NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
1,781 reports5,000 miles · Oct 27, 2016
EnginePower TrainUnknown Or Other
OUR EXPLORER LIMITED UNIT HAS LESS THAN 21,000 MILES ON IT. WHILE ACCELERATING TO PASS ANOTHER VEHICLE, CLIMBING A HILL / MOUNTAIN OR SIMILAR SITUATION EXHAUST FUMES ENTER THE CABIN. THE A/C UNIT IS ON AND IN THE RECIRCULATION MODE WITH THE REAR A/C UNIT OPERATING. THE NOXIOUS FUMES SMELL LIKE ROTTEN EGGS / SULFURIC ACID. THE ON…
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OUR EXPLORER LIMITED UNIT HAS LESS THAN 21,000 MILES ON IT. WHILE ACCELERATING TO PASS ANOTHER VEHICLE, CLIMBING A HILL / MOUNTAIN OR SIMILAR SITUATION EXHAUST FUMES ENTER THE CABIN. THE A/C UNIT IS ON AND IN THE RECIRCULATION MODE WITH THE REAR A/C UNIT OPERATING. THE NOXIOUS FUMES SMELL LIKE ROTTEN EGGS / SULFURIC ACID. THE ONLY WAY TO CLEAR THE DANGEROUS EXHAUST GASES IS TO OPEN WINDOWS ALLOWING FOR A CHANGE IN THE CABIN'S ATMOSPHERE. THIS IS A RECURRING ISSUE THAT CAN BE REPLICATED. WORKING WITH THE DEALERSHIP WE PURCHASED FROM AS WELL AS FORD CORPORATE TO RESOLVE THIS DANGEROUS SITUATION. MANY UNITS ARE EXPERIENCING THIS SAME ISSUE. NO PROVEN REPAIR / FIX TO DATE. HOW LONG WILL IT TAKE FORD'S ENGINEERING TEAM TO ISOLATE THE REASON THIS OCCURS AND PROVIDE A PROVEN REPAIR / RECALL? COULD IT BE THE UNITS EXPERIENCING THIS RECURRING PROBLEM COULD BE COMING OUT OF THE SAME MANUFACTURING FACILITY?
NHTSA ODI #10919354
58,294 miles · Oct 23, 2016
Structure
HAVE BEEN HEARING A VIBRATION SOUND COMING FROM THE DRIVERS SIDE WINDSHIELD FOR ABOUT A WEEK BUT COULDN'T FIND THE SOURCE OF THE SOUND. TODAY, WHILE DRIVING ON THE HIGHWAY AT 65 MPH, THE BLACK MOLDING FROM THE DRIVERS SIDE WINDSHIELD FLEW OFF. LUCKILY, THERE WAS NOBODY BEHIND US WHEN IT HAPPENED. WHEN WE WERE ABLE TO STOP AND I…
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HAVE BEEN HEARING A VIBRATION SOUND COMING FROM THE DRIVERS SIDE WINDSHIELD FOR ABOUT A WEEK BUT COULDN'T FIND THE SOURCE OF THE SOUND. TODAY, WHILE DRIVING ON THE HIGHWAY AT 65 MPH, THE BLACK MOLDING FROM THE DRIVERS SIDE WINDSHIELD FLEW OFF. LUCKILY, THERE WAS NOBODY BEHIND US WHEN IT HAPPENED. WHEN WE WERE ABLE TO STOP AND INSPECT IT, IT WAS CLEAR THE MOLDING HAD BROKEN AT THE CLIPS AND THE VIBRATION SOUND HAD BEEN COMING FROM THERE. *TR
NHTSA ODI #10918132
Mileage unknown · Oct 21, 2016
Engine
HAVE TAKEN THIS VEHICLE TO FORD 4 TIMES WITHOUT RESOLUTION. EXHAUST SMELL OVERPOWERING DURING ACCELERATION AND NOW AFRAID TO TAKE LONG TRIPS OVER INCLINED ED GRADES, ESSENTIALLY LIMITING TO NO TOWING, NO VISITS TO FAMILY, ESSENTIALLY A BIG WHITE ELEPHANT IN MY GARAGE
NHTSA ODI #10917780
33,400 miles · Oct 20, 2016
Electrical SystemElectronic Stability Control (esc)Unknown Or Other
LOOK AT VIDEO LINK @ CBS DETROIT RADIO "VIDEO" -2015 FORD EXPLORER PROBLEMS- ALSO YOU TUBE. (2015 FORD EXPLORER PROBLEMS) HTTP://DETROIT.CBSLOCAL.COM/VIDEO/CATEGORY/NEWS/3563437-COUPLE-SAYS-THEIR-SUV-IS-PUTTING-THEIR-LIVES-AT-RISK/
NHTSA ODI #10917621
33,400 miles · Oct 20, 2016
Electrical SystemElectronic Stability Control (esc)
AUGUST 10-OCTOBER 20TH: NUMEROUS FAULT CODES APPEARED ON DASH: TERRAIN MANAGEMENT FAULT LIGHT APPEARED ON DASHBOARD, THEN THE ENTIRE DASHBOARD WENT BLACK, THE AIR CONDITIONING STOPPED, THE RADIO TURNED OFF, THE TERRAIN MANAGEMENT CONTROL KNOB WAS NO LONGER LIT. SUDDENLY, VERY HOT AIR STARTED POURING OUT OF ALL VENTS WITH WHAT S…
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AUGUST 10-OCTOBER 20TH: NUMEROUS FAULT CODES APPEARED ON DASH: TERRAIN MANAGEMENT FAULT LIGHT APPEARED ON DASHBOARD, THEN THE ENTIRE DASHBOARD WENT BLACK, THE AIR CONDITIONING STOPPED, THE RADIO TURNED OFF, THE TERRAIN MANAGEMENT CONTROL KNOB WAS NO LONGER LIT. SUDDENLY, VERY HOT AIR STARTED POURING OUT OF ALL VENTS WITH WHAT SEEMED LIKE MAXIMUM FAN SPEED. FOR 34 OUT OF 60 DAY PERIOD (6 OCCURRENCES AND 6 VISITS TO DEALERSHIP), FORD KEPT VEHICLE AND TRIED TO DETERMINE THE CAUSE. THEY WERE UNABLE TO RETRIEVE ANY ERROR CODES OR DUPLICATE THE PROBLEM. PROVIDED DETAILS AND PICTURE FROM MY CELL PHONE OF ERROR MESSAGES TO SERVICE DEPT. AUGUST 28: WE WERE DRIVING 6 PEOPLE IN THE EXPLORER ON THE EXPRESSWAY WHEN WE STARTED EXPERIENCING PROBLEMS. CHIMING NOISES WERE HEARD INITIALLY, THEN INTERMITTENTLY. THE DASHBOARD LIGHTS STARTED BLINKING ON AND OFF. THE ENTIRE DASHBOARD THEN WENT BLACK, THEN INTERMITTENTLY ON WITH THE SPEEDOMETER GOING BACK AND FORTH FROM 0 TO AROUND 78, THEN BLACKING OUT AGAIN. LEFT HAND SIDE OF DASHBOARD DISPLAYED BRAKE SYSTEM WARNING SYMBOL AND LOW TIRE PRESSURE WARNING SYMBOL. THE AIR CONDITIONING AND RADIO WENT OFF. AWD OFF MESSAGE APPEARED ON LEFT SIDE OF DASHBOARD. RIGHT HAND SIDE OF DASHBOARD DISPLAYED: STABILITY CONTROL, STABILITY CONTROL SYSTEM OFF & FRONT AIR BAG SYMBOLS. MAXIMUM HEAT STARTED POURING OUT OF VENTS. ABS SYMBOL APPEARED AND RIGHT HAND SIGNAL CAME ON. SERVICE ADVANCE TRAC MESSAGE WAS ALSO DISPLAYED AT SOME POINT. THIS PROBLEM EPISODE LASTED AT LEAST 4 MINUTES WHILE WE WERE DRIVING. WE TOOK PICTURES OF THE DASHBOARD AND VIDEOTAPED PART OF THIS EPISODE. *TR
NHTSA ODI #10917609
Mileage unknown · Oct 16, 2016
EngineFuel/propulsion System
UPDATE TO NHTSA COMPLAINT #10914850 VEHICLE STILL IN SERVICE SINCE 9/26/16. TOTAL DAYS AT DEALER FOR SERVICE DUE TO EXHAUST FUMES / CHEMICAL SMELL IN PASSENGER COMPARTMENT: 26 AS OF 10/16/16. HAVE BEEN TOLD FORD'S ENGINEERING REP (DURING FORD'S "FINAL REPAIR ATTEMPT" UNDER LEMON LAW) ALSO SMELLED FUMES IN CABIN UNDER WOT AND…
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UPDATE TO NHTSA COMPLAINT #10914850 VEHICLE STILL IN SERVICE SINCE 9/26/16. TOTAL DAYS AT DEALER FOR SERVICE DUE TO EXHAUST FUMES / CHEMICAL SMELL IN PASSENGER COMPARTMENT: 26 AS OF 10/16/16. HAVE BEEN TOLD FORD'S ENGINEERING REP (DURING FORD'S "FINAL REPAIR ATTEMPT" UNDER LEMON LAW) ALSO SMELLED FUMES IN CABIN UNDER WOT AND WHEN ENGINE UNDER LOAD. WAS TOLD THAT IT COULD NOT BE CARBON MONOXIDE IN CABIN MAKING ME DIZZY AND SICK FEELING BECAUSE "CATALYTIC CONVERTER CHANGES CARBON MONOXIDE TO CARBON DIOXIDE, WHICH IS WHY DEALER USES CO2 METER NOT CO METER". WAS INFORMED THAT REGIONAL ENGINEER INSTRUCTED DEALER TO REPEAT TSB 14-0130 EVEN THOUGH THEY WERE THEN TELLING ME THAT THE SMELL IS FROM "MILDEW ON THE A/C EVAPORATOR CORE", WHICH CONTRADICTS THEIR PERFORMING THE TSB TO SEAL THE VEHICLE FROM EXHAUST FUMES A SECOND TIME (PERFORMED PREVIOUSLY WITHOUT EFFECT IN 10/2015). HAVE BEEN TOLD MANY DIFFERENT "REASONS" FOR THE FUMES IN CABIN, NONE OF WHICH MAKE MUCH SENSE. MILDEW DOES NOT SMELL LIKE SULFUR OR EXHAUST FUMES. TO MAKE THINGS WORSE, I WAS TOLD THAT I "DO NOT DRIVE ENOUGH MILES" DURING MY TRIPS TO "DRY OUT THE EVAPORATOR CORE" SO I AM TOLD MY DRIVING HABITS, NOT FORD'S DESIGN FLAWS ALLOWING EXHAUST INTO CABIN, ARE THE REASON FOR THE FUMES. SERVICE MANAGER HAS BEEN DILIGENT AND PROFESSIONAL AND IS A GENUINELY NICE PERSON, THOUGH FORD IS TRYING TO SERVE UP A "RED HERRING" BY TRYING TO DIVERT ATTENTION TO THE A/C SYSTEM RATHER THAN ADMIT TO EXHAUST FUMES IN PASSENGER CABIN. FORD REPLACED THE EVAP CORE WHICH RESULTED IN NEARLY NO A/C UPON BEING TOLD VEHICLE READY FOR PICK-UP ON 10/15/16, SO IT IS STILL IN SERVICE..NOW TO REPAIR WHAT THEY BROKE DURING "FINAL REPAIR ATTEMPT". TO CONSUMER, APPEARS FORD HAS PROPPED OPEN FRESH AIR VENTS REGARDLESS OF "RECIRCULATE" BUTTON LIGHT, RESULTING IN WARM A/C. FORD SHOULD RE-PURCHASE THIS HAZARDOUS VEHICLE. *TR
NHTSA ODI #10916309
35,544 miles · Oct 14, 2016
Unknown Or Other
UPON ACCELERATION AT HIGH RPM (300+), A STRONG ODOR OF EXHAUST FUMES IS PRESENT INSIDE THE PASSENGER CABIN. THIS CONDITION IS TYPICAL WHEN ACCELERATING ONTO FREEWAYS, PASSING A VEHICLE OR OTHERWISE UNDER LOAD. SETTING THE ENVIRONMENTAL CONTROL CIRCULATION TO RECIRCULATE INTERIOR AIR DOES NOT PREVENT THE OCCURRENCE. LAST VISIT…
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UPON ACCELERATION AT HIGH RPM (300+), A STRONG ODOR OF EXHAUST FUMES IS PRESENT INSIDE THE PASSENGER CABIN. THIS CONDITION IS TYPICAL WHEN ACCELERATING ONTO FREEWAYS, PASSING A VEHICLE OR OTHERWISE UNDER LOAD. SETTING THE ENVIRONMENTAL CONTROL CIRCULATION TO RECIRCULATE INTERIOR AIR DOES NOT PREVENT THE OCCURRENCE. LAST VISIT TO FORD DEALERSHIP ON 10 OCTOBER 2016 TO ADDRESS CONCERN FOUND NO PROBLEMS. MY VEHICLE CURRENTLY HAS 35,544 MILES AT TIME OF REPORT. IT HAS RESULTED IN NAUSEA AND HEADACHES. MY WIFE HAS EXPERIENCED ABDOMINAL PAIN THAT IS BEING TREATED BUT UNRESOLVED. I QUESTION THE AFFECT OF THE CABIN FUMES ON HER LYMPHATIC SYSTEM RESULTANT FROM EXPOSURE BEYOND NORMAL LIMITS.
NHTSA ODI #10916161
33,000 miles · Oct 12, 2016
Visibility
TL* THE CONTACT OWNS A 2015 FORD EXPLORER. WHILE DRIVING 70 MPH, A PIECE OF TRIM THAT CIRCLED THE WINDSHIELD ON THE DRIVER'S SIDE BLEW OFF. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE WINDSHIELD WAS NOT THE ORIGINAL PART ON THE VEHICLE, WHICH CAUSED THE TRIM PIECE TO FAIL. THE VEHICLE WAS NOT REPAIRED. TH…
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TL* THE CONTACT OWNS A 2015 FORD EXPLORER. WHILE DRIVING 70 MPH, A PIECE OF TRIM THAT CIRCLED THE WINDSHIELD ON THE DRIVER'S SIDE BLEW OFF. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE WINDSHIELD WAS NOT THE ORIGINAL PART ON THE VEHICLE, WHICH CAUSED THE TRIM PIECE TO FAIL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 33,000.
NHTSA ODI #10915548
42,000 miles · Oct 11, 2016
Steering
VERY LOUD POPPING SOUND OCCURS WHEN TURNING VEHICLE TO THE RIGHT AND LOOSE STEERING CONTROL FELT MOMENTARILY WHILE CAR IS IN MOTION. MOST NOTICEABLE AT SLOWER SPEEDS. DIAGNOSED AS STEERING GEAR ASSEMBLY HAS TO BE REPLACED. THIS WAS WITHIN 42,000 MILES (JUST AFTER EXPIRATION OF WARRANTY). VEHICLE HAS ELECTRONIC DRIVER ASSIST …
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VERY LOUD POPPING SOUND OCCURS WHEN TURNING VEHICLE TO THE RIGHT AND LOOSE STEERING CONTROL FELT MOMENTARILY WHILE CAR IS IN MOTION. MOST NOTICEABLE AT SLOWER SPEEDS. DIAGNOSED AS STEERING GEAR ASSEMBLY HAS TO BE REPLACED. THIS WAS WITHIN 42,000 MILES (JUST AFTER EXPIRATION OF WARRANTY). VEHICLE HAS ELECTRONIC DRIVER ASSIST AND HAS A 3.2 LITER ENGINE. .
NHTSA ODI #10915341
400 miles · Oct 8, 2016
EngineFuel/propulsion SystemUnknown Or Other
SMELL OF EXHAUST FUMES AND/OR SULFUR-TYPE ODORS COMING THROUGH AIR CONDITIONING SYSTEM UNDER HEAVY ACCELERATION, PASSING ON HIGHWAY, OR WHEN ENGINE IS UNDER A LOAD. FUMES/SMELL GET SO BAD THAT I HAVE TO ROLL DOWN ALL WINDOWS AND OPEN SUNROOF TO VENTILATE THE PASSENGER COMPARTMENT. TOLERATED THE HEADACHES, NAUSEA, AND LIGHT-H…
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SMELL OF EXHAUST FUMES AND/OR SULFUR-TYPE ODORS COMING THROUGH AIR CONDITIONING SYSTEM UNDER HEAVY ACCELERATION, PASSING ON HIGHWAY, OR WHEN ENGINE IS UNDER A LOAD. FUMES/SMELL GET SO BAD THAT I HAVE TO ROLL DOWN ALL WINDOWS AND OPEN SUNROOF TO VENTILATE THE PASSENGER COMPARTMENT. TOLERATED THE HEADACHES, NAUSEA, AND LIGHT-HEADEDNESS WHILE DRIVING UNTIL SITUATION BECAME INTOLERABLE AND HAD BEGUN TO AVOID DRIVING THE EXPLORER. FIRST SERVICED IN 10/2015, DEALER HAD VEHICLE FOR 4 OR 5 DAYS. I WAS TOLD THAT A TSB WAS PERFORMED WHICH INCLUDED REMOVING THE REAR BUMPER AND USING SEALANT, BUT THAT DID NOT CORRECT THE PROBLEM. FUMES IN PASSENGER COMPARTMENT PERSISTED. ON 9/26/2016 TOOK VEHICLE BACK TO DEALER FOR FURTHER DIAGNOSTICS AND REPAIR ATTEMPTS FOR SAME PROBLEM. DEALER HAD VEHICLE THROUGH 10/4/16, AND CALLED TO TELL ME TO COME PICK-UP VEHICLE AS IT WAS "FIXED" BY CLEANING A/C EVAPORATOR, AND ALSO "SPEAKING WITH FORD ENGINEERS". WENT FOR TEST DRIVE WITH SERVICE MANAGER. AFTER APPROX. 4-5 MILES ON HIGHWAY, UNDER VARYING ACCELERATION CONDITIONS, CABIN BEGAN TO SMELL LIKE FUMES AGAIN, COMING THROUGH THE A/C VENTS. THEN I BEGAN TO FEEL LIGHT-HEADED AND INFORMED SERVICE MANAGER OF SAME. COULD NOT VENTILLATE VEHICLE DUE TO HEAVY RAINS, BUT TAKING A/C OFF OF "RECIRCULATE AIR" HELPED ONLY A LITTLE, AND CHANGED NATURE OF ODOR SLIGHTLY. DEALERSHIP WAS USING A METER TO MEASURE WHAT WAS SUPPOSED TO BE CARBON MONOXIDE. WAS CONSISTENTLY TOLD THROUGHOUT THAT MEASUREMENTS WERE "LOW" AT 900PPM TO MAX 1500PPM. WHEN DRIVING WITH SAME METER, IT ALARMED MULTIPLE TIMES, BUT I WAS TOLD IT WAS BECAUSE METER RESPONDS TO BREATHING IN THE CAR. I DETERMINED THAT METER WAS FOR CARBON DIOXIDE NOT CARBON MONOXIDE. RETURNED VEHICLE TO SERVICE, WAS TOLD FORD IS HAVING REGIONAL REP EXAMINE VEHICLE ON 10/11/16. I HAVE FILED A LEMON LAW COMPLAINT WITH BBB.
NHTSA ODI #10914850
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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