Structure. Review the 584 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Steering. Review the 530 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine. Review the 381 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

39 crash reports14 fire reports43 injury reports

Unknown Or Other complaints

427 reports

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49,000 miles · Jan 18, 2019

EnginePower TrainUnknown Or Other

WHEN YOU DRIVES SLOWLY IN BETWEEN 15MPH TO 20MPH 2ND TO 3RD GEAR SHIFTING IT GAVES TUGG WHEN IT WAS IN WARRENTY I BRING TO FORD DELARSHIP BUT THEY SAID EVERYTHING IS OK NEVER RECOMMEND FORD IT WAS MY 1ST EXPERIENCE WITH FORD BUT ALL CRAP CARS AND SUVS

NHTSA ODI #11170871

35,611 miles · Jan 5, 2019

Unknown Or Other

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I OWN A 2016 FORD EXPLORER WITH 35,611 MILES. ON 01/01/2019, MY WIFE ARRIVED HOME IN THE EXPLORER AND I GET IN THE CAR. IMMEDIATELY I NOTICE IT REEKS OF ROTTEN EGG/SULPHUR. THE SMELL WAS MAKING ME FEEL NAUSEOUS AND LIGHT HEADED. MY WIFE EXPLAINS THAT SMELL HAS BEEN OCCURRING FOR ABOUT A WEEK AND A HALF, AND SHE CHALKED IT UP TO BEING PREGNANT AND HAVING A SENSITIVE SENSE OF SMELL. SHE STATED THAT SHE HAD BEEN GETTING HEADACHES FREQUENTLY AND NAUSEA AS WELL. I OBSERVE THE SMELL IS COMING THROUGH THE AIR CIRCULATION SYSTEM AND THAT IT IS STRONGER IN THE REAR OF THE VEHICLE. I THEN SHUT THE ENTIRE CLIMATE CONTROL OFF-NO AIR CIRCULATION AT ALL, AND THE SMELL IS STILL COMING IN THE VEHICLE. NOT AS INTENSELY, BUT STILL NOTICEABLE. AND THIS IS WHILE DRIVING OR PARKED. AFTER THIS I COMPLETED RESEARCH ON THE TOPIC AND FIND THIS IS A PRETTY COMMON PROBLEM WITH 2011-2017 EXPLORERS AND THAT PEOPLE HAVE BEEN GETTING CO2 POISONING FROM THIS DEFECT. THIS HAPPENS WHEN THE VEHICLE IS IN MOTION OR IN PARK, AIR ON OR OFF. THERE IS A HEAVIER SULFUR SMELL WHEN THE VEHICLE IS IN MOTION. FORD HAS KNOWN ABOUT THIS PROBLEM FOR YEARS AND I AM FRUSTRATED THERE HAS NOT BEEN A SAFETY RECALL. I CALLED THE FORD DEALER I BOUGHT THE EXPLORER FROM, AND THEY TOLD ME THAT THE 17-N03 REPAIR HAD ALREADY BEEN COMPLETED IN FEBRUARY 2018. CLEARLY THE 17-N03 REPAIR HAS NOT BEEN WORKING FOR ME OR OTHER FOLKS. FORD HAS PUT ANOTHER TSB OUT THAT IS APPARENTLY MORE THOROUGH. MY FORD IS CURRENTLY IN THE SHOP GETTING THE NEWEST FORD TSB REPAIR FOR THE EXHAUST/C02 ISSUE. MY TRUST IS LOST IN FORD AND FEEL THAT THEY ARE PUTTING THEIR PROFIT AHEAD OF BEING ETHICAL. I AM CONFIDENT THAT NO CONSUMER WITH PRIOR KNOWLEDGE OF THIS DEFECT WOULD WANT TO PURCHASE THESE FORD EXPLORERS. WE ALSO FOUND OUT THAT WE BOUGHT THE VEHICLE FROM A LOCAL FORD DEALER WITHOUT BEING TOLD THERE WAS AN OUTSTANDING TSB REGARDING THIS ISSUE. THANKS

NHTSA ODI #11165380

41,000 miles · Jan 4, 2019

Unknown Or Other

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I WAS DRIVING DOWN THE HIGHWAY (RT. 84) IN PA AND ALL OF A SUDDEN I HEARD A REALLY LOUD "POP" NOISE. I THOUGH THAT I BLEW A TIRE BUT MY GAUGES WERE ALL FINE. THEN I STARTED TO HEAR THE WIND AS IF A WINDOW BROKE. I ARRIVED AT MY DESTINATION TO FIND OUT THAT MY SUNROOF HAD EXPLODED. IF THE INSIDE SCREEN WASN'T SHUT (ITS NORMALLY OPEN) I WOULD HAVE BEEN COMPLETELY COVERED IN GLASS! THE FOLLOWING DAY I TOOK THE CAR BACK TO THE DEALERSHIP (WHERE I BOUGHT IT & ALL SERVICING IS DONE). I WAS NOT PLEASED WITH THE LACK OF SERVICE THAT I RECEIVED. THE SERVICE MAN TRIED TO TELL ME THAT A ROCK MUST HAVE HIT IT AND IT IS ALSO NOT COVERED UNDER THE WARRANTY. SO I HAD TO SUBMIT AN INSURANCE CLAIM, WAIT FOR A CALL FROM THE ADJUSTER, MAKE AN APPOINTMENT WITH THE ADJUSTER, HAVE THE PARTS ORDERED AND WAIT FOR IT TO BE COMPLETE.

NHTSA ODI #11165220

Mileage unknown · Dec 20, 2018

EngineUnknown Or Other

ROTTEN EGG SULFER SMELL DURING ACCELERATION UP HILLS OR FAST ACCELERATION, HAD FORD RECALL UPGRADES AND SMELL STILL THERE

NHTSA ODI #11162772

50,000 miles · Dec 3, 2018

Unknown Or Other

FOR THE LAST 5 DAYS THERE HAS BEEN A STRONG EXSAUST SMELL IN THE CABIN BAD ENOUGH YOU HAVE TO ROLL THE WINDOWS DOWN AND GET A HEADACHE ! YOU SMELL IT DRIVING AND A STRING SMELL WHEN YOU ARE SITTING AND TURN THE CAR OFF

NHTSA ODI #11155538

2 miles · Nov 19, 2018

Unknown Or Other

VEHICLE WAS "REPAIRED' TO PREVENT SMELL OF EXHAUST FUMES, WHICH ARE CAUSING HEADACHES AND FEELING LIGHT HEADED, BUT THE ISSUE IS STILL PERSISTENT. IT OCCURS ABOUT 10 SECONDS AFTER ACCELERATING THE VEHICLE. THIS IS A HUGE HAZARD AS WHOMEVER IS DRIVING THE CAR CAN POTENTIALLY PASS OUT FROM THE FUMES AND CAUSE A MAJOR ACCIDENT RESU…

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NHTSA ODI #11152431

45,000 miles · Nov 14, 2018

Unknown Or Other

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WE ARE NOTICING VERY BAD EXHAUST LEAKAGE INTO THE CABIN. MY WIFE STARTED COMPLAINING OF HEADACHES AFTER DRIVING. I DROVE IT 60 MILES AND WAS DIZZY AND NAUSEOUS AND HAD A HEAD ACHE. DROVE WITH SOME FAMILY FRIENDS ONE IS A MECHANIC AND HE SAID THERE IS DEFINETLY A PROBLEM AS WELL AND THEY WERE FEELING SICK AFTER ABOUT 20 MINUTES OF DRIVING. THIS IS A VERY COMMON PROBLEM WITH EXPLORERS AFTER DOING SOME QUICK RESEARCH AND I'M VERY DISTURBED THIS HAS NOT BEEN ADDRESSED WITH A RECALL. RIGHT NOW IT'S USELESS SITTING IN THE GARAGE AS WE ARE GETTING HEADACHES JUST ON SHORT TRIPS THRU TOWN.

NHTSA ODI #11151609

23,417 miles · Nov 6, 2018

Unknown Or Other

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I BOUGHT THIS CAR USED WITH ABOUT 19,000 MILES ON IT IN FEBRUARY, 2018. SHORTLY AFTER BUYING IT I NOTICED THE SMELL OF EXHAUST FUMES IN THE CABIN AT TIMES, SOMETIMES WHILE AT IDLE, OTHER TIMES WHILE DRIVING. I TOOK IT BACK TO THE DEALER ON MAY 11, 2018 FOR SERVICE OF SEVERAL ISSUES INCLUDING THIS ONE. THEY PERFORMED THE WORK OF A RECALL (#17N03). I'VE CONTINUED TO NOTICE EXHAUST SMELLS IN THE CABIN FROM TIME TO TIME BOTH WHEN IDLING AND WHEN DRIVING, AND SO PURCHASED A CARBON MONOXIDE DETECTOR FOR CARS. AT TIMES IT ALARMS INDICATING THERE IS CO IN THE CABIN. I TOOK THE VEHICLE TO ANOTHER DEALER ON NOVEMBER 6, 2018 WHERE THEY INSPECTED THE VEHICLE, THE EXHAUST SYSTEM AND VERIFIED THAT THE OTHER DEALER INDEED PERFORMED THE RECALL AND IT WAS DONE PROPERLY. I WAS TOLD THERE IS NOTHING MORE THAN CAN BE DONE TO RESOLVE THIS ISSUE.

NHTSA ODI #11149767

Mileage unknown · Oct 31, 2018

Unknown Or Other

CARBON MONOXIDE POISIONING. LEVEL WAS 7.2 WHEN I WENT TO ER.

NHTSA ODI #11144439

33,000 miles · Sep 9, 2018

EngineStructureUnknown Or Other

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STRONG EXHAUST AND VERY HIGH LEVELS OF CO ENTERING CABIN AT NORMAL ACCELERATION, VERY BAD AT HARD ACCELERATION I HAVE MULTIPLE PICTURES OF MY CO SENSOR I HAD IN THE VEHICLE FOR SOME TIME NOW WITH LETHAL CO LEVELS. I BELIEVE THE EXHAUST MANIFOLDS HAVE BIG ENOUGH CRACKS TO FLOOD IN CO INTO THE CABIN THROUGH OPENINGS. MINE HAS HAD THE 'DEALER ITSB' TO RESOLVE, NO CHANGE AND IT REGISTERED HIGHER AFTER. REPLACE THIS MANIFOLD AND SEAL THIS TRUCK OR BUY IT BACK FROM ME FORD. IF PUTTING MY FAMILY'S LIFE IN DANGER DAILY DOESN'T SCARE YOU, THE PICTURES AND PROOF I HAVE ARE ENOUGH FOR ANOTHER LAWSUIT AGAINST YOU FOR THIS! I NEED TO BE CONTACTED BY A FORD REP (NOT A DEALERSHIP) TO RESOLVE OR MY LAWYERS WILL FOLLOW UP WITH YOU. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).' *PM

NHTSA ODI #11128353

Official recalls

26V448000 · Structure:body

Jul 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.

25V685000 · Equipment:electrical:engine Block Heater

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.

25V347000 · Structure:body

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.

24V031000 · Structure:body:roof And Pillars

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.

21V537000 · Suspension:rear

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.

21V316000 · Structure:body

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.

20V675000 · Suspension:rear

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.

20V692000 · Power Train:axle Assembly:axle Shaft

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.

19V435000 · Suspension:rear

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.

17V767000 · Seats

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.

16V475000 · Seats:front Assembly:recliner

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.

16V183000 · Engine And Engine Cooling:engine

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.

15V605000 · Fuel System, Gasoline:storage:tank Assembly:mounting

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.

15V464000 · Parking Brake

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

PE23001 · 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

Structure:body

Go deeper into Ford Explorer problems

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