NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
86 reportsClear category filter68,700 miles · Jun 12, 2019
EngineFuel/propulsion SystemUnknown Or Other
ON 6/6/19 VEHICLE LOST ENGINE THROTTLE POWER WHEN "WRENCH" LIGHT INDICATOR APPEARED ON DASHBOARD WHILE DRIVING ON INTERSTATE (AT LEAST 65MPH). WRENCH NOTED TERRAIN MANAGEMENT SYSTEM ERROR. ENGINE DID NOT SHUT OFF. VIBRATED VERY BADLY WHEN COMING TO STOP. HAPPENED AGAIN ON 6/12 ON CITY STREET DRIVING APPROX 35MPH. BOTH TIMES …
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ON 6/6/19 VEHICLE LOST ENGINE THROTTLE POWER WHEN "WRENCH" LIGHT INDICATOR APPEARED ON DASHBOARD WHILE DRIVING ON INTERSTATE (AT LEAST 65MPH). WRENCH NOTED TERRAIN MANAGEMENT SYSTEM ERROR. ENGINE DID NOT SHUT OFF. VIBRATED VERY BADLY WHEN COMING TO STOP. HAPPENED AGAIN ON 6/12 ON CITY STREET DRIVING APPROX 35MPH. BOTH TIMES STOPPED VEHICLE, TURNED OFF, AND RESTARTED AND OPERATED NORMALLY. FORD DEALERSHIPS CANNOT DETERMINE PROBLEM BECAUSE THERE COMPUTER SYSTEMS CANNOT SEE ERROR CODE(S) IN DIAGNOSTICS.. ADDITIONALLY, FORD MOTOR COMPANY WILL NOT RESPOND UNTIL "ERROR CODE" IDENTIFIED BY FORD SERVICE DEALERSHIP. READ ONLINE AND YOUTUBE EXACT ISSUES BUT NOT DISCUSSION ON RESOLUTION(S). SEE URL ADDRESS FOR EXAMPLE OF ISSUE THAT OCCURRED WITH OUR VEHICLE: HTTPS://WWW.YOUTUBE.COM/WATCH?V=ASRDPLP4_QE&T=1S. VERY DANGEROUS TO LOSE POWER ON HIGHWAY AND LITTLE CONTROL OF VEHICLE. BELIEVE THIS IS A SYSTEMIC ISSUE WITH FORD EXPLORERS
NHTSA ODI #11219435
45,256 miles · Apr 26, 2019
Fuel/propulsion System
HAVING A FEELING OF NAUSEA WHEN DRIVING EXOLORER. YESTERDAY AND TODAY WE HAVE BEEN RUNNING THE AC DUE TO HOTTER TEMPS. AFTER LETTING CAR IDLE FOR 5-10 MINUTES WHILE USING REMOTE START I START TO FEEL LIGHT HEADED AFTER ABOUT 20 MINUTES OF DRIVING. AFTER FEELING FINE ALL DAY. SEEMS TO BE ONLY WHEN THE CAR USES AC. TODAY I WAS IN …
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HAVING A FEELING OF NAUSEA WHEN DRIVING EXOLORER. YESTERDAY AND TODAY WE HAVE BEEN RUNNING THE AC DUE TO HOTTER TEMPS. AFTER LETTING CAR IDLE FOR 5-10 MINUTES WHILE USING REMOTE START I START TO FEEL LIGHT HEADED AFTER ABOUT 20 MINUTES OF DRIVING. AFTER FEELING FINE ALL DAY. SEEMS TO BE ONLY WHEN THE CAR USES AC. TODAY I WAS IN THE DRIVE THRU FOR MY SON WHILE IDLING WHEN I STARTED TO FEEL LIGHT HEADED. NOTICED THE RECIRCULATION MODE TURNS ITSELF ON AFTER I TURNED IT OFF. THIS ISSUE IS QUITE CONCERNING. WAS SLATED TO HAVE RECALL FIX DONE AT CAPITOL FORD BUT ADVISOR SAID IT WASNT ATTACHED TO THE VIN SO THEY DIDNT DO IT.
NHTSA ODI #11204056
57,600 miles · Apr 16, 2019
Fuel/propulsion System
HAD THE RECALL DONE FOR (FSA 17N03) AFTER THE SERVICE WAS DONE, WE HAVE NOTICED WHEN PASSING ON THE FREEWAY OR GOING UP HILL, HOT AIR BLOWS OUT THE VENTS THEN A HEAVY ODOR OF EXHAUST. MY VEHICLE ALSO USES E85, SO WE HAVE RULED OUT MAYBE A CAR IN FRONT OF US. WHEN USING E85 WE GET A STRONG SMELL OF ALCOHOL TYPE. WE HAVE BEEN TO T…
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HAD THE RECALL DONE FOR (FSA 17N03) AFTER THE SERVICE WAS DONE, WE HAVE NOTICED WHEN PASSING ON THE FREEWAY OR GOING UP HILL, HOT AIR BLOWS OUT THE VENTS THEN A HEAVY ODOR OF EXHAUST. MY VEHICLE ALSO USES E85, SO WE HAVE RULED OUT MAYBE A CAR IN FRONT OF US. WHEN USING E85 WE GET A STRONG SMELL OF ALCOHOL TYPE. WE HAVE BEEN TO THE DEALERSHIP FOR THE SMELL, EACH TIME THEY WANT THE WINDOWS DONE OR HAVE THE A/C ON. I TELL THEM WE DON'T DRIVE WITH IT ON ALL THE TIME OR HAVE THE WINDOWS DOWN ON THE FREEWAY. EVERY 4-6 MONTHS MORE STORIES IN THE NEWS HAVE BEEN COMING UP WITH CONCERNS ABOUT EXHAUST SMELLS IN THE EXPLORER AND NOW FORD IS REDESIGNED THE VEHICLE. THIS SHOULD BE LOOKED AT MORE AND MAYBE WITH THIRD PARTY ENGINEER.
NHTSA ODI #11196823
300 miles · Mar 25, 2019
Fuel/propulsion System
VEHICLE EMITS CARBON MONOXIDE WHEN EXCELERATING. WHEN VEHICLE WAS PURCHASED WE COMPLAINED ABOUT THIS SMELL INSIDE OF THE VEHICLE. THE DEALERSHIP SUPPOSEDLY FIXED THIS ISSUE HOWEVER THE PROBLEM REMAINED. WHEN WE CALLED AGAIN TO VOICE FRUSTRATION, DEALERSHIP SAID THERE WAS NOTHING ELSE THEY COULD DO ABOUT THIS. RECEIVED NOTICE …
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VEHICLE EMITS CARBON MONOXIDE WHEN EXCELERATING. WHEN VEHICLE WAS PURCHASED WE COMPLAINED ABOUT THIS SMELL INSIDE OF THE VEHICLE. THE DEALERSHIP SUPPOSEDLY FIXED THIS ISSUE HOWEVER THE PROBLEM REMAINED. WHEN WE CALLED AGAIN TO VOICE FRUSTRATION, DEALERSHIP SAID THERE WAS NOTHING ELSE THEY COULD DO ABOUT THIS. RECEIVED NOTICE FROM FORD MOTOR CORP JANUARY 2019 INDICATING THEY ARE AWARE THAT SOME OWNERS HAVE CONCERNS ABOUT EXHAUST OR CARBON MONOXIDE AND THAT THESE VEHICLES ARE SAFE HOWEVER FORD IS OFFERING A NO CHARGE SERVICE THAT REDUCES THE POTENTIAL FOR EXHAUST TO ENTER THE VEHICLE. WE HAVE SINCE TAKEN THE VEHICLE IN FOR THIS SERVICE HOWEVER, THE EXHAUST FUMES INSIDE STILL EXIST. MY WIFE DRIVES THIS VEHICLE DAILY TO WORK 25 MILES EACH WAY AND HAS BECOME FREQUENTLY ILL DUE TO THIS VEHICLE. HEADACHES AND NAUSEA AND AN INCREASE OF HER BLOOD PRESSURE. PLEASE ADVISE IF THERE ARE ANY REMEDIES GOING FORWARD AS WE ARE AFRAID TO CONTINUE DRIVING THIS UNSAFE VEHICLE
NHTSA ODI #11191477
59,000 miles · Mar 15, 2019
Fuel/propulsion SystemUnknown Or Other
EXHAUST FUMES IN CAR WHILE DRIVING
NHTSA ODI #11187030
98,300 miles · Oct 23, 2018
Fuel/propulsion SystemUnknown Or Other
WHEN I ACCELERATE MY VEHICLE YOU CAN SMELL TGE EXHAUST FUMES AND I INSTANTLY CAN'T BREATHE, GET A HEADACHE, NAUSEATED, AND AFTER A FEW MINUTES I GET VERY SLEEPY. I HAVE TO ROLL MY WINDOW DOWN AND STICK MY HEAD OUT TO BE ABLE TO BREATHE. IT DOESN'T DO IT EVERY TIME BUT IN A 3 HOUR TRIP, IT HAPPENS AT LEAST 4 TIMES DEPENDING ON …
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WHEN I ACCELERATE MY VEHICLE YOU CAN SMELL TGE EXHAUST FUMES AND I INSTANTLY CAN'T BREATHE, GET A HEADACHE, NAUSEATED, AND AFTER A FEW MINUTES I GET VERY SLEEPY. I HAVE TO ROLL MY WINDOW DOWN AND STICK MY HEAD OUT TO BE ABLE TO BREATHE. IT DOESN'T DO IT EVERY TIME BUT IN A 3 HOUR TRIP, IT HAPPENS AT LEAST 4 TIMES DEPENDING ON HOW MUCH ACCELERATING IS HAPPENING. IF MY AC UNIT IS ON HIGH THEN IT WILL AUTOMATICALLY GO TO BARELY BLOWING AND AS I LET OFF THE ACCLERATOR THEN IT WILL EVENTUALLY CYCLE BACK TO HIGH EVEN THOUGH IT IS ON HIGH. IT IS MAKING ME VERY SICK BECAUSE I'M IN MY CAR SO MUCH. I HAVE TAKEN TO FORD REPEATEDLY, TWO DIFFERENT DEALERSHIPS, AND THEY CAN'T GET IT FIXED. SOMETIMES TO GET THE AC TO GO BACK TO NORMAL, I HAVE TO STOP SOMEWHERE AND TURN THE CAR OFF AND BACK ON. THIS HAS BEEN HAPPENING TO ME SINCE A FEW MONTHS AFTER I BOUGHT THE CAR IN FEB 2017. MY DOCTOR SAYS THE ONLY WAY TO CORRECT PROBLEM IS TO GET RID OF THE CAR BUT I DON'T THINK IT NEEDS TO BE ON THE ROAD AT ALL. IT'LL JUST MAKE SOMEONE ELSE SICK TOO.I STARTED NOTICING THE SMELL IN LATE APRIL 2017 AND IT JUST GOT STRONGER AND I STARTED TAKING IN TO FORD WHEN IT STARTED GETTING REALLY BAD. THE VEHICLE HAD 30000 + MILES WHEN I BOUGHT IT.
NHTSA ODI #11142178
75,000 miles · Oct 13, 2018
Electrical SystemElectronic Stability Control (esc)Fuel/propulsion System
'TAKATA RECAL' WHEN MY CAR HAS BEEN SITTING IN THE DRIVEWAY FOR A FULL DAY WITHOUT BEING DRIVEN OR STARTED. THE FOLLOWING DAY YOU GO TO START THE CAR. IT STARTS NO PROBLEM, ONCE YOUR IN REVERSE THE BATTERY LIGHT WILL COME ON AND AS SOON AS YOU PUT IT IN DRIVE I LOSE ALL POWER AND FUNCTION TO STEER. IF I HIT THE GAS PETAL IT WILL…
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'TAKATA RECAL' WHEN MY CAR HAS BEEN SITTING IN THE DRIVEWAY FOR A FULL DAY WITHOUT BEING DRIVEN OR STARTED. THE FOLLOWING DAY YOU GO TO START THE CAR. IT STARTS NO PROBLEM, ONCE YOUR IN REVERSE THE BATTERY LIGHT WILL COME ON AND AS SOON AS YOU PUT IT IN DRIVE I LOSE ALL POWER AND FUNCTION TO STEER. IF I HIT THE GAS PETAL IT WILL REGAIN POWER. THE LIGHT WILL DISAPPEAR ONLY IF I HIT OK. THIS HAPPENS EVERY TIME WITHOUT FAIL. I ALSO SMELL CARBON DIOXIDE OR GAS FUMES FROM TIME TO TIME
NHTSA ODI #11140084
44,000 miles · Oct 8, 2018
EngineFuel/propulsion SystemPower Train
LOSS OF POWER: WHILE DRIVING MY 2015 FORD EXPLORER XLT WITH 3.5L V-6 ENGINE ON THE HIGHWAY (10/04/18), THE WRENCH LIGHT CAME ON AND THE CAR STARTED TO SHUDDER AND LOSE SPEED. PUSHING DOWN ON THE ACCELERATOR HAD NO AFFECT AND THE CAR RAPIDLY DECELERATED. THE ENGINE WAS RUNNING VERY ROUGH WITH HEAVY VIBRATION. THIS WAS A TERRIFYIN…
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LOSS OF POWER: WHILE DRIVING MY 2015 FORD EXPLORER XLT WITH 3.5L V-6 ENGINE ON THE HIGHWAY (10/04/18), THE WRENCH LIGHT CAME ON AND THE CAR STARTED TO SHUDDER AND LOSE SPEED. PUSHING DOWN ON THE ACCELERATOR HAD NO AFFECT AND THE CAR RAPIDLY DECELERATED. THE ENGINE WAS RUNNING VERY ROUGH WITH HEAVY VIBRATION. THIS WAS A TERRIFYING AND NEARLY FATAL EXPERIENCE AS FASTER MOVING TRAFFIC STARTED PASSING ME ON BOTH SIDES AS I TRIED TO MOVE OFF THE HIGHWAY. I WAS ABLE TO MOVE THE CAR TO THE SIDE OF THE HIGHWAY AND LIMPED OFF THE NEAREST EXIT. ONCE OFF THE EXIT I SHUT THE CAR OFF AND SAT FOR 20 MINUTES WHILE I RE-GAINED MY COMPOSURE AND CALLED MY HUSBAND. WHEN HE ARRIVED HE STARTED THE EXPLORER AND THE WRENCH LIGHT WAS CLEARED. MY HUSBAND DRIVE THE CAR HOME USING ONLY BACK ROADS WHILE I FOLLOWED IN HIS CAR. WE CALLED OUR LOCAL FORD DEALER AND SCHEDULED AN APPOINTMENT. WE STARTED RESEARCHING THIS ISSUE AND FOUND THIS TO BE A WELL KNOWN PROBLEM WITH THE THROTTLE BODY ON FORD'S V6 ENGINES WHICH ARE USED ON MULTIPLE SUV'S, CROSSOVERS AND SEDANS. THE RESEARCH I'VE SEEN SHOWS THIS ISSUE HAS AFFECTED MORE THAN 10,000 OWNERS. HOWEVER, IT'S NOT CLEAR IF THE THROTTLE BODY IS FAULTY DUE TO A MANUFACTURING OR DESIGN DEFECT. IT'S ALSO NOT CLEAR IF REPLACING THE THROTTLE BODY IS A PERMANENT FIX. I'M TERRIFIED TO DRIVE THE CAR ON THE HIGHWAY AND SINCE THIS HAPPENED WE'VE ONLY USED IT FOR SHORTER TRIPS AROUND TOWN. THE FORD DEALER CHECKED THE CAR TODAY (10/08/18) BUT SINCE THE WRENCH LIGHT WAS CLEARED THEY FOUND NOTHING WRONG. I PLEADED WITH THE SERVICE ADVISOR TO NO AVAIL. WE'VE BEEN A FORD FAMILY FOR MORE THAN 15 YEARS BUT THIS FAULT AND EVEN WORSE THE FORD SERVICE ADVISOR'S RESPONSE IS COMPLETELY UNACCEPTABLE. THIS IS A SERIOUS AND DANGEROUS PROBLEM AND ONLY A MATTER OF TIME BEFORE SOMEONE AND THEIR FAMILY ARE KILLED. PLEASE INVESTIGATE AND FORCE FORD TO ISSUE A RECALL.
NHTSA ODI #11139061
70,000 miles · Oct 4, 2018
Fuel/propulsion SystemPower Train
WHEN AT IDLE, EITHER IN PARK OR DRIVE, THE ENGINE RPMS WILL FLUCTUATE AND GO DOWN TO A POINT WHERE THE ENGINEER STALLS OR ALMOST STALLS.
NHTSA ODI #11133252
59,000 miles · Jul 3, 2018
Fuel/propulsion System
DURING ACCELERATION INTO INTERSTATE THERE IS A "BURNT MATCH" TYPE SMELL IN THE INTERIOR OF THE VEHICLE. ONCE SPEED LEVELS OUT THE SMELL DISAPPEARS. I FIRST NOTICED THIS ABOUT A MONTH AGO BUT I PURCHASED THE VEHICLE USED AND THIS WAS ONLY THE SECOND OR THIRD TIME TO HAVE IT ON THE INTERSTATE SINCE I PURCHASED IT.
NHTSA ODI #11105291
Official recalls
8Oct 13, 2025
Ford Motor Company (Ford) is recalling certain 2015-2019 Flex, 2015 Explorer, Lincoln MKT, Lincoln MKZ, 2015-2016 C-Max, Escape, Taurus, 2016 Fusion, 2018-2019 Taurus, 2019 Lincoln MKT, Fiesta, and 2020 Mustang vehicles. The rearview camera may display a distorted, intermittent, or blank image when the vehicle is in reverse.
Consequence & remedy
Consequence: A rearview camera that fails to properly display an image can reduce the driver’s view behind the vehicle, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the rearview camera as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters notifying owners of the safety risk were mailed on October 25, 2025. Additional letters will be mailed once the final remedy is available on each phase. Mustang owner notification letters were mailed January 2, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA9. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 14, 2025.
Jan 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.
Jul 24, 2015
Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Ford Flex, and Lincoln MKS vehicles manufactured May 4, 2015, to May 23, 2015, Lincoln MKT vehicles manufactured May 4, 2015, to May 21, 2015, and 2015-2016 Ford Explorer vehicles manufactured May 4, 2015, to May 23, 2015. The affected vehicles have a parking brake that may not fully engage when applied. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 135, "Light Vehicle Brake Systems."
Consequence & remedy
Consequence: If the parking brake does not fully engage and the transmission is left in a gear other than 'Park' while on a slope, the vehicle may roll away, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will test the operation of the parking brake system, and if necessary, replace the parking brake control assembly, free of charge. The recall began on September 4, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15C07.
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
5PE23001 · 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.
PE15017 · Front Brake Hose Failure
Opened Apr 29, 2015 · Closed Sep 28, 2015
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 reports of low-mileage failures of front brake jounce hoses in model year (MY) 2015 Ford Explorer Police Interceptor vehicles operated as training vehicles by the City of Sacramento, California (ODI VOQ No. 10705832). To date, the Sacramento police fleet has reported a total of 7 front hose failures in 5 different Explorer Police Interceptor vehicles used for its Emergency Vehicle Operation Course (EVOC) training. Most of the failures occurred within the first few miles of service on a closed course used for the EVOC program, which includes evasive accident avoidance and pursuit maneuver training. The hose assemblies either leaked at, or pulled completely free from, the caliper-end attachment where the hose is crimped to the steel end fitting. Most of the failures resulted in a sudden loss of braking performance that caused the vehicle to run off the intended course. None of the failures resulted in any crashes, injuries or property damage.The subject MY 2015 hose assemblies are similar in design to hoses used on MY 2013 through 2014 Explorer Police Interceptor and civilian vehicles. The 5 vehicles used by Sacramento EVOC have all been repaired using MY 2016 front hose assemblies that have been changed to incorporate a short steel tube attached to the caliper end banjo block. No failures have been experienced by the Sacramento fleet to date in the other 37 MY 2014-2015 Explorer Police Interceptor vehicles (2 MY 2014 and 35 MY 2015) used by the fleet in regular law enforcement duty cycles unrelated to the EVOC training. In its response to ODI's information request letter for PE15-017, Ford provided information about 2 additional failures reported by other fleets, including 1 involving a Sacramento Regional Transit vehicle that occurred while being driven on the street.Based on its analysis of failed parts returned from the Sacramento fleet and the fleet's EVOC training duty cycle, Ford attributes the Sacramento fleet hose failures to excessive temperatures produced during hot-soak portions of the EVOC training duty cycle (when the vehicles are stationary after hard braking exercises, with no cooling air flow through the brake rotor vents and across the other brake components). During testing conducted to replicate the EVOC duty cycle, Ford measured temperatures at the subject crimp fittings that exceeded the design limits of the brake hose material after several successive training intervals and hot soaks. Ford has provided the Sacramento fleet with modified replacement hose assemblies for all of its MY 2014-15 Explorer Police Interceptor vehicles. The replacement hose assemblies were developed for use in MY 2016 Explorer vehicles and were modified slightly to accommodate the addition of a ride height sensor in those vehicles. The revised assemblies have an additional length of brake pipe between the caliper end connection and the subject crimp ferrule that results in additional heat dissipation and makes the assemblies more robust to the severe thermal effects experienced during the EVOC testing (the hose material is the same in both assemblies). Ford believes that the excessive temperatures experienced at the crimp fitting in the subject vehicles are unique to the EVOC duty cycle, have not been observed in the standard on-road severe duty cycle testing performed by Ford and police fleets who routinely conduct such testing and are not likely to occur in service usage for on-road Explorer Police Interceptor vehicles.This preliminary evaluation is closed, an Engineering Analysis (EA15-005) has been opened to conduct testing and further
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