NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
369 reportsClear category filter11,000 miles · Jan 27, 2018
Unknown Or Other
I AM CURRENTLY PULLED OVER IN A PARKING LOT. DIZZY, JUST VOMITED, BLURRY VISION. I AM STANDING BESIDE MY VEHICLE TO GET FRESH AIR. I HAVE BEEN IN MY VEHICLE FOR 3 HOURS DRIVING AND STARTED GETTING A HEADACHE THEN IT GOT WORSE. I REMEMBERED THE NEWS ABOUT CARBON MONOXIDE AND I'M SCARED TO GET BACK IN MY VEHICLE. I AM STARTING TO…
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I AM CURRENTLY PULLED OVER IN A PARKING LOT. DIZZY, JUST VOMITED, BLURRY VISION. I AM STANDING BESIDE MY VEHICLE TO GET FRESH AIR. I HAVE BEEN IN MY VEHICLE FOR 3 HOURS DRIVING AND STARTED GETTING A HEADACHE THEN IT GOT WORSE. I REMEMBERED THE NEWS ABOUT CARBON MONOXIDE AND I'M SCARED TO GET BACK IN MY VEHICLE. I AM STARTING TO FEEL BETTER WITH FRESH AIR. I BELIEVE MY VEHICLE HAS A LEAK.
NHTSA ODI #11065429
Mileage unknown · Jan 26, 2018
Unknown Or Other
HEADACHES AND NAUSEA, BLURRED VISION, DRIVING AN HOUR A DAY TO WORK AT HIGHWAY SPEEDS.
NHTSA ODI #11065011
5,000 miles · Jan 24, 2018
Unknown Or Other
STRONG SMELL OF EXHAUST INSIDE THE CABIN. VEHICLE HAS BEEN BACK TO FORD THREE TIMES AND HAS MODIFICATIONS COMPLETED BUT HAS NOT CORRECTED THE PROBLEM. IT HAPPENS MORE AT HIGHWAY SPEED WITH THE AIR ON RECIRCULATE. THE LAT TIME I PICKED IT UP FROM THE DEALER I WAS TOLD TO NOT PUT IT ON RECIRCULATE WHICH IS NOT UP TO MY STANDARD AS…
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STRONG SMELL OF EXHAUST INSIDE THE CABIN. VEHICLE HAS BEEN BACK TO FORD THREE TIMES AND HAS MODIFICATIONS COMPLETED BUT HAS NOT CORRECTED THE PROBLEM. IT HAPPENS MORE AT HIGHWAY SPEED WITH THE AIR ON RECIRCULATE. THE LAT TIME I PICKED IT UP FROM THE DEALER I WAS TOLD TO NOT PUT IT ON RECIRCULATE WHICH IS NOT UP TO MY STANDARD AS I PAID $30K FOR THE VEHICLE I SHOULD BE ABLE TO USE IT AS I WANT. I HAVE A THREE YEAR OLD DAUGHTER AND IT IS PRIMARILY DRIVEN BY MY WIFE. THIS IS UNACCEPTABLE AND WOULD LIKE A NEW VEHICLE AT THIS POINT. THEY TOLD ME THEY CANNOT TEST THIS AS THEY DO NOT DRIVE THE VEHICLES ON THE HIGHWAY AND IT DOESN'T HAPPEN IN THEIR PARKING LOT.
NHTSA ODI #11064729
7,200 miles · Jan 23, 2018
Unknown Or Other
SCOTT PETERSON MOTORS OF STURGIS COMPLETED THE 17N03 SERVICE ON THIS VEHICLE IN ORDER TO REPAIR THE PROBLEM OF EXHAUST ODOR IN THE CABIN. HOWEVER THE INTERMITTENT EXHAUST ODOR IS STILL PRESENT. ALSO TURNED ON A CO METER AND GOT A READING OF 114 PPM OF CO WHILE DRIVING. SURPRISING THAT WE GOT SUCH A HIGH READING AT A TIME WHEN…
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SCOTT PETERSON MOTORS OF STURGIS COMPLETED THE 17N03 SERVICE ON THIS VEHICLE IN ORDER TO REPAIR THE PROBLEM OF EXHAUST ODOR IN THE CABIN. HOWEVER THE INTERMITTENT EXHAUST ODOR IS STILL PRESENT. ALSO TURNED ON A CO METER AND GOT A READING OF 114 PPM OF CO WHILE DRIVING. SURPRISING THAT WE GOT SUCH A HIGH READING AT A TIME WHEN WE DID NOT SMELL THE EXHAUST ODOR AT THAT TIME. WIFE STILL HAS A HEADACHE ALL DAY LONG AFTER GETTING THE INTERMITTENT EXHAUST ODOR IN THE CABIN DURING DRIVING IN TOWN.
NHTSA ODI #11064502
10,000 miles · Jan 23, 2018
Unknown Or Other
NOXIOUS EXHAUST FUMES ARE POURING INTO THE CABIN OF THE VEHICLE WHENEVER THE HEAT OR A/C IS RUNNING AND ARE PARTICULARLY NOTICEABLE WHEN THE VEHICLE IS IN MOTION. NOXIOUS FUMES ARE DETECTABLE BY HUMAN SENSE OF SMELL, AND THE NOXIOUS FUMES INCREASE IN VOLUME AS THE VEHICLE INCREASES IN SPEED.
NHTSA ODI #11064334
306 miles · Jan 23, 2018
Unknown Or Other
VEHICLE IS TWO MONTHS OLD. SINCE PICKUP VEHICLE HAS HAD A SMELL OF ROTTEN EGGS. MORE RECENTLY, I'VE BEEN GETTING A REVERB SOUND (LIKE ONE WINDOW IS CRACKED) WHICH I CAN FEEL IS DUE TO A POOR SEAL ON THE DRIVERS DOOR. WHEN IT WAS VERY COLD HERE WITH 40MPH WINDS I ACTUALLY FELT WIND COME IN THE DOOR-SEAL. WHILE THE ROTTEN EGG SMEL…
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VEHICLE IS TWO MONTHS OLD. SINCE PICKUP VEHICLE HAS HAD A SMELL OF ROTTEN EGGS. MORE RECENTLY, I'VE BEEN GETTING A REVERB SOUND (LIKE ONE WINDOW IS CRACKED) WHICH I CAN FEEL IS DUE TO A POOR SEAL ON THE DRIVERS DOOR. WHEN IT WAS VERY COLD HERE WITH 40MPH WINDS I ACTUALLY FELT WIND COME IN THE DOOR-SEAL. WHILE THE ROTTEN EGG SMELL SUBSIDED, I GET AN EXHAUST FUME SMELL WHEN PARKED NEAR BUILDING REAR-WAYS IN, SUCH AS WHEN I PURCHASED THE CAR AND IT WAS REVERSED AGAINST STEPS. THE SMELL OF THE EXHAUST FUMES FILLS THE CABIN CAUSING A HEADACHE AND HAVING TO CRACK THE WINDOWS TO AVOID THE SMELL. I'VE BEEN AVOIDING DRIVING THE CAR, WILL BE CALLING FORD SOON TO CHECK FOR A FIX FOR THIS. BRAND NEW 2017 FORD EXPLORER SPORT AND EXHAUST FUMES FILLING THE CABIN, EVEN WITH CIRCULATION SELECTED, SO IT SHOULDN'T BE BRINGING OUTSIDE AIR IN. FURTHER A POOR SEAL / FITMENT OF THE DRIVERS SIDE DOOR, POSSIBLY ADDING TO THIS ISSUE?
NHTSA ODI #11064307
Mileage unknown · Jan 18, 2018
Unknown Or Other
SINCE I PURCHASED THE CAR I NOTICED A FOUL SMELL ON THE INTERIOR. IT SMELLS LIKE ROTTEN EGGS. NOW THAT IT IS WINTER AND I AM WARMING UP MY CAR PRIOR TO GETTING AN IT I NOTICED THAT THAT SAME SMELL PERMEATES THE EXTERIOR OF THE CAR AS WELL. MY ONLY ASSUMPTION COULD BE THAT WHATEVER IS COMING OUT OF THE CAR IS SOMEHOW LEAKING INSI…
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SINCE I PURCHASED THE CAR I NOTICED A FOUL SMELL ON THE INTERIOR. IT SMELLS LIKE ROTTEN EGGS. NOW THAT IT IS WINTER AND I AM WARMING UP MY CAR PRIOR TO GETTING AN IT I NOTICED THAT THAT SAME SMELL PERMEATES THE EXTERIOR OF THE CAR AS WELL. MY ONLY ASSUMPTION COULD BE THAT WHATEVER IS COMING OUT OF THE CAR IS SOMEHOW LEAKING INSIDE THE INTERIOR OF MY CAR. IT IS A SMELL THAT MAKES YOU VERY VERY SICK TO YOUR STOMACH. CALLING MY FORD DEALERSHIP DID NO GOOD AS THEY ACTED LIKE THEY HAD NO IDEA WHAT THIS PROBLEM COULD BE.
NHTSA ODI #11063571
16,500 miles · Jan 12, 2018
EngineUnknown Or OtherCrash
THERE'S EXHAUST FUME IN THE CABIN MY WIFE HAS SUFFERED SEVERE HEADACHE AFTER 60 MINS OF DRIVING INCLUDED MY 20MONTHS OLD BABY. MY CAR HAS ALREADY BEEN REPAIRED ONCE AND IS IN THE SHOP AGAIN BECAUSE I LEFT A CO2 SENORS IN BACK SEAT AND HAS GONE OFF MULTIPLE TIMES. FORD IS NOT BEING VERY HELPFUL BECAUSE I DON'T WANT THE CAR AN…
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THERE'S EXHAUST FUME IN THE CABIN MY WIFE HAS SUFFERED SEVERE HEADACHE AFTER 60 MINS OF DRIVING INCLUDED MY 20MONTHS OLD BABY. MY CAR HAS ALREADY BEEN REPAIRED ONCE AND IS IN THE SHOP AGAIN BECAUSE I LEFT A CO2 SENORS IN BACK SEAT AND HAS GONE OFF MULTIPLE TIMES. FORD IS NOT BEING VERY HELPFUL BECAUSE I DON'T WANT THE CAR ANYMORE. IT IS A HUGE SAFETY CONCERN AND I DON'T WANT MY WIFE AND TODDLER IN THE VEHICLE AT ALL.
NHTSA ODI #11062345
17,000 miles · Jan 4, 2018
Unknown Or Other
WHEN APPLYING JUST THE SLIGHTEST BIT OF PRESSURE TO THE BRAKE PEDAL AT THE SAME MOMENT THE BRAKE LIGHTS COME ON A CLANKING OR CLICKING NOISE HAPPENS. THE NOISE SOUNDS LIKE IT IS COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE. THE NOISE IS ALSO RANDOM AND DESPITE EFFORTS TO INTENTIALLY DUPLICATE NOISE, IT APPEARS TO HAPPEN R…
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WHEN APPLYING JUST THE SLIGHTEST BIT OF PRESSURE TO THE BRAKE PEDAL AT THE SAME MOMENT THE BRAKE LIGHTS COME ON A CLANKING OR CLICKING NOISE HAPPENS. THE NOISE SOUNDS LIKE IT IS COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE. THE NOISE IS ALSO RANDOM AND DESPITE EFFORTS TO INTENTIALLY DUPLICATE NOISE, IT APPEARS TO HAPPEN RANDOMLY. BROUGHT THE VEHICLE TO FORD DELEARSHIP 5 PLUS TIMES AND THEY HAVE FIXED EVERYTHING FROM THE SUSPENSION TO NUTS AND BOLTS BUT HAVE YET TO RESOLVE THE PROBLEM. THE NOISE OCCURS WHEN THE VEHICLE IS IN MOTION AND AT THE EXACT MOMENT ANY PRESSURE IS APPLIED TO THE BRAKE PEDAL.
NHTSA ODI #11058519
35,000 miles · Dec 26, 2017
Unknown Or Other
EXHAUST FUMED SMELL IN CAR... SPECIFICALLY WHEN AC IS RUNNING AND BACKING UP
NHTSA ODI #11056380
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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