NHTSA owner reports · September 18, 2026 snapshot.
Suspension complaints
73 reportsClear category filterMileage unknown · Jun 22, 2026
SteeringSuspensionWheels
2016 Ford Explorer, VIN [XXX]. Filing against Planet Ford Dallas regarding incomplete Regional Program 21R01 (Rear Toe Link Replacement), tied to Federal Safety Recall 21V537. May 11, 2026: Vehicle presented for 21R01 service. May 15: Returned with recall marked complete in Ford's system. 21R01 mandates replacement of both rear …
Read full complaint
2016 Ford Explorer, VIN [XXX]. Filing against Planet Ford Dallas regarding incomplete Regional Program 21R01 (Rear Toe Link Replacement), tied to Federal Safety Recall 21V537. May 11, 2026: Vehicle presented for 21R01 service. May 15: Returned with recall marked complete in Ford's system. 21R01 mandates replacement of both rear toe links, alignment check, and rear toe adjustment. None of these steps were correctly completed. Dealer has since acknowledged to me that the toe link was not replaced correctly, but instead with the incorrect part and that rear suspension hardware was left loose upon vehicle release. The vehicle was driven approximately one month in this condition. Progressive symptoms followed: steering pull, steering wheel offset, tire screeching, and vehicle instability. Rear toe was subsequently found approximately 3 degrees out of specification — consistent with loose hardware shifting during normal driving. Dealer is attributing front suspension wear to natural causes while providing no investigation demonstrating the incomplete recall did not contribute to or accelerate that damage. Ford Motor Company Head Office has confirmed 21R01 as applicable (Corporate Case [XXX]). Dealer has declined to accept responsibility. The recall was marked complete in Ford's system despite mandatory work not being performed. I am requesting NHTSA investigate dealer compliance with 21R01/21V537 and whether a reimbursement claim was submitted to Ford for work not performed. This matter may also be referred to the Texas AG Consumer Protection Division and FTC. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11745716
Mileage unknown · May 17, 2026
EnginePower TrainSuspension
Vehicle: 2016 Ford Explorer 2WD V6-3.5L VIN: [XXX] rchase: January 20, 2026 Odometer at Purchase: 70,929 miles (fraudulent — true mileage approximately 123,779 miles) Dealer: Drive Time Car Sales Company LLC, DBA Drive Time, 8805 E Adamo Dr, Tampa, FL 33619-3525 Narrative — Copy and Paste Into NHTSA Online Form: On January 20, …
Read full complaint
Vehicle: 2016 Ford Explorer 2WD V6-3.5L VIN: [XXX] rchase: January 20, 2026 Odometer at Purchase: 70,929 miles (fraudulent — true mileage approximately 123,779 miles) Dealer: Drive Time Car Sales Company LLC, DBA Drive Time, 8805 E Adamo Dr, Tampa, FL 33619-3525 Narrative — Copy and Paste Into NHTSA Online Form: On January 20, 2026, I purchased a 2016 Ford Explorer 2WD V6-3.5L (VIN: [XXX] ) fr [XXX] Sales Company LLC, located at 8805 E Adamo Dr, Tampa, Florida 33619-3525. At the time of sale, the vehicle had three open, unrepaired federal safety recalls: 1. NHTSA Recall 19V435 / Ford 19S17 — Rear Suspension Toe Link Replacement (initiated June 26, 2019, affecting 1,194,173 vehicles). The rear suspension toe links may fracture, causing sudden loss of vehicle handling and risk of crash. 2. NHTSA Recall 21V537 / Ford 21S32 — Rear Suspension Toe Link Cross-Axis Ball Joint (owner notifications mailed March 2022, affecting 644,055 vehicles). The cross-axis ball joint may corrode and seize, causing toe link fracture and loss of steering control. 3. NHTSA Recall 25V347 / Ford 25S53 — B-Pillar Door Trim Detachment (owner notifications mailed June 2025, affecting 492,145 vehicles). B-pillar trim may detach while driving, creating a road hazard for other motorists. None of these recalls were repaired prior to sale. The dealer had documented actual knowledge of all three open recalls. Drive Time provided me with copies of the recall notices as part of the purchase paperwork at the time of sale. Additionally, the recall documentation included a printout from the NHTSA recall lookup website for this specific VIN, timestamped January 19, 2026, at 5:28 PM — the day before the sale — proving that Drive Time actively investigated and confirmed the open recalls within hours of delivering the vehicle. Ford's own dealer notice for Recall 19V435/19S17 states: "Federal law requires dealers to complete this recall service before a new vehicle is INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11738362
100,500 miles · Mar 23, 2026
StructureSuspension
The contact owns a 2016 Ford Explorer. The contact received notifications of NHTSA Campaign Numbers: 19V435000 (SUSPENSION), 21V316000 (STRUCTURE), 24V031000 (STRUCTURE) and 25V347000 (STRUCTURE). The contact stated that while driving approximately 30–35 MPH, the driver's side B-pillar trim detached from the vehicle. The local d…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact received notifications of NHTSA Campaign Numbers: 19V435000 (SUSPENSION), 21V316000 (STRUCTURE), 24V031000 (STRUCTURE) and 25V347000 (STRUCTURE). The contact stated that while driving approximately 30–35 MPH, the driver's side B-pillar trim detached from the vehicle. The local dealer was contacted and informed the contact that the part to do the recall repair was not available. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The failure mileage was approximately 100,500.
NHTSA ODI #11726372
143,000 miles · Oct 30, 2025
Suspension
The contact owns a 2016 Ford Explorer. The contact stated that while his grandmother was driving and decelerating, the rear passenger’s side suspension suddenly failed, rendering the vehicle undrivable. The vehicle was towed to the local dealer, who determined that the rear passenger’s side tow link had failed and that both the …
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that while his grandmother was driving and decelerating, the rear passenger’s side suspension suddenly failed, rendering the vehicle undrivable. The vehicle was towed to the local dealer, who determined that the rear passenger’s side tow link had failed and that both the rear passenger’s side and driver’s side tow links needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, and the contact was informed that the vehicle was previously serviced under NHTSA Campaign Number: 21V537000 (SUSPENSION). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 143,000.
NHTSA ODI #11696576
Mileage unknown · Sep 23, 2025
StructureSuspension
Both an and b pillars are junk and dealer inspected a pillars and said they were fine? And there’s no remedy for the b ones which is annoying. My car shakes bc of a transmission shutter at 100k miles it’s not bad but why is jt going on? And wind noise because of the pillars I’m hoping? Needing help from someone.
NHTSA ODI #11689303
156,580 miles · Aug 6, 2025
SteeringSuspension
The contact owns a 2016 Ford Explorer. The contact stated that while driving at approximately 35 MPH, the steering wheel became stiff and did not drive as intended. The contact stated that the next morning, she observed a sound emanating from the steering column. The check engine warning light was illuminated before the failure.…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that while driving at approximately 35 MPH, the steering wheel became stiff and did not drive as intended. The contact stated that the next morning, she observed a sound emanating from the steering column. The check engine warning light was illuminated before the failure. The vehicle was not diagnosed or repaired. The contact believed that the failure was associated with NHTSA Campaign Number: 20V675000 (Suspension). The manufacturer was not notified of the failure. The failure mileage was approximately 156,580.
NHTSA ODI #11678846
220,000 miles · Nov 14, 2024
SuspensionWheels
The contact owns a 2016 Ford Explorer. The contact stated that while driving at 55 MPH exiting a residential area. The front wheel axle came apart. The contact's husband removed the shocks. The contact was able to drive the vehicle to her residence. There were no warning lights illuminated. The contact stated that the failure wa…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that while driving at 55 MPH exiting a residential area. The front wheel axle came apart. The contact's husband removed the shocks. The contact was able to drive the vehicle to her residence. There were no warning lights illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 17E048000 (Wheels, Suspension). The contact called the local dealer, who confirmed there were no associated recalls. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 220,000.
NHTSA ODI #11625307
199,000 miles · Oct 28, 2024
SteeringSuspension
The contact owns a 2016 Ford Explorer. The contact stated that the vehicle was taken to the dealer to be repaired under NHTSA Campaign Number: 19V435000 (Suspension), and the dealer confirmed that the recall repair was performed. However, the contact stated while driving at various speeds on a bumpy road surface, the vehicle jer…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that the vehicle was taken to the dealer to be repaired under NHTSA Campaign Number: 19V435000 (Suspension), and the dealer confirmed that the recall repair was performed. However, the contact stated while driving at various speeds on a bumpy road surface, the vehicle jerked significantly, and there was an abnormally loud sound coming from the suspension. The contact stated that the failure progressively worsened, causing the steering wheel to seize. The contact stated that the vehicle had become undrivable. The dealer was notified of the failure and advised the contact that the recall repair had been performed. The manufacturer was contacted and informed the contact that the recall repair had not been performed. The vehicle was not diagnosed or repaired. The failure mileage was approximately 199,000.
NHTSA ODI #11622327
85,000 miles · Oct 23, 2024
EnginePower TrainSuspension
The contact owns a 2016 Ford Explorer. The contact stated that while driving at various speeds, the check engine warning light illuminated, and the vehicle failed to properly accelerate while depressing the accelerator pedal. The vehicle was taken to the local mechanic who diagnosed that oil from the turbo booster had leaked ont…
Read full complaint
The contact owns a 2016 Ford Explorer. The contact stated that while driving at various speeds, the check engine warning light illuminated, and the vehicle failed to properly accelerate while depressing the accelerator pedal. The vehicle was taken to the local mechanic who diagnosed that oil from the turbo booster had leaked onto the catalytic converter and both the turbo booster and catalytic converter needed to be replaced. The vehicle was not yet repaired. The contact indicated that previously the power transfer off unit was faulty, causing the vehicle to suddenly lose accelerating power; and the front control arms and ball joints were replaced. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 85,000.
NHTSA ODI #11621498
Mileage unknown · Sep 9, 2024
SteeringSuspension
I recently went to a mechanic sho0 to have a wheel alignment done because my steering wheel is about 50% tilted to the left. The shop told me they were unable to align the vehicle because there was a problem with my toelinks in the back of my car preventing the wheel from being straight. I called Ford to see if there was anythin…
Read full complaint
I recently went to a mechanic sho0 to have a wheel alignment done because my steering wheel is about 50% tilted to the left. The shop told me they were unable to align the vehicle because there was a problem with my toelinks in the back of my car preventing the wheel from being straight. I called Ford to see if there was anything they could do because I got my toelinks done when there was a recall back in 2019. I have since had issues with my steering wheel not being lined and thought it was just out of balance. I would like for the toelinks to be looked at once again because apparently there is an issue with them.
NHTSA ODI #11613376
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
Illustration