2023 Ford Explorer

My 2023 Ford Explorer (VIN: [XXX] ) has a persistent front suspension clunk/rattle/knock when driving over small bumps or uneven pavement at low speeds (8–20 mph). The noise is repeatable and has progressively worsened. It matches the condition described in Ford Special Service Message SSM 52405, which identifies a manufacturing defect involving a loose internal pressure tube inside the front strut assembly on 2023 Explorers built between December 1, 2022 and August 31, 2023. My vehicle falls inside this build range. This defect affects vehicle stability, steering control, and suspension performance over bumps and uneven surfaces. The internal looseness in the strut assembly creates unpredictable handling characteristics, which is a safety issue. Multiple owners have reported the same symptoms, and Ford has not issued a recall. I am requesting that NHTSA investigate this defect and Ford’s handling of repairs, as owners are being asked to pay out‑of‑pocket for repairs related to a known manufacturing defect that affects safe vehicle operation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While driving the car, the steering locked up making the vehicle unable to turn. Thank got it happened in a parking lot where the truck blocked traffic for hours before getting towed. The dealer took 6 weeks of guessing the problem with Ford engineers. Replacing numerous parts in an attempt to guess what the issue was. After contacting Ford directly and expressing my concerns over the safety of the truck. They refused to communicate with me and forwarded all my information to their legal staff. Still no update from Ford regarding the repair was done properly or even confirming the safety of the car.

The system that warns the driver that you do not have both hands on the steering wheel. It turns on while I have both hands on the wheel and sometimes I can not get it to acknowledge that and the car begins to stop on the interstate, in traffic and in a dark tunnel wiht no shoulder. The dealer can not reproduce the proble,. I have had it to them now for the third time.It has been inspected by the dealer and they have only reinstalled the software and can not fix the problem nore can they disable the system.This has been occuring with this care since I purchased it and have had it into the dealer but no fix. During a recent trip it acted very dangerously and I began to slo in a dark tunnel and even after banging ther steering wheel in frustration it continued to activeae and slow the car from 70 MPH to 30 MPG. I tryed to take a video of the problem but that became to dangerous. I stopped during my trip and installed a zip tie on the steering wheel and that seemed to help a bit with but even with both hands on the steering wheel and the zip tie it still activated several times. This has occurred several times over the past two years.

The contact owns a 2023 Ford Explorer. The contact stated while driving at an undisclosed speed, the steering wheel failed to turn into the intended direction. In addition, the contact stated the vehicle failed to remain in the intended lane while driving. The vehicle was taken to the dealer where it was diagnosed and determined that the shocks and struts needed to be replaced. The vehicle was repaired. In addition, the contact stated the vehicle had been taken to the dealer several times prior to the failure. The vehicle was taken to an alternate dealer where it was diagnosed with strut mount failures. The contact was informed that the strut mounts needed to be replaced. The vehicle was being repaired. The manufacturer was made aware of the failure and a case was filed. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 18,000.

What component or system failed or malfunctioned, and is it available for inspection upon request? The steering system failed completely while the vehicle was in motion. It is currently at the Ford service center in Cocoa, Florida, and is available for inspection upon request. How was your safety or the safety of others put at risk? My wife and our two children (ages [XXX] and [XXX] ) were nearly killed due to this catastrophic steering failure. While traveling at approximately 70 MPH on [XXX] near West Melbourne, Florida (between exits XXX and XXX) in the far right lane, the vehicle suddenly and without warning jerked aggressively to the left, crossing into the center lane, nearly causing a high-speed collision with a semi-truck. The truck driver was able to swerve just in time to avoid an accident. At that point, the vehicle became extremely difficult to steer. It continued to pull to the left, and it required all of my wife's strength to get it off the highway and safely stopped on the shoulder. The safety of multiple drivers on the interstate was compromised due to this failure. Has the problem been reproduced or confirmed by a dealer or independent service center? We are currently awaiting confirmation. The vehicle is in the possession of the Ford service center in Cocoa, Florida, and they are attempting to diagnose the issue. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? The vehicle is currently with Ford. We were told they are trying to recreate the issue by driving it in a field behind the dealership, but as of now, they have not taken the vehicle back out on the road or highway for testing. The Florida Highway Patrol was called at the time of the incident, but they did not dispatch a trooper since there was no crash or contact with another vehicle. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No. There were no INFORMATION REDACTED PURSUANT TO THE FREEDOM OF

The contact's wife owns a 2023 Ford Explorer. The contact stated while driving at various speeds, there was an abnormal knocking sound coming from the front end of the vehicle. The vehicle was taken to the dealer, where it was determined that the front struts had failed and needed to be replaced. The vehicle was repaired; however, the failure recurred several times. The dealer replaced the front struts three times; however, the failure persisted. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 24V091000(Suspension, Steering); however, the VIN was not included. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 2,000.

The lane assist system put the vehicle into a skid on snowy road with no markings on roadway. The vehicle is available to inspect but insurance company is pushing to pickup vehicle as it was totaled. The system put vehicle into a skid that resulted into going into the ditch and hitting a power pole. As far as we know nobody has looked into system failure we did report it to sheriff and insurance company. This is the first time the lane departure turned on a snow covered road

The contact owns a 2023 Ford Explorer. The contact stated there was an unknown part loosened at the front of the vehicle. While driving at unknown speeds, there was an abnormal rattling noise detected from the strut that had become louder over time. There were no warning lights illuminated. The vehicle was taken to the local dealer, where the front-end bolts were tightened. The vehicle was repaired, but the failure recurred. The manufacturer was contacted, opened a case, and referred the contact to the NHTSA Hotline. The contact related the failure to NHTSA Campaign Number: 24V091000 (Suspension, Steering). The approximate failure mileage was 3,000.

There seems to be two issues of concern; 1. Braking system .. when you are in your car, you can hear constant clicking from the engine and the brake light keeps turning and on and off. The light keeps indicating that the brake is on. This happens continuously every day. 2. Steering… when you are switching lanes, it’s not a smooth transition. It feels like a jerk each time and feels like if you were to put the brake, the car will flip over. Very concerning. Happens all the time.