NHTSA owner reports · September 18, 2026 snapshot.
Forward Collision Avoidance complaints
9 reportsClear category filterMileage unknown · Aug 31, 2026
Air BagsBack Over PreventionForward Collision Avoidance
Benoit Nissan in DeRidder, LA, was contracted to perform a critical safety repair/recall on my vehicle's airbag system. The dealership charged for the completed repair, but explicitly aborted the physical installation, leaving the vehicle's Supplemental Restraint System (SRS) incomplete, non-functional, and hazardous. They attem…
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Benoit Nissan in DeRidder, LA, was contracted to perform a critical safety repair/recall on my vehicle's airbag system. The dealership charged for the completed repair, but explicitly aborted the physical installation, leaving the vehicle's Supplemental Restraint System (SRS) incomplete, non-functional, and hazardous. They attempted to return the vehicle to me with the air bag safety system compromised, creating an immediate, severe physical risk to occupants in the event of a crash. This involves deliberate service manipulation of a federally mandated safety device. They have a proven record of deceitful operations of criminal negligence and felony theft
NHTSA ODI #11760842
Mileage unknown · Apr 1, 2023
EngineForward Collision AvoidanceCrashInjury
My suv begin to run hot and instantly water begins to boil and I was trying to pull off the road immediately.with no warning from the forward collision as a car hit me. Got a quote from many dealerships or mechanics who says that the water pump failed and is a common problem with my suv and it quoted 2500 with a two week time fr…
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My suv begin to run hot and instantly water begins to boil and I was trying to pull off the road immediately.with no warning from the forward collision as a car hit me. Got a quote from many dealerships or mechanics who says that the water pump failed and is a common problem with my suv and it quoted 2500 with a two week time frame because the water pump is built inside the engine no one wants to work on it due to risk. Help!
NHTSA ODI #11514894
Mileage unknown · Oct 12, 2022
Electrical SystemForward Collision AvoidanceLane DepartureFire
We had an issue with Fuse 34, it popped and sent warning lights to the dash regarding safety systems and sensors, as well as the cameras in front and back stopped working. We replaced the fuse and it held for a while, but then popped again. I noticed a lamp flickering one day on the front of the vehicle, and upon further inspe…
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We had an issue with Fuse 34, it popped and sent warning lights to the dash regarding safety systems and sensors, as well as the cameras in front and back stopped working. We replaced the fuse and it held for a while, but then popped again. I noticed a lamp flickering one day on the front of the vehicle, and upon further inspection saw that the front camera and wiring harness had started on fire. The wiring harness is fully melted and there are signs of smoke and fire damage on the front of the car. I took the vehicle to a Ford dealer who confirmed their wiring harness had failed, but will not take responsibility for the issue. The care only has about 45k miles on it. I called to their corporate office who also rejected any liability. Obviously this is more than just the money for repairs, but a safety hazard that they will not respond to.
NHTSA ODI #11488957
Mileage unknown · Aug 16, 2022
Forward Collision AvoidanceService BrakesCrash
On freeway, pushed brakes but vehicle did not stop or slow down resulting in multi car rear end collision. Auto braking and ABS features did not engage. Vehicle was towed and our insurance agent claim adjuster recommended we reach out to you. No warning lamps, messages, etc. went off at the time or had gone off previously.
NHTSA ODI #11479574
Mileage unknown · Aug 4, 2022
Electrical SystemForward Collision AvoidanceStructure
Our model is a platinum explorer with the panoramic sunroof. Apparently there is a sunroof leak which due to the way the headliner is made , fills the headliner (holds like a bowl) then either spills out at the front of the vehicle or rear depending on going forward , reverse, accelerating, braking, uphill, or downhill etc. …
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Our model is a platinum explorer with the panoramic sunroof. Apparently there is a sunroof leak which due to the way the headliner is made , fills the headliner (holds like a bowl) then either spills out at the front of the vehicle or rear depending on going forward , reverse, accelerating, braking, uphill, or downhill etc. The front is worse because of the electrical in the overhead lights, sunroof motors, and lane departure at the rear view mirror. Also everything electronic below on the dashboard and center console. There are high expenses related to replacing these electronics due to water damage in addition to the driver being suddenly started by a wave of water crashing down on them while accelerating or braking.
NHTSA ODI #11477591
Mileage unknown · Jul 2, 2022
Forward Collision AvoidanceSteering
April 5th 2022 I took my 2017 ford explorer limited to City Ford here in Columbia City Indiana because the steering was sticking. It had been sticking slightly at times for several weeks prior to this. They couldn't find any problem. So in June 2022 my wife and I load up and leave for Virginia for vacation. The slight sticking g…
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April 5th 2022 I took my 2017 ford explorer limited to City Ford here in Columbia City Indiana because the steering was sticking. It had been sticking slightly at times for several weeks prior to this. They couldn't find any problem. So in June 2022 my wife and I load up and leave for Virginia for vacation. The slight sticking got worse after several hours on the road, and finally the driver assist went out completely. making it most difficult to steer. A dangerous situation. Also I had no hill descent, no 4 wheel drive, park assist, cruise control. A multitude of warnings. I took it to Barton Ford in Suffolk Va. and was told it needed a rack and pinion steering which cost me over $3100.00 and over $600.00 for a rental during the time it took to complete the job. I noticed that I was charged for new bolts also. I researched and found that there was a previous recall on a select few of these explorers due to bolt failure. My explorer should have been selected, but there is no open recall on this explorer. Barton Ford told me that my vehicle wasn't effected by the recall. I believe Ford Motor Company should reimburse me for what it cost me.
NHTSA ODI #11472103
Mileage unknown · Jul 8, 2021
EngineForward Collision AvoidanceUnknown Or Other
Initially the cars check engine light came on intermittently for about 3 days, then one day while driving the wrench light came on and the car immediately started decelerating - almost as if I was breaking hard, and would not accelerate over 30. After turning it on and off multiple times the light went away for days until my app…
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Initially the cars check engine light came on intermittently for about 3 days, then one day while driving the wrench light came on and the car immediately started decelerating - almost as if I was breaking hard, and would not accelerate over 30. After turning it on and off multiple times the light went away for days until my appointment with the mechanic, that same day it came back on. We went to a Ford dealership and they said it was the throttle body and repaired it. Two weeks later the same issue occurred. I know this was a big issue in 2016 and earlier models, I believe the problem was never fixed in 2017 models. Our car is currently in the shop and they are "emailing Ford" about what to do. The first incident I was on the interstate when I stopped abruptly and the second was on the highway. I luckily had no one behind me both times otherwise this could've easily caused an accident.
NHTSA ODI #11423908
50,519 miles · Mar 16, 2021
Forward Collision AvoidanceSteering
WE BOUGTH THE CAR ON AUGUST 2019 WITH 4700 MILES. IN NOVEMBER 2019 THE CAR STARTED OCCASIONALLY (3 TIMES DURING 3 MONTH PERIOD) TO SOUND THE REVERSE ALARM SENSOR WHILE DRIVING. THEN CAR DIDN'T START, SO WE CHANGED THE BATTERY. IN MID MARCH, AFTER TAKING MY 3 KIDS (OUR DAUGHTER 6 AND THE TWINS WERE 2) TO THE PARK, THE CAR WILL …
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WE BOUGTH THE CAR ON AUGUST 2019 WITH 4700 MILES. IN NOVEMBER 2019 THE CAR STARTED OCCASIONALLY (3 TIMES DURING 3 MONTH PERIOD) TO SOUND THE REVERSE ALARM SENSOR WHILE DRIVING. THEN CAR DIDN'T START, SO WE CHANGED THE BATTERY. IN MID MARCH, AFTER TAKING MY 3 KIDS (OUR DAUGHTER 6 AND THE TWINS WERE 2) TO THE PARK, THE CAR WILL START BUT THE STEERING WHEEL WAS NOT TURNING. IT WAS JUST STOCK AND HARD TO MOVE. WE ARE SO GRATEFUL THAT THIS DIDN'T HAPPEN WHILE DRIVING. WE COULDN'T TAKE IT TO THE DEALER BECAUSE OF THE PANDEMIC (WE DIDN'T WANTED TO EXPOSED OURSELVES TO ANY OTHER PEOPLE). FINALLY IN SEPTEMBER, THE CAR WAS TOWED TO THE DEALER. THEY CALLED THE FOLLOWING DAY AND EXPLAINED THAT TO REPAIR WILL COST US $ 1790. PLUS OTHER REGULAR ITEMS THAT NEEDED TO BE DONE FOR A TOTAL OF $2098. WHILE I DO UNDERSTAND THAT MANUFACTURING ERRORS DO HAPPEN, STILL I CAN'T COMPREHEND THE FACT THAT THE CAR IS 50519 MILES AND ALREADY NEEDS THESE EXPENSIVE REPAIRS THAT COULD HAVE CAUSE A VERY DANGEROUS ACCIDENT TO MY FAMILY. THIS IS OUR FAMILY CAR! I DRIVE MY KIDS TO SCHOOL AND TO THE PARK EVERY DAY. HOW COME SOMETHING THIS SERIOUS IS NOT PUT ON A TEST BEFORE PUTTING A CAR INTO THE MARKET (?). BUT, MORE THAN BEING VERY DISAPPOINTED AND SHOCKED FROM WHAT HAPPENED AND I FIND THE SITUATION VERY IRRITATING. NEW CARS SIMPLY DON'T DO THAT. I WOULD LIKE TO PLEASE HELP ME UNDERSTAND WHAT HAPPENED TO OUR FAMILY CAR AND I WOULD LIKE FOR YOU TO ENSURE THIS WONT HAPPEN AGAIN, I AM SCARED OF DRIVING MY FAMILY IN THE CAR AND EXPOSE THEM TO SOMETHING LIKE WHAT HAPPENED. IS THERE A RECALL FOR THIS? SHALL WE GIVE WARNING TO OTHER CAR OWNERS? THIS IS VERY DANGEROUS!
NHTSA ODI #11403228
21,000 miles · Jan 3, 2021
Forward Collision AvoidanceLane DepartureWheels
LAST NIGHT ONE OF MY HANKOOK S1 NOBLE ON MY 2017 FORD EXPLORER BLEW OUT WHILE DRIVING ON THE 405 FREEWAY AND REQUIRED ME TO PULL OVER AND CHANGE THE TIRE. AT 21,000 MILES ON THE VEHICLE/ TIRES THE MECHANIC SHOP TOLD ME THE TIRES WERE BASICALLY BALD AND HAD RUBBER EVENLY ERODING (WHICH INDICATES NOT AN ALIGNMENT ISSUE). THE TIRES…
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LAST NIGHT ONE OF MY HANKOOK S1 NOBLE ON MY 2017 FORD EXPLORER BLEW OUT WHILE DRIVING ON THE 405 FREEWAY AND REQUIRED ME TO PULL OVER AND CHANGE THE TIRE. AT 21,000 MILES ON THE VEHICLE/ TIRES THE MECHANIC SHOP TOLD ME THE TIRES WERE BASICALLY BALD AND HAD RUBBER EVENLY ERODING (WHICH INDICATES NOT AN ALIGNMENT ISSUE). THE TIRES WERE ALSO ROTATED AND SUPPOSED TO LAST 50,000 MILES. THERE ARE ALSO MANY OTHER COMPLAINS ON THESE TIRES THROUGHOUT THE INTERNET BUT NOT RECALL HAS BEEN INITIATED BY HANKOOK. THEY HAVE ADVISED THEY WILL GIVE A PRO-RATED DISCOUNT ON NEW TIRES, WHICH IS COMPLETELY UNREASONABLE AND NEGLIGENT..
NHTSA ODI #11386317
Official recalls
13Jul 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.
Feb 20, 2026
Ford Motor Company (Ford) is recalling certain 2017-2019 Explorer vehicles. The rear suspension toe links 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: Dealers will replace the toe links, free of charge. Owner notification letters were mailed on March 16, 2026. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 26S08. This recall is an expansion of previous NHTSA recall number 21V537. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning February 25, 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.
Sep 11, 2019
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer vehicles equipped with power front seats. The seat frames may have sharp edges.
Consequence & remedy
Consequence: Occupants my contact the sharp edges when reaching between the power front seat and center console, increasing their risk of injury.
Remedy: Ford will notify owners, and dealers will install protective tape on the exposed inside edge and tab of the power seat frames, free of charge. The recall began November 8, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S29.
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.
Aug 28, 2017
Ford Motor Company (Ford) is recalling certain 2017 Explorer, Taurus and Police Interceptor Utility and Sedan vehicles. The steering gear heat shield fasteners may corrode, allowing the heat shield to detach.
Consequence & remedy
Consequence: If the heat shield detaches, the steering gear may overheat, increasing the steering effort required by the driver, especially at lower speeds, and increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers to inspect and replace the heat shield fasteners as needed, free of charge. The recall began on September 13, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S23.
May 22, 2017
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence & remedy
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Additional source detail variants (2)
Seats:front Assembly:recliner
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Seats
Ford Motor Company (Ford) is recalling certain 2017 Ford Explorer, F-150, F-250, F-350, F-450 and F-550 vehicles equipped with a manual driver's seat back recliner mechanism. In the event of a crash, the seat back frame may not restrain the occupant due to having inadequate welds. As such, these vehicles may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202a, "Head Restraints" and 207, "Seating Systems."
Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased 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 began on June 7, 2017. Owners may contact Ford at 1-866-436-7332. Ford's number for this recall is 17C08.
Dec 22, 2016
Ford Motor Company (Ford) is recalling certain model year 2016 Ford Taurus, 2016-2017 Ford Flex, Lincoln MKT, 2017 Ford Explorer and Ford Explorer Police Interceptor Utility vehicles equipped with 3.5L GTDI engines. Improperly brazed turbocharger oil supply tubes may leak oil on engine components.
Consequence & remedy
Consequence: An oil leak, in the presence of an ignition source, increases the risk of a fire.
Remedy: Ford will notify owners, and dealers will inspect, and if necessary, replace the turbocharger oil supply tubes, free of charge. The recall began on January 31, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S46.
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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