NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
335 reportsClear category filter25 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
Mileage unknown · May 14, 2018
Unknown Or Other
I PURCHASED AN USED 2014 EXPLORER AND BEEN HAVING ISSUES WITH A GAS ODOR. I WAS NEVER INFORMED ABOUT THIS PROBLEM WHEN I PURCHASED THE VEHICLE. UPON RECEIVING A RECALL I THEN BECAME AWARE OF THE PROBLEM. I BROUGHT IT IN AND THEY SUPPOSEDLY CORRECTED IT. NOW IT IS WORST. I WILL BRING IN AGAIN TO FIX THE SMELL. MY 11 YEAR OL…
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I PURCHASED AN USED 2014 EXPLORER AND BEEN HAVING ISSUES WITH A GAS ODOR. I WAS NEVER INFORMED ABOUT THIS PROBLEM WHEN I PURCHASED THE VEHICLE. UPON RECEIVING A RECALL I THEN BECAME AWARE OF THE PROBLEM. I BROUGHT IT IN AND THEY SUPPOSEDLY CORRECTED IT. NOW IT IS WORST. I WILL BRING IN AGAIN TO FIX THE SMELL. MY 11 YEAR OLD DAUGHTER SUFFERS FROM MIGRAINES AND WAS PLACED ON ADULT MIGRAINE PREVENTATIVE. MY FIANCE HAS BREATHING ISSUES AND NOW USES INHALERS. I BELIEVE THE EXHAUST FUMES IS THE CAUSE OF THE MEDICAL ISSUES.
NHTSA ODI #11093616
57,000 miles · Apr 15, 2018
Unknown Or Other
12 APRIL 2018 ACCELERATING UP HILL AC ON. 80 DEGREES OUTSIDE . NO OTHER PASSENGERS IN THE VEHICLE. VEHICLE WAS SHIFTING AROUND 5000 ROM, IN AUTOMATIC, NOT MANUAL. AGAIN I SMELLED A SULFURRY PROPANISH IDOR. IT LASTED ABOUT 2 MINUTES. I HAVE HAD ALL RECALLS / SERVICE BULLETINS PERFORMED BY MY DEALER. I HAVE INFORMED MY DE…
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12 APRIL 2018 ACCELERATING UP HILL AC ON. 80 DEGREES OUTSIDE . NO OTHER PASSENGERS IN THE VEHICLE. VEHICLE WAS SHIFTING AROUND 5000 ROM, IN AUTOMATIC, NOT MANUAL. AGAIN I SMELLED A SULFURRY PROPANISH IDOR. IT LASTED ABOUT 2 MINUTES. I HAVE HAD ALL RECALLS / SERVICE BULLETINS PERFORMED BY MY DEALER. I HAVE INFORMED MY DEALER. HELP BEFORE FORD KILLS ME! THERE IS EXHAUST GETTING INTO THE PASSENGER CABIN!!!
NHTSA ODI #11085146
35,000 miles · Apr 12, 2018
Electrical SystemPower TrainUnknown Or Other
"DRIVER SIDE DOOR AJAR" LIGHT CONTINUES TO COME ON EACH TIME I START THE CAR. I HAVE TO OPEN AND SHUT THE DOOR TO GET IT TO TURN OFF. THAT OCCURRED FOR ONE MONTH. NOW THE LIGHT WILL NOT TURN OFF AND THE "TRANSMISSION IS NOT IN PARK" LIGHT TURNS ON WHILE I AM DRIVING. IN ADDITION, THE DOME LIGHTS WILL NOT GO OFF WHEN I PARK THE C…
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"DRIVER SIDE DOOR AJAR" LIGHT CONTINUES TO COME ON EACH TIME I START THE CAR. I HAVE TO OPEN AND SHUT THE DOOR TO GET IT TO TURN OFF. THAT OCCURRED FOR ONE MONTH. NOW THE LIGHT WILL NOT TURN OFF AND THE "TRANSMISSION IS NOT IN PARK" LIGHT TURNS ON WHILE I AM DRIVING. IN ADDITION, THE DOME LIGHTS WILL NOT GO OFF WHEN I PARK THE CAR UNLESS I CONSTANTLY ADJUST THE LIGHT DIAL AND EVENTUALLY THE DOME LIGHT WILL GO OFF WHEN THE DOORS ARE LOCKED (30 MINUTES TO GET IT OFF THE OTHER NIGHT). REGARDING THE REAR TRANSMISSION NOISE. OVER 50 PERCENT OF THE TIME WHEN I AM BACKING OUT OF A PARKING SPOT, I HEAR A CLUNKING SOUND AS THOUGH I STRUCK AN OBJECT ONLY TO FIND THAT NOTHING IS BEHIND ME. FINALLY, WHEN I ENTER MY CAR AND START IT, I HEAR A LOUD POPPING SOUND IN THE FRONT WINDSHIELD LIKE THE WINDSHIELD GLASS IS CRACKING. NO IDEA WHAT THAT MAY BE.
NHTSA ODI #11084697
195 miles · Mar 29, 2018
Unknown Or Other
AFTER SEVERAL LONG TRIPS WITH THE 2014 FORD EXPLORER SPORT, I HAVE HAD THE FEELING OF BEING ILL. SPECIFICALLY, HEADACHE, VERY WEAK, LIGHTHEADED AND NAUSEOUS. HAS HAPPENED NUMEROUS TIMES SINCE I BOUGHT THE CAR.
NHTSA ODI #11082086
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
48,000 miles · Mar 19, 2018
Unknown Or Other
PURCHASED IN AUG 2017, RECEIVED CUSTOMER SATISFACTION LETTER REGARDING CARBON MONOXIDE. TOOK LAST MONTH TO FORD DEALER FOR FIX AND THE EXHAUST FUMES ARE NOW WORSE. I HAVE TO DETECTORS IN THE CAR THAT BOTH ARE ALARMING AFTER DRIVING ONLY A FEW MINS, MY ENTIRE FAMILY HAS ONSET OF HEADACHE IF WE RIDE IN THE CAR, I HAVE TO ROLL DOWN…
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PURCHASED IN AUG 2017, RECEIVED CUSTOMER SATISFACTION LETTER REGARDING CARBON MONOXIDE. TOOK LAST MONTH TO FORD DEALER FOR FIX AND THE EXHAUST FUMES ARE NOW WORSE. I HAVE TO DETECTORS IN THE CAR THAT BOTH ARE ALARMING AFTER DRIVING ONLY A FEW MINS, MY ENTIRE FAMILY HAS ONSET OF HEADACHE IF WE RIDE IN THE CAR, I HAVE TO ROLL DOWN ALL THE WINDOWS. FORD STATES THEY FIXED THE ISSUE BUT IT'S WORSE NOW TO ME. IT SMELLS LIKE A LAWN MOWER ON SIDE CABIN OF THE EXPLORER
NHTSA ODI #11080305
Mileage unknown · Mar 15, 2018
Unknown Or Other
WHEN PUTTING THE SHIFTER INTO PARK A WARNING LIGHT COMES ON THAT SAYS TRANSMISSION NOT IN PARK. YOU NEED TO WIGGLE THE SHIFTER TO GET THE WARNING LIGHT TO GO AWAY AND ACTUALLY ENGAGE IN PARK. I BROUGHT IT IN TO THE DEALER AND FOUND OUT THE SHIFTER ASSEMBLY IS FAULTY AND NEEDS TO BE REPLACED. THIS IS A $500 REPAIR ON A CAR THAT O…
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WHEN PUTTING THE SHIFTER INTO PARK A WARNING LIGHT COMES ON THAT SAYS TRANSMISSION NOT IN PARK. YOU NEED TO WIGGLE THE SHIFTER TO GET THE WARNING LIGHT TO GO AWAY AND ACTUALLY ENGAGE IN PARK. I BROUGHT IT IN TO THE DEALER AND FOUND OUT THE SHIFTER ASSEMBLY IS FAULTY AND NEEDS TO BE REPLACED. THIS IS A $500 REPAIR ON A CAR THAT ONLY HAS 33000 MILES ON IT. I'M AFRAID IF I DON'T REPLACE IT I WILL BE STRANDED SOMEPLACE BECAUSE I WON'T BE ABLE TO START IT IF IT WON'T CONNECT WITH THE COMPUTER SAYING IT IS IN DRIVE. I FEEL THIS A FAULTY PART FROM FORD . THIS JUST SEEMS LIKE AN EXPENSIVE REPAIR FOR A VEHICLE WITH SUCH FEW MILES ON IT. OF COURSE IT IS OUT OF WARRANTY.
NHTSA ODI #11079594
38,750 miles · Feb 27, 2018
Unknown Or Other
AFTER DRIVING AND VEHICLE IS TO RUNNING TEMPERATURE WHEN YOU STOP OR ARE IDLE SMELL OF EXHAUST TYPE FUMES ENTER CABIN OF CAR. HAVE BEEN TO DEALER TWICE AND NOT SURE PROBLEM IS FIXED. PROBLEM STARTED AT 38,000 MILES. CAN HARDLY BREATH WHEN OCCURS AND HAVE TO OPEN WINDOW. FEEL NEED TO REPORT BECAUSE CONCERNED FOR CO2 SAFETY. ORDER…
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AFTER DRIVING AND VEHICLE IS TO RUNNING TEMPERATURE WHEN YOU STOP OR ARE IDLE SMELL OF EXHAUST TYPE FUMES ENTER CABIN OF CAR. HAVE BEEN TO DEALER TWICE AND NOT SURE PROBLEM IS FIXED. PROBLEM STARTED AT 38,000 MILES. CAN HARDLY BREATH WHEN OCCURS AND HAVE TO OPEN WINDOW. FEEL NEED TO REPORT BECAUSE CONCERNED FOR CO2 SAFETY. ORDERED CO2 SENSOR FOR CAR FOR SAFETY. PLEASE MAKE FORD DO SOMETHING ABOUT THIS.
NHTSA ODI #11075334
15,000 miles · Jan 30, 2018
EngineUnknown Or Other
SMELL EXHAUST IN CABIN UNDER ACCELERATION WITH HVAC SYSTEM ON ESPECIALLY IN RECIRCULATE MODE. VEHICLE HAS BEEN TO DEALERSHIP 5 TIMES WITH THE CURRENT SERVICE BULLETINS PERFORMED AND CAN STILL SMELL EXHAUST IN THE CABIN. THE VEHICLE WAS UNDER WARRANTY WHEN FIRST REPORTED AND THE ISSUE NOT RESOLVED AND FORD SAYS THAT'S ALL THEY …
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SMELL EXHAUST IN CABIN UNDER ACCELERATION WITH HVAC SYSTEM ON ESPECIALLY IN RECIRCULATE MODE. VEHICLE HAS BEEN TO DEALERSHIP 5 TIMES WITH THE CURRENT SERVICE BULLETINS PERFORMED AND CAN STILL SMELL EXHAUST IN THE CABIN. THE VEHICLE WAS UNDER WARRANTY WHEN FIRST REPORTED AND THE ISSUE NOT RESOLVED AND FORD SAYS THAT'S ALL THEY CAN DO.
NHTSA ODI #11065910
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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