NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
1,675 reports13,000 miles · Aug 10, 2016
SuspensionUnknown Or Other
NHTSA RECALL NUMBER: 16V245, RECALL DATE: APR 25, 2016, FORD RECALL NUMBER: 16S18. RISK TO SAFETY: AN IMPROPERLY WELDED TOE LINK THAT FRACTURES WHILE DRIVING COULD RESULT IN A LOSS OF STEERING CONTROL, INCREASING THE RISK OF A CRASH. MANUFACTURER HAS EXCEEDED REASONABLE AMOUNT OF TIME TO REPAIR VEHICLE, ACCORDING TO RECALL NOTIF…
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NHTSA RECALL NUMBER: 16V245, RECALL DATE: APR 25, 2016, FORD RECALL NUMBER: 16S18. RISK TO SAFETY: AN IMPROPERLY WELDED TOE LINK THAT FRACTURES WHILE DRIVING COULD RESULT IN A LOSS OF STEERING CONTROL, INCREASING THE RISK OF A CRASH. MANUFACTURER HAS EXCEEDED REASONABLE AMOUNT OF TIME TO REPAIR VEHICLE, ACCORDING TO RECALL NOTIFICATION THIS VEHICLE IS NOT SAFE TO DRIVE DO TO INCREASE RISK OF CRASH. ALSO HAVE COMPLAINED TO FORD FOR OVER A YEAR TO HAVE VEHICLE REPAIRED FOR EXHAUST FUMES ENTERING CABIN UPON HARD ACCELERATION. RECEIVED NUMEROUS EMAILS BACK FROM MANUFACTURER THAT THEY HAVE NO REPAIRS AVAILABLE AND IS UNWILLING EVEN TO ATTEMPT TO REPAIR. VEHICLE REMAINS PARKED IN GARAGE NOT WILLING TO DRIVE.
NHTSA ODI #10894886
44,300 miles · Aug 9, 2016
Equipment
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 60 MPH WITH THE AIR CONDITIONER ACTIVATED, THERE WAS AN ABNORMAL EGG ODOR COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE HVAC UNIT WAS FAILING AND NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 60 MPH WITH THE AIR CONDITIONER ACTIVATED, THERE WAS AN ABNORMAL EGG ODOR COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE HVAC UNIT WAS FAILING AND NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS APPROXIMATELY 44,300.
NHTSA ODI #10894376
Mileage unknown · Aug 8, 2016
Suspension
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS AWARE OF THE ISSUE. THE CONTACT…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE. UPDATED 10/19/16*LJ UPDATED 11/03/16.*JB
NHTSA ODI #10894044
Mileage unknown · Aug 8, 2016
Structure
2014 FORD EXPLORER. ATTORNEY REPRESENTING CONSUMER WRITES IN REGARDS TO RUST ALONG FRONT EDGE OF VEHICLE HOOD. DEALERSHIP REFUSES TO REPLACE HOOD OR INCLUDE REQUESTS UNDER EXTENDED WARRANTY PROTECTION. *SMD IT WAS FINALLY DETERMINED, IT WAS NOT RUST AS THE CONSUMER BELIEVED. THE CONSUMER RETURNED TO THE DEALER, WHERE THEY RE…
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2014 FORD EXPLORER. ATTORNEY REPRESENTING CONSUMER WRITES IN REGARDS TO RUST ALONG FRONT EDGE OF VEHICLE HOOD. DEALERSHIP REFUSES TO REPLACE HOOD OR INCLUDE REQUESTS UNDER EXTENDED WARRANTY PROTECTION. *SMD IT WAS FINALLY DETERMINED, IT WAS NOT RUST AS THE CONSUMER BELIEVED. THE CONSUMER RETURNED TO THE DEALER, WHERE THEY REPAIRED AND REPAINTED THE HOOD. THE CONSUMER REQUESTED A REPLACEMENT HOOD, BUT THE FORD REPRESENTATIVE STATED IT WOULD NOT HELP AS THE NEW HOOD WOULD HAVE THE SAME PROBLEM. IN OTHER WORDS, THE SAME REPAIR WOULD LIKELY OCCUR AGAIN, IN THE NEXT 30 MONTHS. *JB
NHTSA ODI #10891437
31,000 miles · Aug 7, 2016
Electrical System
DRIVERS DOOR AJAR LIGHT STAYS ON. TOOK TO FORD DEALER, WAS TOLD THAT FMCO REQUIRES THEY CLEAN CONTACTS FIRST, BEFORE REPLACING. THIS WAS DONE AND SOLVED THE PROBLEM FOR A WHILE. I TOOK BACK TO DEALER WHEN PROBLEM STARTED AGAIN. NOW THEY SAY THE DOOR LATCH IS BROKEN AND WANT $366.00 TO FIX IT, AND THEY HAVE TO ORDER THE PART. …
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DRIVERS DOOR AJAR LIGHT STAYS ON. TOOK TO FORD DEALER, WAS TOLD THAT FMCO REQUIRES THEY CLEAN CONTACTS FIRST, BEFORE REPLACING. THIS WAS DONE AND SOLVED THE PROBLEM FOR A WHILE. I TOOK BACK TO DEALER WHEN PROBLEM STARTED AGAIN. NOW THEY SAY THE DOOR LATCH IS BROKEN AND WANT $366.00 TO FIX IT, AND THEY HAVE TO ORDER THE PART. THIS IS AN ONGOING PROBLEM WITH FORD PRODUCTS AND THEY HAVE IN FACT RECALLED SEVERAL MODELS. I WAS GIVEN THE IMPRESSION TO START WITH THAT IF THE CONTACT CLEANING PROCEDURE DIDN'T WORK THEN IT WOULD BE REPLACED. NOW THEY WANT TO CHARGE FOR THIS.
NHTSA ODI #10893834
40,000 miles · Aug 5, 2016
Steering
DURING MY VACATION IN JULY 2016, WHILE DRIVING ON ROUTE 95 INTERSTATE, I NOTICED THAT THE STEERING WAS GETTING HARD TO CONTROL. I CONTINUED DRIVING AND RECEIVED A ALARM ON THE DASH STATING THAT THE TRACTION CONTROL IS NOW OFF, SERVICE NEEDED. I PROCEEDED TO THE FIRST GAS STATION AND UPON RE-STARTING THE VEHICLE, ANOTHER ALARM ON…
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DURING MY VACATION IN JULY 2016, WHILE DRIVING ON ROUTE 95 INTERSTATE, I NOTICED THAT THE STEERING WAS GETTING HARD TO CONTROL. I CONTINUED DRIVING AND RECEIVED A ALARM ON THE DASH STATING THAT THE TRACTION CONTROL IS NOW OFF, SERVICE NEEDED. I PROCEEDED TO THE FIRST GAS STATION AND UPON RE-STARTING THE VEHICLE, ANOTHER ALARM ON THE DASH SAID POWER STEERING NOT WORKING. I HAD NO POWER STEERING. I HAD TO BE TOWED TO A FORD DEALER WHERE THEY DETERMINED IT WAS A BAD GEAR IN THE STEERING GEARBOX AND THE ENTIRE UNIT WOULD NEED REPLACED. VEHICLE ONLY HAS 40,000 MILES.
NHTSA ODI #10893620
Mileage unknown · Aug 5, 2016
Suspension
TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED A MANUFACTURER'S RECALL PERTAINING TO NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE DEALER WAS UNABLE TO SUPPLY THE PARTS WITHIN A REASONABLE TIME FRAME. THE MANUFACTURER WAS UNABLE TO DETERMINE WHEN THE PARTS WOULD BE SUPPLIED TO THE DEALER. THE CONTACT HAD NO…
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TL* THE CONTACT OWNS A 2014 FORD EXPLORER. THE CONTACT RECEIVED A MANUFACTURER'S RECALL PERTAINING TO NHTSA CAMPAIGN NUMBER: 16V245000 (SUSPENSION). THE DEALER WAS UNABLE TO SUPPLY THE PARTS WITHIN A REASONABLE TIME FRAME. THE MANUFACTURER WAS UNABLE TO DETERMINE WHEN THE PARTS WOULD BE SUPPLIED TO THE DEALER. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.
NHTSA ODI #10893401
37,600 miles · Jul 30, 2016
Unknown Or Other
ON 22 JULY I WENT TO SNOWSHOE, WV, AND ON 24 JULY I RETURNED FROM SNOWSHOE. I SMELLED SULFURISH EXHAUST 4 TIMES THIS TRIP. IT OCCURRED ON UPHILL GRADES WHERE THE VEHICLE HAD DOWNSHIFTED. 3 NEW PLACES, ALL AT 55 MPH OR GREATER, UPHILL AND INVOLVING A DOWNSHIFT, IE HIGHER EXHAUST VOLUME AND PRESSURE. INDICATING TO ME THE PROBL…
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ON 22 JULY I WENT TO SNOWSHOE, WV, AND ON 24 JULY I RETURNED FROM SNOWSHOE. I SMELLED SULFURISH EXHAUST 4 TIMES THIS TRIP. IT OCCURRED ON UPHILL GRADES WHERE THE VEHICLE HAD DOWNSHIFTED. 3 NEW PLACES, ALL AT 55 MPH OR GREATER, UPHILL AND INVOLVING A DOWNSHIFT, IE HIGHER EXHAUST VOLUME AND PRESSURE. INDICATING TO ME THE PROBLEM IS GETTING WORSE. LIKE AN EXHAUST SEAL BREAKING DOWN. WHEN I GOT HOME, I WENT TO GET SOMETHING FROM THE FRONT PASSENGER SEAT. WHEN I WENT TO OPEN THE DOOR THE ODOR WAS THE STRONGEST I HAS SMELLED IT. REINFORCING MY BELIEF IT IS EXHAUST ESCAPING BEFORE THE CATALYTIC CONVERTER. ALSO MEANING I AM PROBABLY GETTING A HEALTHY DOSE OF CARBON MONOXIDE ALL THE TIME FROM THIS EXHAUST LEAK. PLEASE DO A RECALL!!!!!
NHTSA ODI #10891778
Mileage unknown · Jul 28, 2016
EngineFuel/propulsion SystemUnknown Or Other
WE HAVE A 2014 FORD EXPLORER THAT HAS A SMELL INSIDE WHILE ACCELERATING. WE HAVE TAKEN IT TO THE DEALER TO HAVE THE PROBLEM CORRECTED. OUR CONCERN IS THAT EXHAUST HAS BEEN COMING INTO THE VEHICLE. WE AREN'T SURE IF THE CURRENT SOLUTIONS IN PLACE TO FIX THE VEHICLE ARE ENOUGH. WELL KNOWING AND OUR FAMILY IS GETTING SICK FROM THIS…
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WE HAVE A 2014 FORD EXPLORER THAT HAS A SMELL INSIDE WHILE ACCELERATING. WE HAVE TAKEN IT TO THE DEALER TO HAVE THE PROBLEM CORRECTED. OUR CONCERN IS THAT EXHAUST HAS BEEN COMING INTO THE VEHICLE. WE AREN'T SURE IF THE CURRENT SOLUTIONS IN PLACE TO FIX THE VEHICLE ARE ENOUGH. WELL KNOWING AND OUR FAMILY IS GETTING SICK FROM THIS CURRENT ISSUE WE JUST AREN'T SURE WHAT WE'RE BREATHING INSIDE THE VEHICLE IS SAFE. THE SMELL COMES WHEN YOU ACCELERATE HARD EITHER TOWING OR MERGING ONTO THE HIGHWAY OR EVEN FROM A RED LIGHT. THE SMELL IS A SULFUR SMELL OR ROTTEN EGG SMELL THAT SEEMS TO DISSIPATE QUICKLY BUT IS NOTICEABLE.
NHTSA ODI #10889250
46,000 miles · Jul 27, 2016
Exterior Lighting
MY NAME IS [XXX] AND I LIVE IN LORAIN OHIO. I AM THE OWNER OF A 2014 FORD EXPLORER (LIMITED). RECENTLY, MY DRIVER SIDE BRAKE LIGHT FAILED AND AFTER MUCH RESEARCH ON MY PART I CAME TO THE REALIZATION THAT THE BRAKE LIGHTS ARE LED. I WENT TO MY DEALER AND WAS TOLD IT WAS NOT COVERED, EVEN THOUGH I PURCHASED THE PREMIUM MAINTENANC…
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MY NAME IS [XXX] AND I LIVE IN LORAIN OHIO. I AM THE OWNER OF A 2014 FORD EXPLORER (LIMITED). RECENTLY, MY DRIVER SIDE BRAKE LIGHT FAILED AND AFTER MUCH RESEARCH ON MY PART I CAME TO THE REALIZATION THAT THE BRAKE LIGHTS ARE LED. I WENT TO MY DEALER AND WAS TOLD IT WAS NOT COVERED, EVEN THOUGH I PURCHASED THE PREMIUM MAINTENANCE PACKAGE FOR MY VEHICLE. I LOOKED IN THE VEHICLE MANUAL AND IT STATED THE BRAKE LIGHTS ARE LED AND EXPECTED TO LAST FOR THE LIFETIME OF THE VEHICLE. MY EXPLORER IS JUST OVER 2 YEARS OLD AND HAS 45K MILES. I EXPLAINED TO THE DEALER THAT I DIDN'T FEEL AS THOUGH I SHOULD BE RESPONSIBLE SINCE THIS IS EXPECTED TO LAST AND FAILED SO EARLY. I ALSO NOTED AS DID THE DEALER THAT THERE IS MOISTURE AND SOMETHING BLACK IN THE LIGHT INSIDE. THIS PROBABLY ATTRIBUTED TO THE LIGHT FAILING. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10889037
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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