NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
67 reportsClear category filter16,000 miles · Jul 6, 2016
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING VARIOUS SPEEDS OR WHEN THE AIR CONDITIONER WAS ACTIVATED IN RECIRCULATION MODE, THE CONTACT NOTICED EXHAUST FUMES IN THE VEHICLE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VI…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING VARIOUS SPEEDS OR WHEN THE AIR CONDITIONER WAS ACTIVATED IN RECIRCULATION MODE, THE CONTACT NOTICED EXHAUST FUMES IN THE VEHICLE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS 16,000.
NHTSA ODI #10882892
28,900 miles · Jul 5, 2016
Engine And Engine Cooling
I MAY HAVE ALREADY COMPLAINED, BUT THIS CAN UPDATE THAT. WHEN PULLING A LONG GRADE AND THE VEHICLE HAS DOWNSHIFTED,3500 OR MORE RPM AND ABOUT 65 MPH UNDER LOAD, I SMELL SULFUR IN THE CABIN. IT SEEMS TO BE WORSE WHEN THE COVERS FOR MY MOON ROOF AND SUN ROOF ARE RETRACTED. IT HAS BEEN IN TO A DEALER 4 TIMES NOW, SO I HAVE LOST A…
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I MAY HAVE ALREADY COMPLAINED, BUT THIS CAN UPDATE THAT. WHEN PULLING A LONG GRADE AND THE VEHICLE HAS DOWNSHIFTED,3500 OR MORE RPM AND ABOUT 65 MPH UNDER LOAD, I SMELL SULFUR IN THE CABIN. IT SEEMS TO BE WORSE WHEN THE COVERS FOR MY MOON ROOF AND SUN ROOF ARE RETRACTED. IT HAS BEEN IN TO A DEALER 4 TIMES NOW, SO I HAVE LOST A MONTH OF USE. THE LAST RETURN WAS ON FRIDAY 1 JULY. I HAVE NOT HAD A CHANCE TO TAKE IT TO A LOCAL MOUNTAIN THAT MAKES IT SMELL. FORD KEEPS WORKING ON THE BACK END, THE EXHAUST THERE HAS ALMOST NO SMELL. I TOLD THE DEALER THE SULFUR SMELL COMES FORM EXHAUST THAT IS ESCAPING FROM THE ENGINE UP TO THE BACK OF THE CATALYTIC CONVERTERS. THERE ARE TWO TURBOS ON THIS VEHICLE AND I BELIEVE TWO SEPARATE EXHAUST PATHS. SOMEWHERE UP FRONT THERE IS A LEAK THAT STINKS. THANK YOU *TR
NHTSA ODI #10882788
24,191 miles · Jan 19, 2016
Electrical SystemEngine And Engine CoolingPower Train
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 35 MPH, AN EXHAUST ODOR EMITTED INTO THE VEHICLE THROUGH THE FRONT AND REAR AIR VENTS DURING ACCELERATION. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE MUFFLER WAS REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. IN ADDITION, THE INSTRUMENT PANEL FAILED …
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 35 MPH, AN EXHAUST ODOR EMITTED INTO THE VEHICLE THROUGH THE FRONT AND REAR AIR VENTS DURING ACCELERATION. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE MUFFLER WAS REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. IN ADDITION, THE INSTRUMENT PANEL FAILED TO ILLUMINATE WHILE DRIVING 20 MPH. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD AND THE GEAR SHIFTER SEIZED. THE CONTACT RESTARTED THE VEHICLE AND DROVE HOME. ONCE THE CONTACT ARRIVED AT HOME, THE VEHICLE LOST POWER, THE ALARM AND HORN SOUNDED, AND THE TAILGATE OPENED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE GEAR SHIFTER WAS REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 24,191. UPDATED 05/03/16*LJ
NHTSA ODI #10820978
1,200 miles · Apr 26, 2015
Engine And Engine Cooling
THE EXHAUST SEEMS TO BE ENTERING THE CABIN THROUGH THE AC VENTS. WE TOOK THIS BACK TO FORD AS WE BOUGHT IT NEW AND THEY STATED AT FIRST IT WAS JUST STICKERS BURNING OFF. THEN I TOOK IT BACK AGAIN AND MADE A MANAGER TO RIDE WITH ME. HE STATED IT WAS NOT NORMAL AND WE LEFT IT THERE. THEY STATED THEY REPLACED SOME PARTS A REROUT…
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THE EXHAUST SEEMS TO BE ENTERING THE CABIN THROUGH THE AC VENTS. WE TOOK THIS BACK TO FORD AS WE BOUGHT IT NEW AND THEY STATED AT FIRST IT WAS JUST STICKERS BURNING OFF. THEN I TOOK IT BACK AGAIN AND MADE A MANAGER TO RIDE WITH ME. HE STATED IT WAS NOT NORMAL AND WE LEFT IT THERE. THEY STATED THEY REPLACED SOME PARTS A REROUTED SOMETHING. SEEMED TO BE VERY CONFUSED ON WHAT THEY DID. THE SMELL NEVER REALLY WENT AWAY AND NOT THAT IT HAS 20,000 MILES SEEMS TO BE GETTING WORST. MY WIFE IS PREGNANT NOW AND ITS HER DAILY DRIVER. I WOULD JUST TAKE IT BACK AND TRADE IT IN BUT I WILL LOSE SO MUCH IN TRADE!! I JUST THINK THIS IS VERY DANGEROUS AND I AM WORRIED FOR MY WIFE AND FUTURE BABY. *TR
NHTSA ODI #10712975
200 miles · Jan 8, 2015
Engine And Engine CoolingStructure
UPON ACCELERATION EXHAUST ENTERS THE VEHICLE CABIN. SOMETIMES EXHAUST ENTERS THE VEHICLE CABIN WITHOUT ACCELERATION. I THOUGHT I HAD REPORTED THIS BEFORE. *TR
NHTSA ODI #10671159
300 miles · Dec 31, 2014
Engine And Engine Cooling
UPON HARD ACCELERATION MY 2014 FORD EXPLORER HAS EXHAUST FUMES ENTER INTO THE VEHICLE. I TESTED WITH BOTH THE AC ON RECIRC AND RECIRC OFF AND IT HAPPENS EITHER WAY. I HAVE ALREADY HAD THE VEHICLE IN THE FORD SHOP WITH THIS PROBLEM AND A TSB WAS PERFORMED WITH NO IMPROVEMENTS. *JS
NHTSA ODI #10669298
450 miles · Nov 19, 2014
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 35 MPH, THE CONTACT SMELLED AN ABNORMAL SCENT INSIDE THE VEHICLE FROM THE EXHAUST. THE ENGINE RPMS REACHED 3,500. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER TWICE. DURING THE FIRST REPAIR, THE ENTIRE SEAL ON THE REAR HATCH DOOR AND DRAI…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 35 MPH, THE CONTACT SMELLED AN ABNORMAL SCENT INSIDE THE VEHICLE FROM THE EXHAUST. THE ENGINE RPMS REACHED 3,500. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER TWICE. DURING THE FIRST REPAIR, THE ENTIRE SEAL ON THE REAR HATCH DOOR AND DRAIN WAS REPAIRED. DURING THE SECOND REPAIR, THE VEHICLE WAS NOT DIAGNOSED. THE CONTACT STATED HE NOW SUFFERS FROM HEADACHES CONTRIBUTED FROM FUMES INHALED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 450.
NHTSA ODI #10659295
456 miles · Nov 16, 2014
Engine And Engine Cooling
MY 2014 FORD EXPLORER WAS PURCHASED OFF THE SHOW ROOM FLOOR WITH NO TEST DRIVE. MY NORMAL DAILY DRIVE CONSIST OF 2 LANE SIDE ROADS. ON THE WEEKEND MY FAMILY AND I WILL TAKE THE INTERSTATE ROUTES. IN EARLY MARCH AS WE BEGAN OUR TRIP AND I ACCELERATED ONTO THE INTERSTATE THERE WAS A VERY HEAVY EXHAUST ODOR. THE ODOR WAS THICK ENOU…
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MY 2014 FORD EXPLORER WAS PURCHASED OFF THE SHOW ROOM FLOOR WITH NO TEST DRIVE. MY NORMAL DAILY DRIVE CONSIST OF 2 LANE SIDE ROADS. ON THE WEEKEND MY FAMILY AND I WILL TAKE THE INTERSTATE ROUTES. IN EARLY MARCH AS WE BEGAN OUR TRIP AND I ACCELERATED ONTO THE INTERSTATE THERE WAS A VERY HEAVY EXHAUST ODOR. THE ODOR WAS THICK ENOUGH THAT WE HAD TO LOWER EACH OF OUR WINDOWS. WE THOUGHT IT WAS STRANGE BUT PERHAPS JUST A ONE TIME OCCURRENCE BUT THAT WASN'T THE CASE. THE PROBLEM IS OCCURRING DURING HEAVY ACCELERATION ONLY, WITH NO AIR, WITH THE AIR CONDITIONING OR WITH THE HEAT ON. I HAVE TAKEN MY VEHICLE TO FORD 3 TIMES SINCE AUGUST 2014 FOR A TOTAL OF 26 DAYS IN THE SHOP IN HOPES OF GETTING THIS REPAIRED WITH NO LUCK. I DID HAVE A CASE OPEN WITH FORD CASE# [XXX] AND WAS TOLD LAST WEEK (11/13/14) BY CUSTOMER SERVICE PERSON "[XXX]" THAT MY CASE HAD BEEN CLOSED, REASON; "THE ODOR I AM EXPERIENCING IS NORMAL" I WAS NOT NOTIFIED BY FORD THAT THE CASE WAS BEING CLOSED NOR WAS THE DEALER WHERE I PURCHASED THE VEHICLE. I PLACED A CARBON MONOXIDE DETECTOR IN MY VEHICLE AND AFTER 3 TO 4 DAYS ON 11/01/14 RECEIVED A WARNING TO MOVE TO CLEAN AIR! MY VEHICLE IS UNDER FULL WARRANTY HOWEVER THAT IS USELESS AT THIS POINT. ON 11/15/14 I HAD TO TAKE A 6 HOUR ROUND TRIP WITH MY MOTHER, STEP FATHER AND MOTHER-IN-LAW WE HAD TO LOWER WITH WINDOW NO LESS THAN 8 TIMES DURING THE TRAVEL AND MY MOTHER HAD A VERY SICK HEADACHE AFTER THE TRIP. THIS PROBLEM IS REAL AND I HOPE YOU WILL GIVE IT THE TIME AND ATTENTION NEEDED TO MAKE SURE OTHER PEOPLE LIKE MYSELF AREN'T JUST BRUSHED OFF BY FORD. FORD HAS MY MONEY PAID IN FULL FOR A VEHICLE I AM FORCED TO DRIVE DAILY BECAUSE I HAVE NO OTHER TRANSPORTATION. AND YOU ASK DO I ALSO HAVE HEADACHES YES AND THEY ARE VERY REAL. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10655265
Mileage unknown · Nov 10, 2014
Engine And Engine Cooling
I HAVE EXPERIENCED A BURNING SMELL ENTERING THE CABIN AREA WHEN ACCELERATING TO PASS A VEHICLE AND WHEN CLIMBING A HILL. ALSO HAVE HAD A "SOUR" SMELL LIKE SOURED CLOTHING FROM AC WHEN I START MY VEHICLE. I DID ASK A SERVICE MANAGER ABOUT THE "SOUR" SMELL AND HE SAID HE NEVER HEARD OF IT, NOT A BIG HELP. *TR
NHTSA ODI #10653896
200 miles · Oct 16, 2014
Engine And Engine CoolingFuel/propulsion System
DURING HARD ACCELERATION, A "SMELL" ENTERS THE INTERIOR OF THE CAR. THE "SMELL" IS OF SULFUR OR ROTTEN EGGS. THE SMELL IS DEFINITELY COMING FROM THE EXHAUST. FORD ACKNOWLEDGED THE PROBLEM AND PERFORMED A TSB TO FIX. THE TSB DID NOT FIX THE PROBLEM, AND THE DEALERSHIP SAYS THEY HAVE TO WAIT FOR AN ENGINEER. SERVICE MANAGER S…
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DURING HARD ACCELERATION, A "SMELL" ENTERS THE INTERIOR OF THE CAR. THE "SMELL" IS OF SULFUR OR ROTTEN EGGS. THE SMELL IS DEFINITELY COMING FROM THE EXHAUST. FORD ACKNOWLEDGED THE PROBLEM AND PERFORMED A TSB TO FIX. THE TSB DID NOT FIX THE PROBLEM, AND THE DEALERSHIP SAYS THEY HAVE TO WAIT FOR AN ENGINEER. SERVICE MANAGER SAYS THERE IS ONLY 1 FORD ENGINEER FOR ALL OF SOUTH TEXAS. *TR
NHTSA ODI #10648221
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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