Structure. Review the 655 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
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Power Train. Review the 123 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

34 crash reports11 fire reports36 injury reports

Wheels complaints

60 reports

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16,000 miles · Sep 14, 2019

Wheels

TIRES ARE DEEMED WORN OUT AT 16000 MILES.

NHTSA ODI #11255496

23,800 miles · Sep 6, 2019

Wheels

I TOOK MY 2017 FORD EXPLORER SPORT WITH 23,800 MILES TO BE INSPECTED TODAY AND IT FAILED INSPECTION. I WAS TOLD THAT THE TIRES ARE SEVERELY WORN. I TOOK IT TO A TIRE PLACE AND THEY CONCURRED. THE TIRES ARE HANKOOK VENTUS S1 NOBLE 2. THERE IS ALMOST NO TREAD LEFT AND THE THEY ARE SCALLOPING AND FLAKING PIECES OF RUBBER.

NHTSA ODI #11253677

25,000 miles · Aug 22, 2019

Wheels

HANKOOK BRAND TIRES ON FORD EXPLORER. I HAVE HAD TO REPLACE 2 SETS OF HANOOK TIRES ON MY FORD EXPLORER AT 25,00 AND 20,000 MILES ON THE TIRES FOR LOW TRED ON TIRES. THE TIRES HAVE A 70,000 MILE WARRANTY AND THE WAS NO CAUSE FOR TIRE WEAR, I.E. OUT OF ALIGNMENT.

NHTSA ODI #11245860

27,000 miles · Aug 19, 2019

Wheels

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THE VEHICLE IN QUESTION IS A 2017 FORD EXPLORER WITH HANKOOK VENTUS S1NOBLE2 FRONT TIRES THAT ARE SHREDDING BOTH ON THE INTERIOR AND EXTERIOR PARAMETER OF THE TIRES. THE DELAMINATION IS MIGRATING TOWARDS THE CENTER OF THE TIRE AS WELL WITH FLAPS AND CHUNKS OF RUBBER SOME OVER 10MM ARE SEPARATING FROM THE SUBSTRATE. THE TIRES ONLY HAVE 27,000 MILES ON THEM AND LOOK LIKE THEY HAVE 50,000+. I HAVE NEVER SEEN A VULCANIZATION PROBLEM LIKE THIS IN MY CAREER. THERE IS CLEARLY SOMETHING WRONG WITH THIS RUBBER COMPOUND REMINISCENT OF THE FORD FIRESTONE DEBACLE. THIS IS A SERIOUS ISSUE AND THE DEALER SEAMS TO BE INEFFECTIVE IN GETTING A CORRECTIVE ACTION IN PLACE. THE DEALER IS SKALNEK FORD IN LAKE ORION, MI AND WAS NOTIFIED ON SATURDAY AUGUST 17TH WHEN I WAS INFORMED THAT I WOULD NEED TO BRING MY CAR BACK ON MONDAY AUGUST 19TH AT WHICH TIME THEY WOULD FIX THE VEHICLE. I HAVE SINCE RETURNED FROM THE DEALER WITH THE REPAIR NOT COMPLETED AS THE DEALER IS WAITING FOR HANKOOK TO RESPOND BACK TO THEM WITH THE REPAIR AUTHORIZATION. AS OF THIS COMPLAINT THE DEALER SAID FORD WOULD NOT COVER THE ISSUE AS IT IS OUT OF THE 12/12 WARRANTY PERIOD FOR THE TIRES, AND THEY ARE NOT SURE IF OR WHEN HANKOOK WOULD RESPOND. ON A SEPARATE NOTE WHEN I WAS IN THE SERVICE AREA OF THE DEALER ANOTHER CUSTOMER WHICH ALSO HAPPENED TO BE AN ENGINEER SAID HE HAD THE EXACT SAME PROBLEM WITH HIS VEHICLE AND REPLACED AT HIS EXPENSE ALL 4 TIRES WITH ANOTHER BRAND. IN SHORT THIS IS NOT AN ISOLATED INCIDENT AND COULD IN FACT PUT CONSUMERS AT RISK. MY WIFE ONLY DISCOVERED THE ISSUE BECAUSE SHE TOOK THE CAR IN FOR A POTENTIAL TRADE-IN AND THE DEALER ALERTED HER TO THE ISSUE OF THURSDAY THE 15TH OF AUGUST.

NHTSA ODI #11245005

15,000 miles · Aug 12, 2019

Wheels

HANCOOK 255/50R20 105H VENTUS S1 NOBLE 2 TIRES WORN TO POINT OF STEEL BELT SHOWING WITH UNDER 20K MILES. SERIOUS SAFETY CONCERN.

NHTSA ODI #11243177

28,222 miles · Jun 26, 2019

Wheels

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I TOOK MY VEHICLE IN FOR SERVICE AT LANDERS FORD IN COLLIERVILLE, TN ON 6/11/2019 BECAUSE I HAD A SLOW LEAK IN ONE OF MY TIRES AND NEEDED AN OIL CHANGE. THE TECHNICIAN WHO COMPLETED THE SERVICES TOLD ME THAT I NEED NEW TIRES. I QUESTIONED THIS BECAUSE THE TIRES ONLY HAD 28,222 MILES ON THEM. I WAS TOLD THAT THE TIRES THAT FORD PLACED ON THIS VEHICLE BEFORE IT WAS SOLD TO ME (HANKOOK) WERE WEARING OUT BEFORE THEY NORMALLY WOULD. (MY UNDERSTANDING IS THAT THE TIRES HAVE A 50,000 MILE WARRANTY ON THEM.) I ASKED WHAT WE COULD DO ABOUT GETTING THEM REPLACED AND WAS TOLD BY THE SERVICE ADVISOR THAT I WOULD HAVE TO BUY NEW TIRES. I EXPLAINED THAT THIS WAS UNACCEPTABLE AND CALLED FORD MOTOR COMPANY. I SPOKE WITH SEVERAL REPRESENTATIVES AT FORD BECAUSE I KEPT GETTING HUNG UP ON DURING THE CONVERSATION. ONE OF THE REPRESENTATIVES TOLD ME THAT FORD WOULD PAY 30% OF THE COST OF NEW TIRES. WE EVENTUALLY WERE ABLE TO GET A CASE OPEN ON THE ISSUE (CASE #CAS-21837229). FORD CONTACTED THE DEALER TO WORK ON A SOLUTION. ON 6/26/19, I RECEIVED A CALL FROM THE DEALERSHIP THAT THEY HAD CONTACTED THE TIRE MANUFACTURER AND WAS TOLD THAT THERE IS NOTHING THEY WOULD DO. THE SERVICE MANAGER INSTRUCTED ME TO CALL FORD BACK. I CALLED FORD, AND THEY TOLD ME THEY WOULD NOT DO ANYTHING FOR ME BUT THAT I SHOULD SAVE MY RECEIPT WHEN I GET NEW TIRES IN CASE A SERVICE ACTION/RECALL WAS ISSUED IN THE FUTURE.

NHTSA ODI #11222792

33,042 miles · Jun 25, 2019

Wheels

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WE NOTICED SEVERE PREMATURE TIRE WEAR ON THE FACTORY TIRES ON OUR 2017 FORD EXPLORER. THE SUV CAME WITH HANKOOK 255/50R20 105H VENTUS S1 NOBLE 2 TIRES WHICH STARTED SHOWING SIGNS OF PREMATURE WEAR WITHIN 15,000 MILES. NOW ONE IS COMPLETELY BALD AT 33,042 MILES AND THE OTHERS ARE PEELING/CRACKING. WE MADE SURE THE TIRES HAD SUFFICIENT AIR PRESSURE, AND ROTATED THEM AT EVERY OIL CHANGE, YET THEY STILL KEPT WEARING. THAT ONE TIRE HAS BEEN COMPLETELY BALD SINCE 30,000 MILES (ZERO TREAD AND WEAR INDICATOR BAND SHOWING). WE SAW THE NOTICE UNDER NHTSA ID: 10137109 (MANUFACTURER COMMUNICATION NUMBER: SSM 47195) AND MULTIPLE REPORTS OF BLOWOUTS. WE CALLED FORD ON 6-25-2019 AND FORD TOLD US THEY WOULD COVER 30% OF THE COST BUT WOULD REPLACE THEM WITH THE SAME KIND OF TIRE. WE CHOSE TO GET ANOTHER BRAND OUT OF AN ABUNDANCE OF CAUTION. THESE TIRES ARE GOING TO GET SOMEONE KILLED.

NHTSA ODI #11222439

Mileage unknown · Jun 21, 2019

Wheels

EQUIPPED WITH HANKOOK TIRES VENTUS S1 NOBLE 2 255/50R20 THAT HAVE EXCESSIVE EARLY TREAD WEAR AND SCALLOPING/FLAKING ALONG THE EDGES. CAR HAD LESS THAN 16,000 MILES WHEN WEAR NOTICED. HAD TIRES ROTATED AND ALIGNED AGAIN TO ENSURE NOT CAUSED BY THESE ISSUES. NOW WORN TO THE POINT OF UNSAFE. ONLY DRIVEN ON HIGHWAY AND CITY STREETS…

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NHTSA ODI #11221679

20,000 miles · May 11, 2019

TiresWheels

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I PURCHASED A 2017 FORD EXPLORER XLT AND AFTER 20,000 MILES I WAS TOLD THE TIRES NEEDED TO BE REPLACED. I AGREE WITH THE SERVICE MAN AND AM LOOKING TO REPLACE THEM. I LOOKED AT THE TIRES, HANKOOK, VENOUS S1NOBLE 2, 255/50R20 105H AND SAW THE DOT DATE WAS 002881, 2012.. IF I'M READING THIS CORRECT THE TIRES WERE FIVE YEARS OLD UPON BUYING THE VEHICLE AND THEY ARE NOW SEVEN YEARS OLD WITH 20,000 MILES ON THEM. I BELIEVE THEY ARE UNSAFE AND WERE PROBABLE UNSAFE WHEN I BOUGHT THE VEHICLE

NHTSA ODI #11206989

25 miles · Apr 19, 2019

WheelsCrash

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ON APRIL 19, 2019 I BROUGHT MY CAR TO FORD IN TORRANCE CALIFORNIA. THIS IS THE SECOND TIME I BROUGHT MY CAR TO THEM. I'M LEASING A 2017 FORD EXPLORE WITH HANCOCK TIRES. THESE HANCOCK TIRES ARE STANDARD ON ALL THE FORD EXPLORES. AT MILE 3000 I RECEIVED A SIDEWALL BLOWOUT ON MY PASSENGER REAR TIRE. AND WHILE 20,000 I NOTICED THE TREADING ON THE TIRES WERE VERY LOW, AND AT 25,000 THE RADIOS BEGAN TO SHOW. THIS IS WHEN I BROUGHT THE CAR BACK TO THE FORD DEALER. THE TECHNICIANS STATED THAT THIS TIRE WAS DEFECTIVE AND NEEDED TO BE REPLACED. ALL FOUR HAD A TREADING THAT WAS EXTREMELY LOW. THE PROBLEM IS FORD IS CHARGING THE CONSUMER THE COST OF LABOR THE COST OF TAXES AND 70% THE COST OF THE TIRE. I BELIEVE WHEN THERE'S A DEFECTIVE TIRE OR ANY COMPONENT IN THE CAR THE SALES VENDOR IS RESPONSIBLE FOR REPLACING THE DEFECTIVE PART. FURTHERMORE I BELIEVE THE SALES VENDOR FORD SHOULD MITIGATE THE PROBLEM WITH THESE TIRES TO PROTECT THE CONSUMERS THEY ARE SELLING TO. THIS IS NOT WHAT HAPPENED IN THIS CASE AND MANY OTHER CASES. THE REASON I FOUND OUT MY TIRE TRADE-IN WAS LOW , WAS I PROCEEDED TO STOP MY CAR AT A STOP SIGN WHERE THERE WAS WATER OVERFLOWING AND I HYDROPLANED THROUGH THE INTERSECTION WITH MY YOUNG KIDS IN THE BACKSEAT. THESE TIRES ARE GOING TO KILL PEOPLE IF THEY ARE NOT RECALLED AND TAKE IT OFF ALL HER CARS. I AM A DOCTOR, AND I SEE PATIENTS WHO ARE INJURED IN ACCIDENTS ALL THE TIME BUT USUALLY TWO PERSONAL AIR. AFTER REVIEWING ALL OF THE NEGATIVE REVIEWS AND DEFECTS FROM THIS TIRE ONLINE I BELIEVE IT'S NEGLIGENCE BY THE FORD MOTOR COMPANY AND HANCOCK TIRES IF THIS MATTER IS NOT RESOLVED.

NHTSA ODI #11197377

Official recalls

26V448000 · Structure:body

Jul 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.

26V101000 · Suspension:rear

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.

25V685000 · Equipment:electrical:engine Block Heater

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.

25V347000 · Structure:body

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.

24V031000 · Structure:body:roof And Pillars

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.

21V537000 · Suspension:rear

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.

21V316000 · Structure:body

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.

20V675000 · Suspension:rear

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.

19V651000 · Seats

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.

19V435000 · Suspension:rear

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.

17V530000 · Steering

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.

17V332000 · Seats; Seats:front Assembly:recliner

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

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

Consequence: If the occupant is not adequately restrained in the event of a crash, they have an increased risk of injury.

16V925000 · Engine And Engine Cooling:engine:gasoline:turbo/supercharger

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

PE23001 · 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

Structure:body

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