NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
369 reportsClear category filter23,000 miles · Jul 28, 2020
Unknown Or Other
THE TOP RAIL OF THE ROOF RACK OF THIS CAR ISN'T ATTACHED TO THE VEHICLE VERY WELL AT ALL. I JUST LOST ONE WHILE GOING DOWN THE FREEWAY. AFTER TALKING TO THE DEALERSHIP - IT SOUNDS LIKE THIS IS A PROBLEM THAT FORD IS VERY MUCH AWARE OF. THE ROOF RACK IS IN TWO PIECES AND THE TOP PIECE IS FLIMSY AND JUST SNAPS IN. WHEN AIR GOT UND…
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THE TOP RAIL OF THE ROOF RACK OF THIS CAR ISN'T ATTACHED TO THE VEHICLE VERY WELL AT ALL. I JUST LOST ONE WHILE GOING DOWN THE FREEWAY. AFTER TALKING TO THE DEALERSHIP - IT SOUNDS LIKE THIS IS A PROBLEM THAT FORD IS VERY MUCH AWARE OF. THE ROOF RACK IS IN TWO PIECES AND THE TOP PIECE IS FLIMSY AND JUST SNAPS IN. WHEN AIR GOT UNDER IT GOING DOWN THE FREEWAY - I HEARD IT POP AND REALIZED IT WAS OFF THE VEHICLE. IT'S LUCKY THAT IT DIDN'T HIT ANY OTHER CARS (OR A MOTORCYCLE!).
NHTSA ODI #11341928
52,000 miles · Jul 20, 2020
Unknown Or Other
COSMETIC PLASTIC PANELING HAS TWICE COME OFF MY VEHICLE WHILE DRIVING ON AN INTERSTATE. THE FIRST TIME IF WAS THE SILVER PLASTIC MOLDING ON THE RIGHT SIDE OF THE ROOF RACK RAILS. THE SECOND TIME IT WAS A BLACK PIECE OF MOLDING JUST AFT OF THE PASSENGER WINDOW. FOR THE FIRST INSTANCE, A SMALL PIECE OF PLASTIC BROKE DUE TO WIND PR…
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COSMETIC PLASTIC PANELING HAS TWICE COME OFF MY VEHICLE WHILE DRIVING ON AN INTERSTATE. THE FIRST TIME IF WAS THE SILVER PLASTIC MOLDING ON THE RIGHT SIDE OF THE ROOF RACK RAILS. THE SECOND TIME IT WAS A BLACK PIECE OF MOLDING JUST AFT OF THE PASSENGER WINDOW. FOR THE FIRST INSTANCE, A SMALL PIECE OF PLASTIC BROKE DUE TO WIND PRESSURE. THE SECOND INSTANCE REVEALED THAT THE PART WAS JUST GLUED ON IN TWO SPOTS. I HAVE STARTED NOTICING OTHER EXPLORERS IN GEORGIA/FLORIDA MISSING PIECES OF PLASTIC MOLDING. I BELIEVE THIS IS A MANUFACTURING PROBLEM. MY CONCERN IS IF THE PLASTIC COMES OFF AT A HIGH SPEED AND HITS A CAR BEHIND ME.
NHTSA ODI #11340441
42,000 miles · Jun 25, 2020
EngineFuel/propulsion SystemUnknown Or Other
STRONG SULPHUR SMELL ENTERS CABIN WHEN ACCELERATING. NOT A ONE-TIME EVENT. *TR
NHTSA ODI #11330876
5,000 miles · May 22, 2020
Unknown Or Other
THE VEHICLE HAS COMPLETELY SHUT DOWN WHILE IN MOTION AND WHILE PARKED ON MULTIPLE OCCASIONS. THE VEHICLE HAS ALSO HAD MULTIPLE INSTANCES WHERE IT ACCELERATES ON ITS OWN, THE MOST NOTABLE BEING WHEN IT WILL APPLY FULL ACCELERATION WHILE IN A CORNER. THIS HAS BEEN REPORTED TO BOTH THE LOCAL DEALERSHIP NETWORKS AND FORD CORPORATE W…
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THE VEHICLE HAS COMPLETELY SHUT DOWN WHILE IN MOTION AND WHILE PARKED ON MULTIPLE OCCASIONS. THE VEHICLE HAS ALSO HAD MULTIPLE INSTANCES WHERE IT ACCELERATES ON ITS OWN, THE MOST NOTABLE BEING WHEN IT WILL APPLY FULL ACCELERATION WHILE IN A CORNER. THIS HAS BEEN REPORTED TO BOTH THE LOCAL DEALERSHIP NETWORKS AND FORD CORPORATE WITH NO WILLINGNESS TO DOCUMENT THE ISSUES OR INVESTIGATE. THE DATE OF FIRST INSTANCE HAS BEEN NOTATED BELOW. THIS VEHICLE HAS BEEN PARKED DUE TO THESE SAFETY CONCERNS AND REPLACED PRIOR TO LEASE EXPIRATION. *TR
NHTSA ODI #11325608
5 miles · Apr 22, 2020
SteeringUnknown Or OtherVehicle Speed Control
AS I WAS DRIVING THE EXPLORER THE CROSS TRAFFIC ALERT SENSORS WENT HAYWARE, THEN THE NAVIGATOR, RADIO, HVAC, AND EVERYTHING ELSE FROZE DID COMMANDS ON ITS OWN. THE PART ASSIST MODE CAME ON IT OWN, STEERING WHEEL CONTROLS WOULD NOT WORK AND CAR STARTED TO TAKE CONTROL. VERY SCARY AS THE CAR WAS TAKING COMMANDS I COULD NOT CONTROL…
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AS I WAS DRIVING THE EXPLORER THE CROSS TRAFFIC ALERT SENSORS WENT HAYWARE, THEN THE NAVIGATOR, RADIO, HVAC, AND EVERYTHING ELSE FROZE DID COMMANDS ON ITS OWN. THE PART ASSIST MODE CAME ON IT OWN, STEERING WHEEL CONTROLS WOULD NOT WORK AND CAR STARTED TO TAKE CONTROL. VERY SCARY AS THE CAR WAS TAKING COMMANDS I COULD NOT CONTROL. TOOK IT TO THE LOCAL FORD DEALER WHERE IT WAS DETERMINED TO BE THE ACCESSORY PROTOCOL INTERFACE MODULE (APIM). MY VEHICLE IS JUST OUT OF WARRANTY AND FORD MOTOR COMPANY WOULD NOT HELP. VERY DANGEROUS, COST ME $1,200. FORD HAD THIS SAME PROBLEM ON EARLIER MODELS AND RECALLED, BUT NOT ON MINE. THIS FAILURE NEED TO BE ADDRESSED AND IF NOT FIXED COULD LEAD TO A SERIOUS ACCIDENT. FORD NEEDS TO ISSUE A RECALL. FORD WAS NO HELP TO ME, VERY DISAPPOINT IN FORD AND THEIR NEGLECT TO MINE AND MY FAMILIES STAFEY.
NHTSA ODI #11321932
Mileage unknown · Mar 20, 2020
Unknown Or Other
EXHAUST COMES INTO CABIN WHEN AC IS ON
NHTSA ODI #11318781
Mileage unknown · Mar 10, 2020
Unknown Or OtherInjury
I WAS SITTING IN THE DRIVERS SEAT AND DROPPED MY BELT CLIP FOR MY CELL PHONE BETWEEN THE DRIVERS SEAT AND THE CENTER CONSOLE. I REACHED BETWEEN THE DRIVERS SEAT AND CENTER CONSOLE TO RETRIEVE MY BELT CLIP AND AS I BROUGHT MY HAND BACK UP THE BRACKET THE SEAT IS ATTACHED TO SLICED THE SIDE OF MY HAND/THUMB OPEN. BLOOD SHOT OUT IM…
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I WAS SITTING IN THE DRIVERS SEAT AND DROPPED MY BELT CLIP FOR MY CELL PHONE BETWEEN THE DRIVERS SEAT AND THE CENTER CONSOLE. I REACHED BETWEEN THE DRIVERS SEAT AND CENTER CONSOLE TO RETRIEVE MY BELT CLIP AND AS I BROUGHT MY HAND BACK UP THE BRACKET THE SEAT IS ATTACHED TO SLICED THE SIDE OF MY HAND/THUMB OPEN. BLOOD SHOT OUT IMMEDIATELY SO I DROVE TO THE EMERGENCY ROOM WHERE I RECEIVED SEVERAL STITCHES.
NHTSA ODI #11317234
15,000 miles · Mar 4, 2020
Unknown Or Other
TL* THE CONTACT OWNED A 2017 FORD EXPLORER. THE CONTACT STATED WHILE TESTING THE VEHICLE WITH AN ELECTROMAGNETIC READING DEVICE, HE NOTICED A HIGH LEVEL ELECTROMAGNETIC RADIATION. THE VEHICLE WAS TAKEN TO LEBANON FORD LOCATED AT (770 COLUMBUS AVE, LEBANON, OH 45036), WERE THE DEALER WAS MADE AWARE OF THE FAILURE. THE VEHICLE H…
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TL* THE CONTACT OWNED A 2017 FORD EXPLORER. THE CONTACT STATED WHILE TESTING THE VEHICLE WITH AN ELECTROMAGNETIC READING DEVICE, HE NOTICED A HIGH LEVEL ELECTROMAGNETIC RADIATION. THE VEHICLE WAS TAKEN TO LEBANON FORD LOCATED AT (770 COLUMBUS AVE, LEBANON, OH 45036), WERE THE DEALER WAS MADE AWARE OF THE FAILURE. THE VEHICLE HAD BEEN DIAGNOSED BUT NOT REPAIRED. THE MANUFACTURER INFORMED OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 15,000.*DT*JB*DT*JB
NHTSA ODI #11316071
17,300 miles · Jan 30, 2020
Unknown Or OtherFire
WE WERE DRIVING FORWARD ON THE INTERSTATE WHEN THE CAR LOST POWER, A WRENCH LOGO APPEARED ON THE DASH DISPLAY, THEN WE COASTED THE CAR TO A STOP AT THE LEFT SIDE OF THE ROAD. THEN WE SMELLED SMOKE, SAW FLAMES FLICKERING UP FROM THE HOOD, VACATED THE VEHICLE AND CALLED 911 AS THE FRONT OF THE CAR UNDER THE HOOD BURST INTO FLAMES.…
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WE WERE DRIVING FORWARD ON THE INTERSTATE WHEN THE CAR LOST POWER, A WRENCH LOGO APPEARED ON THE DASH DISPLAY, THEN WE COASTED THE CAR TO A STOP AT THE LEFT SIDE OF THE ROAD. THEN WE SMELLED SMOKE, SAW FLAMES FLICKERING UP FROM THE HOOD, VACATED THE VEHICLE AND CALLED 911 AS THE FRONT OF THE CAR UNDER THE HOOD BURST INTO FLAMES. THE CAR WAS QUICKLY ENGULFED IN FLAMES. CITY POLICE ARRIVED TO CONTROL TRAFFIC AWAY FROM OUR BURNING CAR, AND THEN THE FIRETRUCK AND FIREFIGHTERS ARRIVED AND PUT OUT THE FIRE. THE CAR WAS TOWED AWAY ON A FLATBED.
NHTSA ODI #11306139
83,200 miles · Dec 18, 2019
Unknown Or Other
VERY STRONG ODOR OF EXHAUST FUMES INSIDE CABIN. I WAS USING THE CAR'S AUTOMATIC START FEATURE AND WHEN I GOT IN CAR TO DRIVE KIDS TO SCHOOL, YOU COULD SMELL EXHAUST THROUGHOUT CAR. JUST RECENTLY PURCHASED CAR AND NOTICED THIS ISSUE ON 2ND DAY OF OWNERSHIP. WHEN DRIVING ON HIGHWAY ODOR SEEMS TO GO AWAY BUT IF YOU STOP AT A LIGHT …
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VERY STRONG ODOR OF EXHAUST FUMES INSIDE CABIN. I WAS USING THE CAR'S AUTOMATIC START FEATURE AND WHEN I GOT IN CAR TO DRIVE KIDS TO SCHOOL, YOU COULD SMELL EXHAUST THROUGHOUT CAR. JUST RECENTLY PURCHASED CAR AND NOTICED THIS ISSUE ON 2ND DAY OF OWNERSHIP. WHEN DRIVING ON HIGHWAY ODOR SEEMS TO GO AWAY BUT IF YOU STOP AT A LIGHT OR ARE IN SLOW MOVING TRAFFIC, FUMES QUICKLY BUILD UP AGAIN.
NHTSA ODI #11289791
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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