NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
2,449 reports97,000 miles · Aug 13, 2025
Steering
The contact owns a 2016 Ford Explorer. The contact stated that the vehicle lost power steering assist functionality, and the steering wheel was stuck while attempting to turn the steering wheel to the left or the right. There were no warning lights illuminated. The contact spoke with the dealer and was informed that the power st…
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The contact owns a 2016 Ford Explorer. The contact stated that the vehicle lost power steering assist functionality, and the steering wheel was stuck while attempting to turn the steering wheel to the left or the right. There were no warning lights illuminated. The contact spoke with the dealer and was informed that the power steering assist had failed and needed to be repaired. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 97,000.
NHTSA ODI #11680362
Mileage unknown · Aug 12, 2025
Structure
I am writing to you today with an urgent and serious safety concern regarding my 2016 Ford Explorer XLT. My vehicle is affected by the A-pillar molding inspection recall, Campaign 24S02/24V031. Last week, while I was driving on the interstate, the passenger side A-pillar molding detached from my vehicle and flew off. This creat…
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I am writing to you today with an urgent and serious safety concern regarding my 2016 Ford Explorer XLT. My vehicle is affected by the A-pillar molding inspection recall, Campaign 24S02/24V031. Last week, while I was driving on the interstate, the passenger side A-pillar molding detached from my vehicle and flew off. This created an extreme safety hazard for myself and other drivers on the road. I contacted my local Ford dealership, Cloninger Ford of Salisbury, to have the recall addressed. They informed me that they cannot perform the repair because the necessary part is out of stock. This is a critical safety issue. The driver's side A-pillar molding is also loose and could detach at any time, posing the same risk. I have found the replacement part is available for purchase from various online retailers, which contradicts the dealership's claim of part unavailability. The recall documentation states that a detached trim piece can become a road hazard, increasing the risk of a crash. Given that this has already occurred with my vehicle, I need an immediate and concrete solution. I am requesting a specific timeframe for when a permanent remedy will be available for recall 24S02/24V031 and when I can bring my vehicle in for the repair. The safety of myself and others on the road is at risk. Thank you for your prompt attention to this matter. [XXX] [XXX] [XXX] VIN: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11680239
65,000 miles · Aug 11, 2025
Structure
The contact owns a 2016 Ford Explorer. The contact stated while driving at various speeds, the driver's side exterior A-pillar trim was hanging off the windshield, obstructing the contact's view while driving. The contact stated that condensation was entering the vehicle through the driver's side exterior A-pillar trim, also obs…
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The contact owns a 2016 Ford Explorer. The contact stated while driving at various speeds, the driver's side exterior A-pillar trim was hanging off the windshield, obstructing the contact's view while driving. The contact stated that condensation was entering the vehicle through the driver's side exterior A-pillar trim, also obstructed her view while driving. The contact later received notifications of NHTSA Campaign Numbers: 24V031000 (Structure) and 25V347000 (Structure); however, the parts to do the recall repairs were not yet available. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was made aware of the failure but offered no assistance. The failure mileage was approximately 65,000.
NHTSA ODI #11679920
Mileage unknown · Aug 11, 2025
Structure
The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (STRUCTURE); however, the part to do the recall repair was unavailable. The contact used tape to secure A-pillar trim to prevent the trim from detaching from the vehicle. The contact stated that the manufacturer had excee…
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The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (STRUCTURE); however, the part to do the recall repair was unavailable. The contact used tape to secure A-pillar trim to prevent the trim from detaching from the vehicle. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure.
NHTSA ODI #11679908
Mileage unknown · Aug 11, 2025
Structure
2016 Ford Explorer. A-Pillar trim piece flew off vehicle while driving on highway. Part recalled Jan 2024, currently no solution available from Ford. Paid out of pocket to replace in 2022. B-Pillar trim piece flew off vehicle while driving on highway, remained attached by soldered wires. Part recalled May 2025, currently no so…
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2016 Ford Explorer. A-Pillar trim piece flew off vehicle while driving on highway. Part recalled Jan 2024, currently no solution available from Ford. Paid out of pocket to replace in 2022. B-Pillar trim piece flew off vehicle while driving on highway, remained attached by soldered wires. Part recalled May 2025, currently no solution available from Ford. Paid out of pocket to replace heavy duty, waterproof double sided tape in Jan 2025, tape failed again by July ‘25. Cannot tie piece on because the window won’t function. Tape fails, so currently having to reattach while driving with my arm out the window or pull over every few minutes and drive slowly. Left with no options to repair from Ford!
NHTSA ODI #11679858
Mileage unknown · Aug 11, 2025
Unknown Or Other
I was made aware of a recall for my 2016 Ford Explorer Sport involving the Exterior A-Pillar Appliqué molding recall#24S02 and NHTSA# 24V031 I had an inspection done on 12/30/24 and it was determined at that time it needed to be replaced, but parts were not yet available. I have since then regularly checked with the dealership…
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I was made aware of a recall for my 2016 Ford Explorer Sport involving the Exterior A-Pillar Appliqué molding recall#24S02 and NHTSA# 24V031 I had an inspection done on 12/30/24 and it was determined at that time it needed to be replaced, but parts were not yet available. I have since then regularly checked with the dealership to see if parts were available, but they have not become available. I reached out to Ford directly on 7/28/25 and was told my case was escalated and I need to work with my 'case handler' who did not contact me until 8/11/25 after I made multiple repeated requests to speak to someone. They informed me there are no parts, there is no ETA and despite assurances to the contrary(they informed me that they "...works daily with your dealership's management team." have not spoken to the service advisor at the dealership as of yet. their case number at ford is [XXX] The part flew off on the highway on [XXX] and now today, [XXX] the rubber around the windshield is coming loose. Ford continues to say they have no updates. The dealership said the last they checked, last week, there were over 30,000 orders in for this part, that Ford was no longer accepting new orders from dealers for this, and that they will not give any ETA on this being remedied. I'm concerned that more damage is being done to my vehicle and based on Ford's behavior thus far will try to not cover any additional repairs that caused by their inability to provide a repair in a reasonable and timely fashion. I'd like this repaired, correctly, and any other repairs necessary due to the delay, by no later than the end of the month of August. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11679845
115,000 miles · Aug 11, 2025
Structure
The contact owns a 2016 Ford Explorer. The contact stated that the passenger’s side A-pillar trim was loose. The contact used glue to secure the trim piece. The contact had not taken the vehicle to a dealer. The contact had received notification of NHTSA Campaign Number: 24V031000 (Structure) and 25V347000 (Structure); however, …
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The contact owns a 2016 Ford Explorer. The contact stated that the passenger’s side A-pillar trim was loose. The contact used glue to secure the trim piece. The contact had not taken the vehicle to a dealer. The contact had received notification of NHTSA Campaign Number: 24V031000 (Structure) and 25V347000 (Structure); however, after calling the dealer to schedule an appointment, the contact was informed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not informed of the failure. The failure mileage was approximately 115,000.
NHTSA ODI #11679832
120,000 miles · Aug 11, 2025
Structure
The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that while driving at an undisclosed speed, the front driver’s side and passenger’s side A-pillar trims detached. The local …
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The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that while driving at an undisclosed speed, the front driver’s side and passenger’s side A-pillar trims detached. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 120,000.
NHTSA ODI #11679757
Mileage unknown · Aug 10, 2025
Unknown Or Other
The water pump has been replaced 3 times within a 2 year period on this vehicle . Something is causing it to fail and the constant leaking of fluid causes the vehicle to drive erratically in highway traffic. The alternator has been replaced twice within a 10 month period. Something is causing it to fail and it has caused major a…
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The water pump has been replaced 3 times within a 2 year period on this vehicle . Something is causing it to fail and the constant leaking of fluid causes the vehicle to drive erratically in highway traffic. The alternator has been replaced twice within a 10 month period. Something is causing it to fail and it has caused major anxiety because the vehicle has completely turned off in the middle of extreme traffic. This is a dangerous situation and has yet to be fully remedied. I believe this model to be a lemon.
NHTSA ODI #11679633
53,000 miles · Aug 8, 2025
Structure
The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, the A-pillar trim on both sides of the windshield started to detach. The contact also stated that the B-pillar trim on the driver's side started to detach. The contact received notification of NHTSA Campaign Numbers: 24V031000 (…
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The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, the A-pillar trim on both sides of the windshield started to detach. The contact also stated that the B-pillar trim on the driver's side started to detach. The contact received notification of NHTSA Campaign Numbers: 24V031000 (Structure) and 25V347000 (Structure). The vehicle was taken to the dealer, but was not diagnosed or repaired. The dealer confirmed that parts were not yet available. The manufacturer was not made aware of the failure. The approximate failure mileage was 53,000.
NHTSA ODI #11679385
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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