NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
381 reportsClear category filterMileage unknown · Feb 22, 2024
EnginePower Train
The explorer started having issues with the heater not working when stopped. After some research it recommended that we check the coolant level. The coolant was low. Then we refilled it and then it happened again 3 weeks later and the coolant was low. This made us believe there was a coolant leak. After removing the bottom cover…
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The explorer started having issues with the heater not working when stopped. After some research it recommended that we check the coolant level. The coolant was low. Then we refilled it and then it happened again 3 weeks later and the coolant was low. This made us believe there was a coolant leak. After removing the bottom cover under the car it was saturated with coolant with drops coming from various areas on the passenger side. We took it to a mechanic and then transferred to a dealer and both confirmed it was the water pump. Ford negligently designed the water pump within the engine with the timing chain. If enough of the coolant mixes with oil it will cause the engine to seize and the car to shut off. I have two little kids that are in the car with me. This negligent placement can lead to cars seizing in unsafe areas. It was confirmed by a private mechanic and a ford dealer and there were no warning lights. Other than the heat not functioning properly there we no other signs or lights of water pump failure.
NHTSA ODI #11573259
Mileage unknown · Feb 14, 2024
EngineSuspensionUnknown Or Other
Subject: Urgent Vehicle Safety Complaint Regarding Defective Water Pump in Ford and Lincoln Vehicles I am writing to bring to your attention a critical safety concern affecting numerous Ford and Lincoln vehicles worldwide, specifically those equipped with Cyclone (Duratec) engines. The issue at hand revolves around a defective …
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Subject: Urgent Vehicle Safety Complaint Regarding Defective Water Pump in Ford and Lincoln Vehicles I am writing to bring to your attention a critical safety concern affecting numerous Ford and Lincoln vehicles worldwide, specifically those equipped with Cyclone (Duratec) engines. The issue at hand revolves around a defective water pump, which has manifested in various models, including but not limited to: - Ford Edge - Ford Explorer - Ford Flex - Ford Fusion - Ford Taurus - Lincoln Continental - Lincoln MKT - Lincoln MKX Owners of these vehicles are experiencing a significant and alarming risk of stalling in traffic, posing a severe threat to both driver and passenger safety. The potential consequences, including the increased likelihood of accidents and fatalities, demand immediate attention and action from Ford Motor Company who has been sued multiple times and is avoiding to respond to the judgements against them trying to use any excuse not to pay. It is imperative to address this widespread concern promptly, as the safety and well-being of Ford and Lincoln vehicle owners are at stake. I urge your organization to conduct a thorough investigation into the defective water pump issue, implement a comprehensive recall, and provide a reliable solution to rectify the problem. Your commitment to prioritizing the safety of consumers is paramount, and I trust that Ford Motor Company will take swift and decisive action to remedy this situation. By addressing this issue promptly, you not only ensure the protection of current owners but also uphold the reputation of Ford and Lincoln in the automotive industry. It's impossible to say that it is a mere coincidence that thousands of Ford vehicles have the same defect with exactly the same engine and symptoms. Thank you for your immediate attention to this matter, and I anticipate a proactive response that prioritizes the safety and satisfaction of Ford and Lincoln vehicle owners.
NHTSA ODI #11571881
Mileage unknown · Feb 9, 2024
Engine
The water pump failed causing coolant to leak into the oil pan causing my vehicle to die suddenly and without any warning lights or messages on a high speed, heavy traffic metropolitan interstate/highway (35W in Minneapolis). I was commuting home from work. It was completely dark. I was in the far left lane and had to quickly …
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The water pump failed causing coolant to leak into the oil pan causing my vehicle to die suddenly and without any warning lights or messages on a high speed, heavy traffic metropolitan interstate/highway (35W in Minneapolis). I was commuting home from work. It was completely dark. I was in the far left lane and had to quickly maneuver across 4 lanes to the right shoulder narrowly missing being slammed into by other cars before the vehicle completely died. I waited for a towing service in the dark while other vehicles including semis sped extremely close to my vehicle with only my hazards to warn them I was there. Vehicle was towed to a local repair shop and they confirmed the water pump failed and coolant leaked into the oil, ruining the engine. I've been researching online and am reading that this is a very common and known issue with lawsuits. My vehicle only had 132k miles. This issue put me in a dangerous, potentially life-threatening situation that could have caused harm to me and the many other drivers and their passengers on the highway - and it needs to be addressed and dealt with - for me and apparently the many others that have been affected by this manufacturers defect.
NHTSA ODI #11570998
Mileage unknown · Feb 6, 2024
Engine
My engine sounded strange at startup in the mornings so I asked the ford dealer to look at it because Firestone could not find anything wrong with it and I had two recalls needing addressed. I took it to the dealership in diberville, MS first and scheduled the current recalls to be fixed. I was told my engine needs to be replac…
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My engine sounded strange at startup in the mornings so I asked the ford dealer to look at it because Firestone could not find anything wrong with it and I had two recalls needing addressed. I took it to the dealership in diberville, MS first and scheduled the current recalls to be fixed. I was told my engine needs to be replaced because there is evidence of coolant in the cylinder head causing a random misfire but couldn’t tell me if that was it for sure without breaking down the engine to diagnosis properly. I bought an extended warranty policy incase there was an issue in the future. I was actually told by one dealer to “clear the code and trade it in immediately or wait till the engine blows up”. They didn’t even fix the recall because they had to order the parts… The same problem kept happening randomly this time with the engine light coming on and then going off while I am waiting parts to come in, it was a “cold start” type of engine sound when starting up first thing in the morning. I then took it to the dealership in Gulfport,ms and they said they thought they knew what the problem was and my extended warranty would cover it. Turns out they do not cover the block and that is what the mechanics said the issue was, because it is not a moving part and it seems to be a manufacturer quality of the block. Since it was not caused by moving part damage. How can I get this addressed by ford? I have seen that a similar engine from ford had a recall for this and my engine has the same block as that one. (2.0 ecoboost ford escape) I have the 2.3 ecoboost ford explorer. I also have knowledge of another explorer with the same issues and a total engine replacement through diberville MS dealership. My car still runs but the cylinder no longer builds or sustains the pressure for the engine to run properly causing a safety risk during operation.
NHTSA ODI #11570210
Mileage unknown · Jan 24, 2024
Engine
Water pump went out and water and oil mixed started smoking and loss of power then engine just shut off now wont turn over
NHTSA ODI #11567566
Mileage unknown · Jan 8, 2024
Engine
in 2021 my check engine light came on. My Vehicle was just 5 years old, but 14K miles out of the manufacture warranty. My Engine failed and I had pay out of pocket to get another one. It's all documented by my mechanic and in Ford's system. I know there is an investigation of a possible recall for the engine failures and FORD is…
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in 2021 my check engine light came on. My Vehicle was just 5 years old, but 14K miles out of the manufacture warranty. My Engine failed and I had pay out of pocket to get another one. It's all documented by my mechanic and in Ford's system. I know there is an investigation of a possible recall for the engine failures and FORD is saying one is not needed because all the engines were fixed under warranty. Well, mine was not. My vehicle hardly drove and had no power. I had to come out of the pocket $6,000 dollars and at the time Ford would not cover it or help in any way financially. I believe the #4 in the engine failed. Coming up with the money was very difficult and I am still paying the engine cost off on top of my car note.
NHTSA ODI #11564229
Mileage unknown · Dec 27, 2023
Engine
Coolant (water) pump leak, leading to replacement or eventual failure. As the pump is located internally of the engine, the effort to repair is quite extensive. This is a known issue for this engine, with previous versions under a recall. The pump location was relocated externally of the engine in future designs, further evidenc…
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Coolant (water) pump leak, leading to replacement or eventual failure. As the pump is located internally of the engine, the effort to repair is quite extensive. This is a known issue for this engine, with previous versions under a recall. The pump location was relocated externally of the engine in future designs, further evidence of the knowledge of the issue.
NHTSA ODI #11562045
Mileage unknown · Dec 11, 2023
EngineEngine And Engine Cooling
Water pump leaking and needs to be replaced. Can cause engine failure and lead to being stranded on highway. Multiple forums have people with the same issue. No warning lights have come on. I took the vehicle in for another issue and they pointed out the leak to me.
NHTSA ODI #11559601
Mileage unknown · Nov 28, 2023
Engine
1. Component: Electronic throttle body 2. Our vehicle shut down (limp home mode) on the Interstate traveling at high speeds. We narrowly avoided catastrophic accident with other vehicles on the road. 3. The problem was confirmed at the dealership where it is currently being replaced at our expense of roughly $1,000.00 4. Only …
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1. Component: Electronic throttle body 2. Our vehicle shut down (limp home mode) on the Interstate traveling at high speeds. We narrowly avoided catastrophic accident with other vehicles on the road. 3. The problem was confirmed at the dealership where it is currently being replaced at our expense of roughly $1,000.00 4. Only inspected by dealership (Crain ford little rock, ar) 5. No warning until the part failed. We received airbag light and service light during shut down on the interstate. I have called ford pleading with them for some assistance with this large bill, which is hard to deal with right before Christmas with 2 children. I was told that my VIN# was not effected even after ford posted a notice for 2016 ford explorers Electronic Throttle Body replacement. Ford customer service ended our call after stating that nothing can be done due to this not being a recall item yet. However I do have a 2016 Ford explorer that does have a ETB issue and I hope that my letter will help others before fatalities start adding up due to this unsafe part. I feel that we should have received a letter as soon as ford realized that my 2016 ford explorer could potentially have this issue. I realize that's not what large corporations practice especially when it would hurt profits, however we are dealing with human lives and families. I have included the ford campaign number for 2016 ford explorer ETB replacement for reference, I truly hope you are able to spare the lives of so many family's trusting safe passage in a 2016 ford explorer. campaign #16B32
NHTSA ODI #11557278
Mileage unknown · Nov 12, 2023
Engine
My Explorer engine blew a head gasket while I was driving and I had to maneuver quite a bit to avoid having multiple accidents. I had it towed to a shop and they said the engine was bad and caused by a known problem with Ford Ecoboost engines.
NHTSA ODI #11554766
Official recalls
14Jul 14, 2026
Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The roof rail covers may come loose and detach from the vehicle.
Consequence & remedy
Consequence: A detached roof rail cover can create a road hazard, increasing the risk of a crash.
Remedy: Dealers will inspect the roof rail covers and as necessary, repair or replace the push-pins, rail clips, or roof rail covers, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 28, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S54. This recall expands previous NHTSA recall number 21V316. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.
Oct 10, 2025
Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
Consequence & remedy
Consequence: An electrical short circuit can increase the risk of a fire.
Remedy: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.
May 23, 2025
Ford Motor Company (Ford) is recalling certain 2016-2017 Explorer vehicles. The driver and front passenger B-Pillar door trim may detach while driving.
Consequence & remedy
Consequence: Door trim that detaches while driving can create a road hazard, increasing the risk of a crash.
Remedy: Dealers will repair the B-pillar trim, free of charge. Interim letters, notifying owners of the safety risk, were mailed June 5, 2025. A second notice will be sent once the final remedy is available, anticipated November 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S53.
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.
May 5, 2021
Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The retention pins could loosen and allow the roof rail covers to detach from the vehicle.
Consequence & remedy
Consequence: A detached roof rail cover can create a road hazard, increasing the risk of a crash.
Remedy: Dealers will install push-pins and replace any damaged rail clips and roof rail covers, as necessary, free of charge. The interim owner notification letter was mailed on June 22, 2021. Owner notification letters (remedy available) were mailed on October 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S22.
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.
Nov 29, 2017
Ford Motor Company (Ford) is recalling certain 2016 F-150 and Explorer vehicles. Loose power seat adjuster pivot bolts may cause the front seat cushions to detach and not properly restrain the seat occupant in the event of a crash.
Consequence & remedy
Consequence: In the event of a crash, a seat occupant that is not properly restrained has an increased risk of injury.
Remedy: Ford will notify owners, and dealers will inspect the tightness of the power seat track upper pivot link bolt, either applying threadlocker or replacing the lift link and hardware, free of charge. Interim letters are expected to go out January 15, 2018. Owners will receive a second notice when the remedy becomes available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S40.
Jun 28, 2016
Ford Motor Company (Ford) is recalling certain model year 2016 Ford Explorer and F-150 vehicles equipped with a manual recline driver's seat. The seat back frame may have insufficient welds which may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202, "Head Restraints" and 207, "Seating Systems."
Consequence & remedy
Consequence: The seat back may not adequately restrain the occupant during a crash, increasing the risk of injury.
Remedy: Ford will notify owners, and dealers will inspect and, if necessary, replace the seat back frame, free of charge. The recall begin on August 18, 2016. Owners may contact Ford at 1-800-392-3673. Ford's number for this recall is 16C11.
Mar 31, 2016
Ford Motor Company (Ford) is recalling certain model year 2015-2016 Lincoln MKC vehicles manufactured November 25, 2013, to January 25, 2016, and 2016 Ford Explorer vehicles manufactured October 20, 2014, to January 28, 2016. The affected vehicles are equipped with 2.3L GTDI engines and engine block heaters. These engine block heaters have elements that may overheat while plugged in.
Consequence & remedy
Consequence: Overheating of the engine block increase the risk of a fire.
Remedy: Ford will notify owners, and dealers will replace the engine block heater, free of charge. Dealers will also inspect and replace the electrical cord, as necessary. The recall began on May 18, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S14. Note: Owners should not use the engine block heater until the vehicle has been remedied.
Sep 28, 2015
Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Lincoln MKS, and 2016 Ford Explorer vehicles manufactured on July 24, 2015. During vehicle production, the fuel tank attachment bolts may not have been properly tightened. As a result, the fuel tank straps may fracture and the fuel tank could separate from the vehicle.
Consequence & remedy
Consequence: If the fuel tank separates from the vehicle, a fuel leak may occur, increasing the risk of a fire.
Remedy: Ford will notify owners, and dealers will tighten the fuel tank attachment bolts, as necessary, free of charge. The recall began on October 19, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S26.
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
2PE23001 · 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
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