NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
62 reportsClear category filter75,000 miles · Jan 24, 2019
Fuel/propulsion System
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 25 MPH, THE VEHICLE STALLED AND THE P1450 WARNING INDICATOR ILLUMINATED. THE CONTACT PULLED THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL SYSTEM FAILED. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE RECURRED. THE CONT…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING 25 MPH, THE VEHICLE STALLED AND THE P1450 WARNING INDICATOR ILLUMINATED. THE CONTACT PULLED THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL SYSTEM FAILED. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE RECURRED. THE CONTACT SCHEDULED A DIAGNOSTIC APPOINTMENT WITH MCREE FORD (2800 GULF FWY, DICKINSON, TX 77539). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE FAILURE MILEAGE WAS 75,000.
NHTSA ODI #11171843
80,000 miles · Sep 13, 2018
Fuel/propulsion SystemUnknown Or Other
WHEN VEHICLE IS STOPPED BUT RUNNING THERE IS A GAS SMELL THAT COMES INTO THE CAR BUT IT DOES NOT HAPPEN ALL THE TIME NOR DOES IT LINGER FOR VERY LONG AFTER CONTINUING TO DRIVE AGAIN.
NHTSA ODI #11129307
Mileage unknown · Aug 15, 2018
Fuel/propulsion SystemStructure
FOR ABOUT 8 MONTHS I HAVE BEEN SUFFERING FROM DIZZINESS SPELLS THAT HAPPEN QUITE OFTEN, NAUSEA , HEADACHES, BLURRED VISION, AND ANXIETY THAT IS BROUGHT ON FROM THESE SYMPTOMS. I HAVE BEEN TO THE DOCTOR COUNTLESS TIMES ATTEMPTING TO FIGURE OUT THE PROBLEM OF THE CAUSE OF MY SICKNESS. BEFORE I FOLLOWED UP ON THE RECALL I WASN'T AW…
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FOR ABOUT 8 MONTHS I HAVE BEEN SUFFERING FROM DIZZINESS SPELLS THAT HAPPEN QUITE OFTEN, NAUSEA , HEADACHES, BLURRED VISION, AND ANXIETY THAT IS BROUGHT ON FROM THESE SYMPTOMS. I HAVE BEEN TO THE DOCTOR COUNTLESS TIMES ATTEMPTING TO FIGURE OUT THE PROBLEM OF THE CAUSE OF MY SICKNESS. BEFORE I FOLLOWED UP ON THE RECALL I WASN'T AWARE THAT MY CAR WAS BEING RECALLED FOR CARBON MONOXIDE CONCERNS. BUT IT ALL MAKES SENSE THE MAJORITY OF TIME I FEEL THESE SYMPTOMS IS EITHER WHEN I'M DRIVING OR HAVE FINISHED DRIVING. (NEXT DR'S VISIT I WILL REQUEST THEY DO LAB WORK FOR POTENTIAL CARBON MONOXIDE POISONING.) OF COURSE ALL THE SYMPTOMS LINGER BECAUSE OBVIOUSLY IT STAYS IN MY SYSTEM. I FEEL LIKE MY CAR IS MAKING ME REALLY SICK. I AM AFRAID TO DRIVE MY CAR THAT I HAVE HAD FOR 2 YEARS.
NHTSA ODI #11120017
25 miles · May 23, 2018
Fuel/propulsion SystemUnknown Or Other
MY HUSBAND, SON AND MYSELF WERE DRIVING FROM HIGH POINT NC TO WINSTON SALEM NC ABOUT 30 MINUTES DRIVE, BEFORE ARRIVE TO OUR DESTINATION WE HAVE TO STOP ALMOS IN THE MIDDLE OF A ROAD BECAUSE WE WERE FEELING SHORT OF AIR ALMOST UNABLE TO BREATH AND FEELING CHEST SUPPRESSION AND NAUSEA OUR SON GIVE COMPLAIN ABOUT THE SMELL IN THE B…
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MY HUSBAND, SON AND MYSELF WERE DRIVING FROM HIGH POINT NC TO WINSTON SALEM NC ABOUT 30 MINUTES DRIVE, BEFORE ARRIVE TO OUR DESTINATION WE HAVE TO STOP ALMOS IN THE MIDDLE OF A ROAD BECAUSE WE WERE FEELING SHORT OF AIR ALMOST UNABLE TO BREATH AND FEELING CHEST SUPPRESSION AND NAUSEA OUR SON GIVE COMPLAIN ABOUT THE SMELL IN THE BACK SEAT BUT I WAS UNABLE TO FEEL IT DUE TO STUFF NOSE. MY HUSBAND HAD TO DRINK TWO BOTTLES OF WATER AND WE GOT OFF THE VEHICLE LIVING ALL DOORS OPEN, THE ODOR WAS VERY STRONG. IN MAY 15 2018 WE TOOK THE VEHICLE TO THE DEALER WHEN WE LEARNED ABOUT THE CARBON MONOXIDE RECALL THEY SAY THEY MADE THE REPAIR AND TODAY MAY 23 WE ALMOST CRASH. I THANKS GOD WE STOPPED AND GOT OFF THE CAR.
NHTSA ODI #11097703
65,000 miles · Mar 26, 2018
Fuel/propulsion SystemUnknown Or Other
THE SMELL OF EXHAUST WAS OVERWHELMING AND FINALLY A "FIX" WAS GENERATED. THE FIX IS WORSE THAN THE ORIGINAL PROBLEM. NOW THERE IS AN EXTREMELY STRONG SMELL OF GASOLINE THAT FLOODS THE CABIN OF THE VEHICLE. THIS OCCURS WHEN IN IDLE, WHEN DRIVING, WHEN OTHER CARS ARE AROUND OR IF I AM THE ONLY CAR IN THE LOT. OFTEN I NOTICE WHEN T…
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THE SMELL OF EXHAUST WAS OVERWHELMING AND FINALLY A "FIX" WAS GENERATED. THE FIX IS WORSE THAN THE ORIGINAL PROBLEM. NOW THERE IS AN EXTREMELY STRONG SMELL OF GASOLINE THAT FLOODS THE CABIN OF THE VEHICLE. THIS OCCURS WHEN IN IDLE, WHEN DRIVING, WHEN OTHER CARS ARE AROUND OR IF I AM THE ONLY CAR IN THE LOT. OFTEN I NOTICE WHEN THE HEATING SYSTEM IS ON.
NHTSA ODI #11081417
Mileage unknown · Jan 25, 2018
Fuel/propulsion System
THE CAB FILLS UP WITH A STRONG EXHAUST ODOR PERIODICALLY, PROBABLY 40 PERCENT OF THE TIME. IT HAPPENS MOST FREQUENTLY AFTER THE CAR HAS BEEN DRIVEN OVER 35 MPH AND THEN SLOWS DOWN. I HAVE HAD THIS [PROBLEM CHECKED OUT TWICE AT MY A FORD SERVICE PROVIDER, BUT THEY SAY THEY CAN'T SMELL IT AND THEY DENY IT IS PRESENT. THEY DID SOME…
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THE CAB FILLS UP WITH A STRONG EXHAUST ODOR PERIODICALLY, PROBABLY 40 PERCENT OF THE TIME. IT HAPPENS MOST FREQUENTLY AFTER THE CAR HAS BEEN DRIVEN OVER 35 MPH AND THEN SLOWS DOWN. I HAVE HAD THIS [PROBLEM CHECKED OUT TWICE AT MY A FORD SERVICE PROVIDER, BUT THEY SAY THEY CAN'T SMELL IT AND THEY DENY IT IS PRESENT. THEY DID SOME TYPE OF REPAIR THAT DID NOT SOLVE THE PROBLEM. ODOR IS VERY STRONG IN BACK SEAT AREA WHERE SMALL CHILDREN RIDE. ODOR IS ALSO STRONG AT RED LIGHTS AND PULLING INTO THE GARAGE. THIS HAS BEEN A PROBLEM FOR ABOUT A YEAR.
NHTSA ODI #11064922
Mileage unknown · Jan 24, 2018
Fuel/propulsion System
SMELL EXHAUST FUMES INSIDE OF SUV AT DIFFERENT TIMES. SMELL OCCURS WHEN PUSHING ON THE GAS. CAR IS IN MOTION ON ANY TYPE OF STREET OR HIGHWAY. DEALERSHIP RECOMMEND REPLACING THE POWER TRANSFER UNIT($1,800) NO CHANGE. STILL HAVE SMELL
NHTSA ODI #11064584
50,000 miles · Oct 27, 2017
EngineFuel/propulsion SystemStructure
EXHAUST FUMES IN CABIN WHEN ACCELERATING AT HIGHER SPEEDS, ESPECIALLY WHEN ENTERING INTERSTATE AND PASSING CARS AT HIGHER SPEEDS.
NHTSA ODI #11040479
30,200 miles · Oct 6, 2017
Fuel/propulsion SystemVehicle Speed Control
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE ATTEMPTING TO ACCELERATE THE VEHICLE AT HIGHWAY SPEEDS, THE CABIN BEGAN TO FILL WITH A FUEL ODOR. THE CONTACT WOULD HAVE TO LOWER THE WINDOWS IN ORDER FOR THE ODOR TO DISSIPATE. THE CONTACT HAD NOT TAKEN THE VEHICLE TO THE DEALER. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. TH…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE ATTEMPTING TO ACCELERATE THE VEHICLE AT HIGHWAY SPEEDS, THE CABIN BEGAN TO FILL WITH A FUEL ODOR. THE CONTACT WOULD HAVE TO LOWER THE WINDOWS IN ORDER FOR THE ODOR TO DISSIPATE. THE CONTACT HAD NOT TAKEN THE VEHICLE TO THE DEALER. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 30,200.
NHTSA ODI #11032083
20,000 miles · Oct 2, 2017
EngineFuel/propulsion System
FORD EXPLORER EXHAUST-LEAK. MY 2014 FORD EXPLORER FIRST EXHIBITED A STRONG EXHAUST LEAK SMELLS IN THE CABIN ABOUT 18 MONTHS AGO WITH APPROXIMATELY 18-20,000 MILES. THE SMELL WAS MOST NOTICEABLE AFTER COMING TO A STOP WITH THE CAR AT FULL OPERATING TEMPERATURE. AROUND TOWN IT NEVER SEEMS TO BE PRESENT. I TOOK IT TO LOVELAND FOR…
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FORD EXPLORER EXHAUST-LEAK. MY 2014 FORD EXPLORER FIRST EXHIBITED A STRONG EXHAUST LEAK SMELLS IN THE CABIN ABOUT 18 MONTHS AGO WITH APPROXIMATELY 18-20,000 MILES. THE SMELL WAS MOST NOTICEABLE AFTER COMING TO A STOP WITH THE CAR AT FULL OPERATING TEMPERATURE. AROUND TOWN IT NEVER SEEMS TO BE PRESENT. I TOOK IT TO LOVELAND FORD AND THEY INSTALLED A "KIT" WHICH SEEMED TO STOP THE PROBLEM, HOWEVER IT HAS RECENTLY COME BACK STRONGER THAN EVER. YESTERDAY, I DROVE FROM DENVER UP INTO THE ROCKIES AND THE PROBLEM WAS PARTICULARLY BAD ON THE RETURN TRIP IN STOP AND GO TRAFFIC TO THE POINT I WAS FEELING SICK BY THE TIME I GOT HOME. I HAVE HAD THIS BEFORE BUT THE CIRCUMSTANCES MADE THIS PARTICULARLY UNPLEASANT. SO THE CIRCUMSTANCE WHEN IT MOST OFTEN EXHIBITS THE STRONG "ROTTEN EGG" SMELL MIXED WITH EXHAUST IS WHEN THE VEHICLE IS AT FULL TEMPERATURE AND COMES TO A STOP.
NHTSA ODI #11030807
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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