGHTS. I WAS STOPPED BEHIND A VEHICLE AND WHEN WE STARTED MOVING THE VEHICLE IN FRONT WAS ONLY GOING ABOUT 20-25MPH IN A 45MPH ZONE. SO I SIGNALED AND SAW A VAN IN THE LANE ABOUT 100 YARDS BACK SO I PRESSED ON THE GAS TO GET SOME SPEED TO PASS HIM BEFORE THE LANE ENDED AND AGAIN NOTHING CRAZY JUST TO GET UP TO 45-50MPH OR SO AND THE DARN THING STALLED ON ME AGAIN! THE BIG CONCERN I HAVE NOW IS THAT THE FAMILY AND I ARE PLANNING ON A CROSS-COUNTRY ROAD TRIP THIS SUMMER FROM MAY 24-JUNE 10, 2014. *TR
NHTSA ODI #10576912
390 miles · Nov 11, 2013
EngineFuel System, GasolinePower Train
WITHIN 24 HRS. OF PURCHASE, DRIVING ON EVEN ROAD DRY CONDITIONS APPROX. 40 MPH ENGINE SHUT OFF WHILE IN MOTION NO HESITATION NO BUCKING JUST SHUT OFF. PULLED OFF SIDE OF ROAD RESTARTED OK TOOK TO DEALER (JACK BYRNE FORD) NO CODE NO IDEA WHAT CAUSED IT, COULD NOT GET TO REPEAT . THIS VEHICLE IS PRIMARILY DRIVEN ON THE HIGHWAY WE…
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WITHIN 24 HRS. OF PURCHASE, DRIVING ON EVEN ROAD DRY CONDITIONS APPROX. 40 MPH ENGINE SHUT OFF WHILE IN MOTION NO HESITATION NO BUCKING JUST SHUT OFF. PULLED OFF SIDE OF ROAD RESTARTED OK TOOK TO DEALER (JACK BYRNE FORD) NO CODE NO IDEA WHAT CAUSED IT, COULD NOT GET TO REPEAT . THIS VEHICLE IS PRIMARILY DRIVEN ON THE HIGHWAY WE ARE DEATHLY AFRAID THAT THIS WILL HAPPEN AGAIN AT A HIGHER SPEED AND WILL RESULT IN A REAR END COLLISION. SPOKE TO THE SR. REGIONAL CUSTOMER SERVICE MANAGER FOR NY/NJ. SHE STATES THAT THE DEALER LOOKED VEHICLE OVER AND COULD NOT FIND PROBLEM NOR COULD THEY REPEAT IT NO CODE SHE COULD NOT STATE THE VEHICLE IS SAFE TO DRIVE JUST THAT THE DEALER COULDN'T FIND ANYTHING AND ITS READY TO BE PICKED UP AT DEALERSHIP. *TR
NHTSA ODI #10551743
1,100 miles · Aug 2, 2013
EnginePower Train
I BOUGHT MY FORD EXPLORER 2014 ON JULY 1ST 2013. ON AUGUST 1ST, 2013, MY CAR DID NOT MOVE FORWARD WHILE I STARTED THE CAR AND PUT IT TO 'D' (DRIVE) IN A PARKING LOT. INSTEAD, THE CAR WENT BACKWARDS WHILE I STEPPED ON GAS. I WAS VERY CONFUSED, AND THOUGHT IT WAS MY ILLUSION. SO I STEPPED ON BRAKE AND CHECKED THE DRIVE PANEL, …
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I BOUGHT MY FORD EXPLORER 2014 ON JULY 1ST 2013. ON AUGUST 1ST, 2013, MY CAR DID NOT MOVE FORWARD WHILE I STARTED THE CAR AND PUT IT TO 'D' (DRIVE) IN A PARKING LOT. INSTEAD, THE CAR WENT BACKWARDS WHILE I STEPPED ON GAS. I WAS VERY CONFUSED, AND THOUGHT IT WAS MY ILLUSION. SO I STEPPED ON BRAKE AND CHECKED THE DRIVE PANEL, THE LIGHT FOR 'D' IS ON. THEN I SWITCH TO 'P' AND AFTER A FEW SECONDS PUT TO 'D' AGAIN. HOWEVER, MY CAR STILL WENT BACKWARD AND MY REAR BUMP HIT THE FRONT BUMPER OF ANOTHER CAR WHICH PARK BEHIND MINE. THEN I GOT CONFIRMED THAT MY CAR WAS MALFUNCTIONING. I WAS 100% SURE THAT THE GEAR OF MY CAR WAS IN 'D', SINCE I DID NOT SEE THE BACK UP MIRROR ON FROM THE LCD DISPLAY, AND THE INDICATING LIGHT OF THE GEAR WAS 'D'. AND MY CORPORATE PARKING LOT IS VERY FLAT. AFTER THAT, I TURNED OFF MY EXPLORER, AND WENT OUT TO CHECK IF THERE IS DAMAGE TO THE CAR THAT I HIT. THEN I RESTART MY EXPLORER, PUT GEAR SHIFT IN 'D' AND IT WENT BACK TO NORMAL. I COULD NOT BELIEVE IT HAPPENED TO MY NEW CAR PURCHASED ONLY ABOUT A MONTH. THIS PROBLEM MADE ME PANIC. WHAT IF THE PROBLEM HAPPENED AGAIN IN A BUSY STREET? WHAT IF THERE ARE PEDESTRIANS IN THE PARKING LOT WHEN MY CAR WAS MOVING BACKWARD BUT IT SUPPOSES TO GO FORWARD? I HOPE SOME AUTHORITIES COULD HELP INVESTIGATE THE PROBLEM, AND ALERT THE MANUFACTURE AND OTHER OWNERS FOR SIMILAR QUESTIONS. *TR
NHTSA ODI #10533188
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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