NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
335 reportsClear category filter68,000 miles · Sep 19, 2017
Fuel/propulsion SystemUnknown Or Other
PURCHASED 2 YR OLD EXPLORER-CERTIFIED-AND IMMEDIATELY STARTED HAVING HEADACHES, GETTING SLEEPY DURING HOUR COMMUTE TO AND FROM WORK. WHEN CAR ACCELERATES ON HIGHWAY THE SMELL OF FUMES ENTERS THE CABIN. AFTER ONLINE RESEARCH WE REALIZED THAT FORD ACKNOWLEDGED A FACTORY DEFECT IN THE EXHAUST SYSTEM OF THEIR EXPLORERS THAT LEAKS …
Read full complaint
PURCHASED 2 YR OLD EXPLORER-CERTIFIED-AND IMMEDIATELY STARTED HAVING HEADACHES, GETTING SLEEPY DURING HOUR COMMUTE TO AND FROM WORK. WHEN CAR ACCELERATES ON HIGHWAY THE SMELL OF FUMES ENTERS THE CABIN. AFTER ONLINE RESEARCH WE REALIZED THAT FORD ACKNOWLEDGED A FACTORY DEFECT IN THE EXHAUST SYSTEM OF THEIR EXPLORERS THAT LEAKS EXHAUST FUMES AND CARBON MONOXIDE (CAN BE LETHAL) INTO THE CABIN. THEY ALSO HAVE A BULLETIN THAT STATES "CARBON MONOXIDE AND OTHER EXHAUST FUMES ENTERING THE CABIN ARE NEITHER HARMFUL NOR DEADLY". REALLY?! I GUESS WE'RE ALL WASTING OUR MONEY ON CO MONITORS FOR OUR HOMES. AND THE SEVERAL COPS DRIVING EXPLORERS, PASSING OUT AND CRASHING FROM THE CO-SOME OF WHOM WERE NEARLY KILLED-WERE IN NO DANGER EITHER. WONDER WHY AUSTIN, TEXAS AND A FEW OTHER CITIES HAVE PULLED THEIR ENTIRE FLEET OF EXPLORERS. I HAD TO FIGHT THE LOCAL DEALERSHIP TO GET THEM TO PAY FOR "REPAIRS"---TWO DIFFERENT OCCASIONS. THE FIRST WAS A PATCH JOB WHICH I FULLY EXPECTED, AS WELL AS A RETURN TRIP TO REPAIR A MONTH LATER. NOT CONVENIENT AS IT'S AN HOUR AWAY IN LA TRAFFIC. FIRST "REPAIR" TOOK OVER 3 WEEKS AND THEY CONTINUALLY WANTED ME TO RETURN THE RENTAL CAR AS IT WAS COSTING THEM---I TOLD THEM I WOULD BE GLAD TO RETURN IT AS SOON AS THE CAR WAS FIXED. THEY TRIED THEIR BEST TO GET ME TO PAY FOR EACH REPAIR, WHICH I REFUSED AS I PURCHASED A CERTIFIED-SUPPOSEDLY SAFE-VEHICLE WHICH FORD ACKNOWLEDGED HAD A KNOWN FACTORY DEFECT. SAME STORY WITH 2ND REPAIR WHICH TOOK 10 DAYS WHERE THEY SUPPOSEDLY REPLACED THE ENTIRE EXHAUST SYSTEM. I HAVE MY DOUBTS THOUGH AS WE HAVE THE SAME MUFFLER AND EXHAUST PIPE WHICH I WOULD ASSUME WAS PART OF THE EXHAUST SYSTEM. SO FAR WE DON'T SMELL ANY FUMES IN THE CABIN---WHAT'S SCARY THOUGH IS THAT CO HAS NO ODOR SO WE'RE GETTING A CO MONITOR FOR THE CABIN.
NHTSA ODI #11024518
49,000 miles · Sep 16, 2017
Unknown Or Other
HAS A STRONG EXHAUST SMELL DURING ACCELERATION. I JUST PURCHASED THIS VEHICLE USED FROM A FORD DEALER. IT IS A WEEKEND AS I WRITE THIS AND I WILL NOTIFY THE DEALER AS WELL.
NHTSA ODI #11023774
100,000 miles · Sep 16, 2017
Unknown Or Other
WHILE STOPPED WITH AIR CONDITIONING ON THE CABIN OF THE VEHICLE FILLS WITH EXHAUST FUMES. THIS MAKES MY FAMILY AND ME SICK, FEELING NAUSEOUS WITH HEADACHES. AS A SINGLE MOTHER I USE MY VEHICLE NOT ONLY TO GET MY FAMILY AROUND BUT ALSO AS MY LIVELIHOOD. I AM A LYFT DRIVER AND THIS NEGATIVELY AFFECTS MY RATINGS FROM MY CUSTOMERS …
Read full complaint
WHILE STOPPED WITH AIR CONDITIONING ON THE CABIN OF THE VEHICLE FILLS WITH EXHAUST FUMES. THIS MAKES MY FAMILY AND ME SICK, FEELING NAUSEOUS WITH HEADACHES. AS A SINGLE MOTHER I USE MY VEHICLE NOT ONLY TO GET MY FAMILY AROUND BUT ALSO AS MY LIVELIHOOD. I AM A LYFT DRIVER AND THIS NEGATIVELY AFFECTS MY RATINGS FROM MY CUSTOMERS WHO CAN SMELL THE FUMES.
NHTSA ODI #11023759
Mileage unknown · Sep 10, 2017
Unknown Or Other
I HAVE EXPERIENCE EXHAUST COMING INTO THE CABIN OF BOTH FORD EXPLORERS I'VE OWNED( 2012 AND 2014). THE EXHAUST ENTERS THE CABIN SECTION THROUGH THE AIR CONDITION VENTS. WHEN PASSING ANOTHER VEHICLE AND OR WHEN THE PASSING GEAR IS ENGAGED AND RETURNING TO NORMAL SPEED THE EXHAUST ENTERS THE CABIN. I COMPLAINED TO THE DEALERS…
Read full complaint
I HAVE EXPERIENCE EXHAUST COMING INTO THE CABIN OF BOTH FORD EXPLORERS I'VE OWNED( 2012 AND 2014). THE EXHAUST ENTERS THE CABIN SECTION THROUGH THE AIR CONDITION VENTS. WHEN PASSING ANOTHER VEHICLE AND OR WHEN THE PASSING GEAR IS ENGAGED AND RETURNING TO NORMAL SPEED THE EXHAUST ENTERS THE CABIN. I COMPLAINED TO THE DEALERSHIP BACK ON 2012 AND NOTHING WAS SAID OR DONE. WHEN NORMAL DRIVING OCCURS I DON'T EXPERIENCE THE LEAK. WHEN I EXPERIENCE THE EXHAUST LEAK I LET ALL WINDOWS DOWN TO AIR OUT THE CABIN.
NHTSA ODI #11022554
40,000 miles · Sep 8, 2017
EngineUnknown Or Other
FUMES IN THE CAR AND EVEN AFTER TAKING IT TO THE DEALERSHIP IT STILL HAS NOT FIXXED THE ISSUE THEY HAVE PUT NEW REAR VENTS IN AND ADDED MORE UNDER COATING
NHTSA ODI #11022371
Mileage unknown · Sep 8, 2017
Unknown Or Other
AWFUL ODOR COMING INTO THE CAR - SMELLS LIKE EXHAUST OR SOMETHING ROTTEN. I GET TERRIBLE HEADACHES AND WILL GET SLEEPY WHILE DRIVING. FOUND MYSELF BOBBING MY HEAD ALMOST FALLING ASLEEP. THE HEADACHES WILL LAST AFTER I STOP DRIVING THE CAR. BEEN GOING ON FOR CLOSE TO 2 YEARS. MAINLY HAPPENS ON HIGHWAY DRIVING (WHICH I DRIVE…
Read full complaint
AWFUL ODOR COMING INTO THE CAR - SMELLS LIKE EXHAUST OR SOMETHING ROTTEN. I GET TERRIBLE HEADACHES AND WILL GET SLEEPY WHILE DRIVING. FOUND MYSELF BOBBING MY HEAD ALMOST FALLING ASLEEP. THE HEADACHES WILL LAST AFTER I STOP DRIVING THE CAR. BEEN GOING ON FOR CLOSE TO 2 YEARS. MAINLY HAPPENS ON HIGHWAY DRIVING (WHICH I DRIVE 270 EVERYDAY TO WORK).
NHTSA ODI #11022302
56,000 miles · Sep 7, 2017
Unknown Or Other
CAR FILLS WITH FUMES AND STRONG "SULFUR" ORDER WHEN EXCELLING ON ON UPGRADE CLIMB.
NHTSA ODI #11022109
Mileage unknown · Sep 3, 2017
Unknown Or Other
FAULTY DOOR AJAR ASSEMBLY. DOES NOT RECOGNIZE WHEN THE DOOR IS CLOSED. ALSO LOSES CONNECTION WHILE CAR IS OFF AND THE DOOR IS CLOSED, TRIGGERS THE ALARM TO GO OFF. APPARENTLY THIS IS HAPPENING ON SEVERAL MODELS AND YEARS.
NHTSA ODI #11021246
65,000 miles · Aug 25, 2017
Unknown Or Other
I HAVE OWNED A 2014 FORD EXPLORER FOR A YEAR NOW. WHEN I PURCHASED IT, IT HAD 40,000 MILES ON IT SO, OUT OF THE MANUFACTURERS WARRANTY PERIOD. NOW, EVERY TIME I GET ON THE INTERSTATE OR TRY TO PASS A SLOWER MOVING VEHICLE. THERE IS A STRONG SMELL OF EXHAUST THAT ENTERS THE CABIN OF THE SUV WHICH RESULTS IN ME GETTING A HEADAC…
Read full complaint
I HAVE OWNED A 2014 FORD EXPLORER FOR A YEAR NOW. WHEN I PURCHASED IT, IT HAD 40,000 MILES ON IT SO, OUT OF THE MANUFACTURERS WARRANTY PERIOD. NOW, EVERY TIME I GET ON THE INTERSTATE OR TRY TO PASS A SLOWER MOVING VEHICLE. THERE IS A STRONG SMELL OF EXHAUST THAT ENTERS THE CABIN OF THE SUV WHICH RESULTS IN ME GETTING A HEADACHE AND MY SON COMPLAINING OF HIS NOSE BURNING. I SCHEDULED AND TOOK THE CAR IN THE MULLINAX FORD HERE IN MOBILE, AL WHERE THEY CHARGED ME 99.00 TO RUN TEST ON THE VEHICLE TO SEE IF CARBON MONOXIDE WAS ENTERING THE CABIN AND THE TEST CAME BACK POSITIVE. NOW THEY WANT TO CHARGE ME $553.00, WHICH THEY CALL A DISCOUNT, TO FIX THE PROBLEM. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD THEY CREATED A CASE AND SENT IT TO THE SERVICE MANAGER. THIS WAS ONLY TO GET A DECISION FROM THE MANAGER THAT I STILL HAD TO PAY $553.00. THIS IS A MANUFACTURING DEFECT, AND THEY WANT ME TO PAY FOR IT. THIS VEHICLE IS POISONING MY FAMILY (3 KIDS) AND THEY WON'T FIX THE PROBLEM. I WAS TOLD THAT THEY WERE ONLY REPAIRING POLICE CARS AS OF NOW.
NHTSA ODI #11019512
3,150 miles · Aug 22, 2017
EngineUnknown Or Other
THERE IS A STRONG EXHAUST ODOR COMING INSIDE THE VEHICLE WITH ALL OF ITS WINDOWS UP EVERY TIME AFTER A HEAVY ACCELERATION, REGARDLESS OF WHETHER OR NOT THE A/C VENTILATION IS ON OR NOT. THE STRONG EXHAUST ODOR IS INESCAPABLE AFTERWARD WHILE STILL IN MOTION ON A CITY STREET OR HIGHWAY OR WHILE STOPPING AFTER THE ACCELERATION. TH…
Read full complaint
THERE IS A STRONG EXHAUST ODOR COMING INSIDE THE VEHICLE WITH ALL OF ITS WINDOWS UP EVERY TIME AFTER A HEAVY ACCELERATION, REGARDLESS OF WHETHER OR NOT THE A/C VENTILATION IS ON OR NOT. THE STRONG EXHAUST ODOR IS INESCAPABLE AFTERWARD WHILE STILL IN MOTION ON A CITY STREET OR HIGHWAY OR WHILE STOPPING AFTER THE ACCELERATION. THIS HAS BEEN A CONSISTENTLY REPEATABLE ISSUE WITH MY VEHICLE SINCE PURCHASING IT AS BRAND NEW. MY DEALERSHIP DID NOT FIND A TSB AND OFFERED NO RESOLUTION FOR THE PROBLEM.
NHTSA ODI #11018812
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.
Illustration