NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
427 reportsClear category filter23,720 miles · Jan 26, 2018
Unknown Or Other
BEEN GETTING HEADACHES FOR THE PAST MONTH AS WELL AS DIZZINESS AND FEELINGS OF NAUSEA. YESTERDAY CAR HAD OVERWHELMING EXHAUST ODOR INSIDE OF CAR THAT MADE ME EXTREMELY ILL ALL DAY YESTERDAY... I DID CALL FORD AND THEY HAD IT TOWED TO A FORD DEALER WHO STATED THEY WILL CHANGE OUT CLIPS. WANT TO BE SURE TO REPORT AS IT APPEARS…
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BEEN GETTING HEADACHES FOR THE PAST MONTH AS WELL AS DIZZINESS AND FEELINGS OF NAUSEA. YESTERDAY CAR HAD OVERWHELMING EXHAUST ODOR INSIDE OF CAR THAT MADE ME EXTREMELY ILL ALL DAY YESTERDAY... I DID CALL FORD AND THEY HAD IT TOWED TO A FORD DEALER WHO STATED THEY WILL CHANGE OUT CLIPS. WANT TO BE SURE TO REPORT AS IT APPEARS IT IS AN ONGOING PROBLEM WITH THIS VEHICLE TYPLE.. THE SMELL COULD BE SMELT AS SOON AS CAR WAS TURNED ON, AND WORSENED AS CAR WAS DRIVING DOWN ROAD. FASTER THE CAR WOULD MOVE THE WORSE IT GOT.
NHTSA ODI #11065213
30,000 miles · Jan 26, 2018
Unknown Or Other
ANYTIME I ACCELERATE TO HIGHWAY SPEEDS, A STRONG EXHAUST ODOR FILLS THE PASSENGER CABIN. I WAS TOLD IT WAS NOTHING TO WORRY ABOUT BUT NOW I SAW A NEWS ARTICLE THAT RAISED NEW CONCERNS AND SUGGESTED REPORTING THIS ISSUE IF PRESENT.
NHTSA ODI #11065027
31,680 miles · Jan 26, 2018
Unknown Or Other
I WAS DRIVING ON A MAJOR HIGHWAY AND MY SUV SUDDENLY STARTED LOOSING POWER AND JERKING (HESITATING TO MOVE) I PULLED OVER AND STARTED TO SMELL BURNING OIL OR VERY UNIQUE SMELL ALMOST LIKE BURNING BREAK FLUID OR CARBON. TOOK THE CAR TO THE DEALERSHIP AND THE SMELL WAS NOTICED IMMEDIATELY BY THE SERVICE REP. THEY COULD NOT FIND TH…
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I WAS DRIVING ON A MAJOR HIGHWAY AND MY SUV SUDDENLY STARTED LOOSING POWER AND JERKING (HESITATING TO MOVE) I PULLED OVER AND STARTED TO SMELL BURNING OIL OR VERY UNIQUE SMELL ALMOST LIKE BURNING BREAK FLUID OR CARBON. TOOK THE CAR TO THE DEALERSHIP AND THE SMELL WAS NOTICED IMMEDIATELY BY THE SERVICE REP. THEY COULD NOT FIND THE ISSUE AND CANNOT EXPLAIN THE SMELL IN MY CARS CABIN. THE SMELL IS SO STRONG WHEN PARKED OR DURING IDLE THAT WE CANNOT RUN THE AC OR HEATER FOR FEAR OF THE SMELL MAKING YA ALL SICK. FORD WILL NOT PROVIDE ANY INSIGHT OR HELP AND THE SMELL IS LITERALLY HARMING ME AND MY CHILDREN. THE ISSUE IS ONGOING AND THE SMELL HAS NOT LET UP. THE CAR DOES SPUTTER OUT WHEN ACCELERATING FROM TIME TO TIME..NO ANSWERS FROM FORD ON WHY THAT HAPPENS....COMPLETELY LOST AND FRUSTRATED!
NHTSA ODI #11065000
23,000 miles · Jan 24, 2018
Unknown Or Other
CAR HAS SMELLED AWFUL SINCE LEASING. BEING GASSED WITH CARBON MONOXIDE EVERY TIME I DRIVE IT. TOOK IN FOR RECALL TO VARSITY LINCOLN. THEY DID NOT ADDRESS IT. DROVE CAR TO FRANKENMUTH FOR THANKSGIVING DINNER 1 1/2 HOUR RIDE. SOMETHING POPPED AND THE MOST AWFUL GAS SMELL CAME OUT AND NEVER WENT AWAY EVERYBODY AROUND US COULD SMELL…
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CAR HAS SMELLED AWFUL SINCE LEASING. BEING GASSED WITH CARBON MONOXIDE EVERY TIME I DRIVE IT. TOOK IN FOR RECALL TO VARSITY LINCOLN. THEY DID NOT ADDRESS IT. DROVE CAR TO FRANKENMUTH FOR THANKSGIVING DINNER 1 1/2 HOUR RIDE. SOMETHING POPPED AND THE MOST AWFUL GAS SMELL CAME OUT AND NEVER WENT AWAY EVERYBODY AROUND US COULD SMELL IT. DROPPED IT OFF AT TOM HOLZER FORD. THEY ADDRESSED THE RECALL AND SMELL BY PUTTING ADSHESIVE (TAPE) AND SEALANT (GLUE) CALLED AND TOLD IT IT WAS READY. THE SMELL WAS NOT GONE TOOK IT BACK 4 DAYS LATER. WAS TOLD THE TRANSFER CASE BLEW AND THEY WOULD NEED IT FOR A FEW DAYS TO FIX IT. PICK UP CAR STILL SMELLED AWFUL. WENT UP NORTH LAST WEEK. THREE HOUR RIDE. THE FIRST HOUR I HAD THE BACK WINDOWS OPEN AS ALWAYS CAUSE I KNOW I AM BEING POISONED. THE NEXT TWO HOURS WERE POURING RAIN COULD NO LONGER DRIVE WITH WINDOWS OPEN. STOPPED FOR GAS AND GROCERIES. GOT OUT OF EXPLORER AND WAS DIZZY, NAUSEATED AND MY HEART HURT COULDN'T THINK OF WHAT GROCERIES I NEEDED CLERK ASKED IF I WAS OK. TOLD HIM NOT SURE WHAT WAS WRONG WITH ME FIGURED IT OUT I WAS POISONED CARBON MONOXIDE
NHTSA ODI #11064645
31,500 miles · Jan 24, 2018
Unknown Or Other
THE INTERIOR OF THE CAR FILLS WITH EXHAUST SMELLS. IT IS OVERPOWERING AND HAS CAUSED NAUSEA AND HEADACHES IN MYSELF AS WELL AS MY TWO OLDER CHILDREN. I AM NOT SURE HOW IT IS AFFECTING MY 3 MONTH OLD. THE SMELL IS UNCOMFORTABLE AND THE ONLY WAY TO GET RID OF IT IS TO STOP THE CAR AND OPEN WINDOWS. IT HAPPENS WHEN VEHICLE IN MOTIO…
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THE INTERIOR OF THE CAR FILLS WITH EXHAUST SMELLS. IT IS OVERPOWERING AND HAS CAUSED NAUSEA AND HEADACHES IN MYSELF AS WELL AS MY TWO OLDER CHILDREN. I AM NOT SURE HOW IT IS AFFECTING MY 3 MONTH OLD. THE SMELL IS UNCOMFORTABLE AND THE ONLY WAY TO GET RID OF IT IS TO STOP THE CAR AND OPEN WINDOWS. IT HAPPENS WHEN VEHICLE IN MOTION AS WELL AS STATIONARY.
NHTSA ODI #11064562
Mileage unknown · Jan 20, 2018
Fuel/propulsion SystemUnknown Or Other
I BOUGHT THE 2016 FORD EXPLORER XLT LAST WEEK FROM A FORD DEALER, I DROVE IT HOME WHICH IS 35-40 MINUTES AWAY FROM THE FORD DEALERSHIP AND BOTH MY WIFE AND I HAD SEVERE HEADACHE. THERE WAS AN ODOR INSIDE THE CABIN WHICH WAS CAUSING THE HEADACHE/NAUSEA. WE COULDNT EXPLAIN WHY THE ODOR WAS THERE AND WHEN WE RESEARCHED ONLINE, WE W…
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I BOUGHT THE 2016 FORD EXPLORER XLT LAST WEEK FROM A FORD DEALER, I DROVE IT HOME WHICH IS 35-40 MINUTES AWAY FROM THE FORD DEALERSHIP AND BOTH MY WIFE AND I HAD SEVERE HEADACHE. THERE WAS AN ODOR INSIDE THE CABIN WHICH WAS CAUSING THE HEADACHE/NAUSEA. WE COULDNT EXPLAIN WHY THE ODOR WAS THERE AND WHEN WE RESEARCHED ONLINE, WE WERE SHOCKED TO FIND THAT THE FORD EXPLORER HAD THE CARBON MONOXIDE LEAK ISSUE. WE ARE NOT ABLE TO DRIVE OUR CAR FOR MORE THAN 15-20 MINUTES WITHOUT GETTING A HEADACHE.
NHTSA ODI #11063902
5,000 miles · Jan 17, 2018
EngineUnknown Or Other
VERY STRONG EXHAUST FUMES ENTERING VEHICLE AT OR ABOVE 3500 RPM. IT HAPPENS EVERY TIME ACCELERATING TO HIGHWAY SPEED. ENTIRE CAB FILLS WITH FUMES IMMEDIATELY AND DOES NOT DISAPATE UNTIL ALL WINDOWS ARE ROLLED DOWN. EXPERIENCED HEADACHES, DIZZINESS AND NAUSEA. OWNER HAD TO TRADE VEHICLE (AT THEIR EXPENSE) AS DEFECT WAS CAUSIN…
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VERY STRONG EXHAUST FUMES ENTERING VEHICLE AT OR ABOVE 3500 RPM. IT HAPPENS EVERY TIME ACCELERATING TO HIGHWAY SPEED. ENTIRE CAB FILLS WITH FUMES IMMEDIATELY AND DOES NOT DISAPATE UNTIL ALL WINDOWS ARE ROLLED DOWN. EXPERIENCED HEADACHES, DIZZINESS AND NAUSEA. OWNER HAD TO TRADE VEHICLE (AT THEIR EXPENSE) AS DEFECT WAS CAUSING DAILY HEALTH PROBLEMS. FORD NEEDS TO BE FORCED TO NOTIFY CONSUMERS ABOUT THIS PROBLEM BEFORE VEHICLE IS PURCHASED. OWNER HAD 2015 FORD EXPLORER WITH SAME PROBLEM AND WON LEMON LAW CASE AGAINST FORD - LEMON LAW ARBITRATORS SMELLED WHAT THEY DESCRIBED AS EXHAUST FUMES DURING LEMON LAW HEARING TEST DRIVE. FORD REPAIR ATTEMPTS DO NOT WORK! NHTSA AND FORD NEED TO DETERMINE FIX OR RECALL VEHICLES. EXHAUST FUMES CONTAIN CARBON MONOXIDE AS WELL AS MANY OTHER TOXIC CHEMICALS. FORD ADMITS EXHAUST FUMES ENTERING VEHICLE BUT CLAIMS LOW VOLUME/SAFE. PLEASE CONSIDER THAT INFANTS AND YOUNG CHILDREN CANNOT BE EXPOSED TO SAME CARBON MONOXIDE LEVELS AS ADULTS WITHOUT VERY SERIOUS AND LIFE THREATENING HARM. ASK A DOCTOR, NOT FORD!!!
NHTSA ODI #11063238
Mileage unknown · Dec 19, 2017
Unknown Or Other
SMELLING EXHAUST ODORS IN THE OCCUPANT COMPARTMENT. CONCERNS ABOUT EXPOSURE TO CARBON MONOXIDE. SMELL IS WORSE WHEN CAR IS STATIONARY AND WHEN HEATER IS ON.
NHTSA ODI #11055510
20,000 miles · Dec 17, 2017
EngineFuel/propulsion SystemUnknown Or OtherInjury
CAR SMELLS STRONGLY LIKE NATURAL GAS INSIDE CABIN WHEN DRIVING, AND WHEN SITTING STILL - EYES BURN, THROAT SORE, HEADACHE AFTER DRIVING IT FOR 5 MINS OR MORE.
NHTSA ODI #11055125
45,000 miles · Nov 19, 2017
Unknown Or Other
EXHAUST FUMES ARE SOME HOW LEAKING THROUGH THE CABIN. FUMES ARE MOSTLY NOTICED WHEN GETTING ON THE FREEWAY OR HARD ACCELERATION.
NHTSA ODI #11047317
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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