COMPONENT SPOTLIGHT

Ford Explorer electrical problems

2,242 distinct owner reports with an electrical-system component in this snapshot.

Includes the electrical-system component and its detailed subcategories. Related recalls and investigations must also name this component; they are not linked by narrative keyword alone.

44 crash reports312 fire reports36 injury reports

Reports by model year

Recall and investigation columns show each year’s full history. A report naming several years can appear in more than one row.

When problems were reported

Mileage at the reported incident

246

0–25K

179

25–50K

194

50–75K

154

75–100K

198

100–150K

123

150K+

1,094 reports with mileage · 1,148 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What owners actually said

2,242 reports

2005 model year · 36,000 miles · May 1, 2008

Electrical SystemFuel System, Gasoline

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I RECENTLY PURCHASED A NEAR NEW 2005 FORD EXPLORER. THE VEHICLE IS IN PRISTINE CONDITION AND HAS VERY LOW MILEAGE TO THE POINT WHERE IT IS BELOW THE INDUSTRIAL AVERAGE. SINCE I PURCHASED THE VEHICLE, I HAVE FUELED IT SEVERAL TIMES, ALWAYS FILLING THE TANK TO THE TOP. EVERY TIME I HAVE FILLED THE VEHICLE UP, THE FUEL GAUGE HAS DROPPED TO EMPTY AND THE MILEAGE TILL EMPTY INDICATOR SHOWS JUST DASHES. IN ADDITION TO THE GAUGE DROPPING TO EMPTY MY "SERVICE ENGINE LIGHT" COMES ON IMMEDIATELY FOLLOWING THE FUEL GAUGE DROPPING. AT FIRST I THOUGHT IT WAS POSSIBLY JUST A PROBLEM WITH MY VEHICLE SO I FIGURED I'D HAVE IT FIXED. THEN OUT OF CURIOSITY I DECIDED TO CHECK ONLINE AND WITH OTHER FELLOW OWNERS OF THE 2002-2005 FORD EXPLORER MODEL TO SEE IF THEY WERE HAVING THIS PROBLEM AS WELL. AND TO MY SURPRISE I FOUND THAT IT WAS A VERY COMMON PROBLEM. THIS ISSUE DISTURBS ME MAINLY BECAUSE IT IS A SAFETY ISSUE. GOD FORBID MY WIFE IS TRAVELING DOWN THE ROAD WITH MY 14-MONTH-OLD SON AND RUNS OUT OF FUEL DUE TO A FAULTY FUEL GAUGE ON A DESERTED DARK HIGHWAY. SINCE THIS WAS SUCH A COMMON PROBLEM I THOUGHT I WOULD BE ABLE TO COME ONLINE AND FIND OUT THAT THERE WAS A RECALL. BUT I DID NOT FIND THAT. ALL I FOUND WAS A BUNCH OF PEOPLE COMPLAINING ABOUT THE SAME EXACT THING. NOW MY QUESTION IS, WHY HASNT THERE BEEN A RECALL YET WITH AN UPDATED PART FOR REPLACEMENT? IF SOMEONE COULD CONTACT ME AND ASSIST ME WITH THIS MATTER I WOULD GREATLY APPRECIATE IT. THANK YOU *TR

NHTSA ODI #10226347

2002 model year · 75,000 miles · May 1, 2008

Electrical System

DOOR AJAR LIGHT STAYS ON AND CAUSES DOME LIGHTS TO FLASH ON AND OFF AND CHIME WHILE DRIVING. CAR ALARM GOES OFF RANDOMLY FOR NO APPARENT REASON. HAVE TALK TO FORD THEY TELL ME I NEED TO BRING IT IN WHILE THIS IS ALL HAPPENING SO THEY CAN FIGURE OUT WHAT'S GOING ON. CAR NEVER SEEMS TO DO IT AT A TIME I CAN TAKE IT IN. *TR

NHTSA ODI #10226393

2002 model year · 128,000 miles · Apr 17, 2008

Electrical System

DOOR AJAR LIGHT AND ALARM ARE COMING ON INTERMITTENTLY . ALSO THE ANTI-THEFT ALARM WILL GO OFF FOR NO REASON. *TR

NHTSA ODI #10224823

2000 model year · 100,000 miles · Apr 11, 2008

Electrical SystemExterior LightingVehicle Speed Control

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TL*THE CONTACT OWNS A 2000 FORD EXPLORER. FOR THE PAST TWO MONTHS, THE CONTACT HAS EXPERIENCED ELECTRICAL FAILURE WITH HIS VEHICLE. THE INSTRUMENT PANEL AND HEADLIGHTS DO NOT ILLUMINATE, THE WINDSHIELD WIPERS WORK INTERMITTENTLY, AND THE BATTERY IS ALWAYS LOW. THE VEHICLE WAS TAKEN TO THE AUTO GARAGE, BUT THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER ON APRIL 8, 2008 AND THEY STATED THAT THE HEADLIGHT AND GLOBE WIRING WERE THE CAUSE OF THE FAILURES. THE COST OF THE REPAIR IS $800. ACCORDING TO THE MANUFACTURER, THE DEALER INFORMED THEM THAT THE FAILURE WAS NOT UNDER THE HOOD; THEREFORE, THEY WERE NOT RESPONSIBLE. THE CONTACT BELIEVES THAT HIS VEHICLE IS INCLUDED IN NHTSA CAMPAIGN ID NUMBER 00V072000 (ELECTRICAL SYSTEM:FUSES AND CIRCUIT BREAKERS) AND HE DID NOT RECEIVE A RECALL NOTICE. THE VIN, ENGINE SIZE, AND NUMBER OF CYLINDERS WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 100,000. UPDATED 05/19/08 *BF UPDATED 05/19/08. *JB

NHTSA ODI #10224207

1997 model year · 108,000 miles · Apr 4, 2008

Electrical SystemFire

TODAY IS THE FIRST TIME SINCE I HAVE OWNED THE TRUCK AS I WAS DRIVING IT AND STARTED RIGHT BACK UP, AND ABOUT 6 HOURS LATER MY NEIGHBOR NOTICED MY TRUCK ON FIRE. FLAMES WERE COMING FROM BEHIND THE LEFT FRONT WHEEL WELL. MY MECHANIC SAID LOOKS LIKE E-BRAKE CABLE STARTED TO WELD IT SELF AND CAUGHT THE BODY MOUNT ON FIRE. E-BRAK…

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NHTSA ODI #10223410

1999 model year · 89,999 miles · Apr 2, 2008

Electrical SystemFire

TL*- THE CONTACT OWNS A 1999 FORD EXPLORER. WHEN ARRIVING HOME FROM THE STORE THE VEHICLE WAS PARKED AND MINUTES LATER THE VEHICLE WENT UP IN FLAMES. THE FIRE CAME FROM UNDER THE HOOD OF THE VEHICLE. TWO EXPLOSIONS OCCURRED BEFORE THE FIRE DEPARTMENT CAME TO PUT OUT THE FIRE. THE FIRE MARSHAL ADVISED THAT AN ELECTRICAL ISSUE WAS…

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NHTSA ODI #10223191

2004 model year · 56,000 miles · Mar 7, 2008

Electrical SystemFuel System, Gasoline

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I HAVE A 2004 FORD EXPLORER WITH 57,000 THAT STARTED STALLING WHILE DRIVING ABOUT 3 MONTH AGO. IT SHUTS OFF LIKE SOMEONE TURNED THE KEY. THE OCCURRENCE IS VERY RANDOM AND THERE IS NEVER ANYTHING COMMON BETWEEN OCCURRENCES EXCEPT IT TYPICALLY HAPPENS WHEN I AM BRAKING. IT'S AS IF IT'S RUNNING OUT OF GAS. IT TOOK ABOUT 10 MINUTES EACH TIME BEFORE IT WOULD RESTART. ALL 4 TIMES, EVEN THOUGH IT DIED LIKE THE KEY WAS TURNED OFF, IT ACTED LIKE IT WAS OUT OF GAS WHEN I WAS TRYING TO RESTART IT AND THEN ALL OF THE SUDDEN IT WOULD START LIKE NORMAL. SINCE THEN THE FOLLOWING HAS BEEN DONE: FUEL FILTER REPLACED, MAF SENSOR CLEANED AND THE IAC VALVE INSPECTED. THE SERVICE SHOP WHERE IT IS TAKEN SAYS THERE IS NEVER AN ERROR CODE IN THE SYSTEM WHEN I BRING IT IN. THE VEHICLE IS CURRENTLY UNSAFE TO DRIVE WITH THIS CONDITION. *TR

NHTSA ODI #10220397

1997 model year · 130,000 miles · Mar 4, 2008

Electrical System

VEHICLE STARTED OUT FINE. AFTER A MONTH OF DRIVING, FAR LEFT DASH LIGHTS DIED OUT. THOSE ARE THE ONES ILLUMINATING THE OIL PRESSURE AND BATTERY. A FEW MONTHS LATER, THE LIGHTS ILLUMINATING THE SPEEDOMETER AND TACHOMETER DIED OUT AS WELL. THIS IS NOT NORMAL. PERSONALLY, I THINK IT MIGHT BE A SHORT TO GROUND, BUT I STILL HAVE YET …

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NHTSA ODI #10220097

2000 model year · Mileage unknown · Mar 3, 2008

Electrical System

AUG 2007, RECEIVED RECALL NOTICE FROM FORD MOTOR CO TO REPLACE DEFECTIVE SPEED CONTROL DEACTIVATION SWITCH (SCDS). SEP 2007, RECEIVED NOTICE FROM FORD MOTOR CO ADVISING OF PARTS SHORTAGE TO REPAIR DEFECT AND AUTHORIZING "AN INTERIM REPAIR OF DISCONNECTING THE SPEED CONTROL SYSTEM" ON THE VEHICLE. ON SUBSEQUENT SERVICE VISITS AND…

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NHTSA ODI #10219968

2004 model year · 97,750 miles · Mar 3, 2008

Electrical System

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PURCHASED A 2004 FORD EXPLORER IN JUNE 2005. IN 2006 HAD TO REPLACE THE O2 SENSOR. IN MAY 2007, HAD TO REPLACE THE SAME O2 SENSOR. NOW IN JANUARY 2008, WAS DRIVING AND TRUCK JUST STOPPED ON A HILL WITH TRAFFIC COMING UP, LARGE DIESEL TRUCK, ALMOST CAUSING AN REALLY BAD ACCIDENT. HAD VEHICLE CHECKED AND THE EXACT SAME 02 SENSOR IS OUT FOR THE 3RD TIME AND WAS TOLD THIS WAS NOT NORMAL AND THAT THERE IS A LARGE NUMBER OF 2004 VEHICLES WITH THE SAME PROBLEM. WAS TOLD THIS BY 2 DIFFERENT DEALERSHIPS IN TWO DIFFERENT STATES. CONTACTED FORD AND WAS PRETTY BLOWN OFF AND STATED THAT BECAUSE OF THE MILEAGE ON THE VEHICLE, THERE WAS NOTHING THAT COULD BE DONE BECAUSE I HAD AN OUTSIDE WARRANTY AND NOT A FORD WARRANTY. THEY DIDN'T EVEN CONTACT THE DEALERSHIPS AFTER CLAIMING TO HAVE DONE A INVESTIGATION. WAS TOLD I JUST HAD TO PAY AGAIN. NOW WHAT IF THIS HAPPENS AGAIN AND I'M NOT SO LUCKY THAT A BIG DIESEL TRUCK CAN WHIP INTO THE OTHER LANE TO AVOID HITTING ME. *TR

NHTSA ODI #10219960

Related Official recalls

26V165000 · Back Over Prevention:software; Electrical System:adas

Mar 18, 2026

Ford Motor Company (Ford) is recalling certain 2022-2025 Lincoln Navigator, 2024-2025 Lincoln Nautilus, 2025 Lincoln Aviator and Explorer vehicles. The Image Processing Module A (IPMA) may experience multiple unexpected resets, resulting in loss of the rearview camera image and advanced driver assistance (ADAS) features, including pre-collision assist, lane-keeping assist, and blind-spot monitoring.

Consequence & remedy

Consequence: Loss of the rearview camera image and certain driver assistance features, can reduce the driver’s ability to detect hazards, increasing the risk of a crash.

Remedy: The Image Processing Module A software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. This is a Phased campaign. Phase 1 will include 2025 Aviator, 2025 Explorer, 2025 Nautilus notified owners on 4/13/2026. Phase 2 will include 2025 Navigator will notify owners on or about 4/20/2026. Phase 3 will include 2022-2024 Navigator will notify owners on or about 6/8/2026. Phase 4 will include 2024 Nautilus will notify owners on or about 6/22/2026. Owner notification letters were mailed April 13, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S21. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 25, 2026.

Additional source detail variants (2)

Back Over Prevention:software

Consequence: Loss of the rearview camera image and certain driver assistance features, can reduce the driver’s ability to detect hazards, increasing the risk of a crash.

Remedy: The Image Processing Module A software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. This is a Phased campaign. Phase 1 will include 2025 Aviator, 2025 Explorer, 2025 Nautilus notified owners on 4/13/2026. Phase 2 will include 2025 Navigator will notify owners on or about 4/20/2026. Phase 3 will include 2022-2024 Navigator will notify owners on or about 6/8/2026. Phase 4 will include 2024 Nautilus will notify owners on or about 6/22/2026. Owner notification letters were mailed April 13, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S21. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 25, 2026.

Electrical System:adas

Consequence: Loss of the rearview camera image and certain driver assistance features, can reduce the driver’s ability to detect hazards, increasing the risk of a crash.

24V685000 · Electrical SYSTEM:12V/24V/48V Battery:cables; Hybrid Propulsion System

Sep 13, 2024

Ford Motor Company (Ford) is recalling certain 2024 Ford Explorer vehicles equipped with 3.3L Hybrid engines. The 12-Volt battery cable may chafe against the Belt-integrated Starter Generat (BiSG) and short circuit.

Consequence & remedy

Consequence: A short circuit increases the risk of a fire.

Remedy: Dealers will install a tie strap between the battery cable and high voltage cable, free of charge. Owner notification letters were mailed November 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S61.

Additional source detail variants (2)

Hybrid Propulsion System

Consequence: A short circuit increases the risk of a fire.

Remedy: Dealers will install a tie strap between the battery cable and high voltage cable, free of charge. Owner notification letters were mailed November 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S61.

Electrical SYSTEM:12V/24V/48V Battery:cables

Consequence: A short circuit increases the risk of a fire.

23V686000 · Back Over Prevention:display Function; Electrical System:wiring

Oct 13, 2023

Ford Motor Company (Ford) is recalling certain 2023 Explorer vehicles equipped with a standard rearview camera. Due to a manufacturing error in the wire harness, the rearview camera may display a blue image on the SYNC screen when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Consequence & remedy

Consequence: A rearview camera that does not properly display an image can reduce the driver's rear view, increasing the risk of a crash.

Remedy: Dealers will inspect the rearview camera wire harness and repair any loose splices, free of charge. Owner notification letters were mailed November 2, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C31.

Additional source detail variants (2)

Back Over Prevention:display Function

Consequence: A rearview camera that does not properly display an image can reduce the driver's rear view, increasing the risk of a crash.

Remedy: Dealers will inspect the rearview camera wire harness and repair any loose splices, free of charge. Owner notification letters were mailed November 2, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C31.

Electrical System:wiring

Consequence: A rearview camera that does not properly display an image can reduce the driver's rear view, increasing the risk of a crash.

23V626000 · Electrical System:propulsion System:traction Battery

Sep 8, 2023

Ford Motor Company (Ford) is recalling certain 2020-2022 Lincoln Aviator and Ford Explorer vehicles equipped with 3.0L PHEV engines. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.

Consequence & remedy

Consequence: Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.

Remedy: Dealers will perform a Battery Energy Control Module (BECM) diagnostic test and replace the high voltage battery pack, as necessary, free of charge. Owner notification letters were mailed on April 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford Motor Company's number for this recall is 23S53.

19V687000 · Electrical System:wiring

Sep 30, 2019

Ford Motor Company (Ford) is recalling certain 2020 Ford Explorer vehicles equipped with 2.3L or 3.3L engines. The wiring harness may not have been properly secured and may contact the air conditioner compressor (A/C) pulley, potentially damaging the harness or the A/C belt.

Consequence & remedy

Consequence: The A/C pulley may rub through the wiring harness insulation and contact the unfused battery positive wire, resulting in a short circuit, increasing the risk of a fire.

Remedy: Ford will notify owners, and dealers will install a tie strap to the wiring harness at the hand shock tower clip, free of charge. The recall began October 21, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S32.

19V575000 · Electrical System: Instrument Cluster/panel; Parking Brake; Power Train:automatic Transmission:gear Position Indication (prndl)

Aug 5, 2019

Ford Motor Company (Ford) is recalling certain 2020 Explorer and Lincoln Aviator vehicles. The Manual Park Release (MPR) cover may not be installed. In addition, the vehicles may be in Factory Mode, which disables warning alerts and does not display the transmission gear selected. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 114, "Theft Prevention" and 102, "Trans Shift Lever Seq/Starter Interlock/Trans Braking Effect."

Consequence & remedy

Consequence: Without the cover, the MPR lever may be unintentionally moved, allowing the vehicle to roll away. Being in Factory Mode, the vehicle will not display warnings and/or gear selection on the instrument cluster. Both conditions increase the risk of a crash.

Remedy: Ford will notify owners, and dealers will inspect and, if necessary, install a MPR cover. Dealers will verify the instrument cluster is not in Factory Mode and clear any fault codes, free of charge. The recall began August 23, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19C06.

Additional source detail variants (3)

Parking Brake

Consequence: Without the cover, the MPR lever may be unintentionally moved, allowing the vehicle to roll away. Being in Factory Mode, the vehicle will not display warnings and/or gear selection on the instrument cluster. Both conditions increase the risk of a crash.

Remedy: Ford will notify owners, and dealers will inspect and, if necessary, install a MPR cover. Dealers will verify the instrument cluster is not in Factory Mode and clear any fault codes, free of charge. The recall began August 23, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19C06.

Electrical System: Instrument Cluster/panel

Power Train:automatic Transmission:gear Position Indication (prndl)

00V072000 · Electrical System:wiring:fuses And Circuit Breakers

Mar 7, 2000

VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES EQUIPPED WITH 4.0L ENGINES AND ALL-TIME 4-WHEEL DRIVE (A4WD) POWERTRAINS. THE GENERIC ELECTRONIC MODULE (GEM) COULD EXPERIENCE A CONDITION REFERRED TO AS "LOCK-UP" IN WHICH THE GEM CONTROLLED ELECTRONIC FUNCTIONS (E.G., FRONT WINDSHIELD WIPERS, INTERIOR LIGHTS, 4X4 SYSTEM, ETC.) COULD NOT BE TURNED ON OR, IN SOME CASES IF THE FUNCTION IS ON, COULD NOT BE TURNED OFF.

Consequence & remedy

Consequence: AN INOPERATIVE WINDSHIELD WIPER SYSTEM COULD AFFECT DRIVER VISIBILITY, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL A RESISTOR IN THE GEM CIRCUIT.

97V215000 · Electrical SYSTEM:IGNITION:ANTI-THEFT:CONTROL Module

Nov 24, 1997

VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES, EDDIE BAUER AND LIMITED EDITIONS. THE KEY-IN-IGNITION/DOOR OPEN WARNING CHIME MAY NOT FUNCTION WHEN THE DOOR IS OPENED. THIS DOES NOT FULLY COMPLY WITH FMVSS NO. 114, "THEFT PROTECTION."

Consequence & remedy

Consequence: THE STANDARD SPECIFIED THAT A WARNING TO THE DRIVER SHALL BE ACTUATED WHENEVER THE KEY HAS BEEN LEFT IN THE LOCKING SYSTEM AND THE DRIVER'S DOOR IS OPENED.

Remedy: DEALERS WILL INSTALL A JUMPER WIRE TO PROVIDE THE NECESSARY GROUND CIRCUIT IN THESE VEHICLES.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

Related NHTSA investigations

EA05005 · Engine Compartment Fires

Opened Mar 22, 2005 · Closed Aug 2, 2006

Status: closed (inferred from source dates) · Electrical System; Electrical System:wiring:front Underhood; Vehicle Speed Control:cruise Control

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

Additional source detail variants (21)

Electrical System

Electrical System:wiring:front Underhood

Vehicle Speed Control:cruise Control

PE97010 · Electrical Fire In Center Console

Opened Mar 13, 1997 · Closed Sep 4, 1997

Status: closed (inferred from source dates) · Electrical System

THIS INVESTIGATION REVEALED THAT CONSOLE FIRES IN THE SUBJECT VEHICLES MOST OFTEN OCCURRED WHILE VEHICLES EQUIPPED WITH THE LAMP OUTAGE MODULE (LOM), WHICH IS PART OF THE MESSAGE CENTER, WERE TOWING A TRAILER AND WHICH HAD BEEN MODIFIED BY ADDING AN AFTERMARKET TRAILER WIRING HARNESS INTO THE VEHICLE'S TAILLIGHT CIRCUITS.THE OWNER'S MANUAL STATES NEVER AND MORE THAN OTHER TRAILER LIGHT BULB TO ONE CIRCUIT HOWEVER TRAILERS FREQUENTLY CONTAIN SEVERAL BULBS.THE RESULTING EXCESS CURRENT PASSING THROUGH THE LOM COULD CAUSE IT TO OVERHEAT RESULTING IN A FIRE.PROPER AFTERMARKET INSTALLATION OF TRAILER WIRING REQUIRES THE USE OF A BYPASS MODULE, WHICH OBTAINS POWER FOR THE TRAILER LIGHTS DIRECTLY FROM THE BATTERY RATHER THAN FROM THE VEHICLE'S TAIL LIGHT AND STOP LAMP CIRCUITS, OR THE USE OF THE MANUFACTURER'S WIRING HARNESS.IN A LETTER DATED SEPTEMBER 2, 1997, FORD NOTIFIED ODI THAT IT INTENDS TO TAKE ACTION TO PRECLUDE FURTHER INCIDENTS INCLUDING ISSUING A TECHNICAL SERVICE BULLETIN TO ITS DEALERS, NOTIFYING TRAILER RENTAL ASSOCIATIONS AND AGENCIES WHERE KNOWN, AND ADVISING OWNERS BY LETTER OF THE PROPER METHOD FOR CONNECTION OF TRAILER TOW WIRING ON THE SUBJECT VEHICLES.THERE WAS NO DEFECT TREND IN THE SUBJECT VEHICLES IDENTIFIED AS A RESULT OF THIS INVESTIGATION, AND FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT WARRANTED TO CONTINUE THE INVESTIGATION.

PE96066 · Driver Door Electrical Fire

Opened Nov 22, 1996 · Closed May 15, 1997

Status: closed (inferred from source dates) · Electrical System

THE CONTACT ASSEMBLY FOR THE REMOTE POWER MIRROR CONTROL SWITCH MAY DEVELOP A SHORT CIRCUIT BETWEEN THE SWITCH POSITIVE PAD AND CHASSIS GROUND PAD AS A RESULT OF WATER INTRUSION.EXCESS CURRENT FLOW RESULTING FROM THE SHORT CIRCUIT CONDITION MAY OVERHEAT THE REMOTE POWER MIRROR CONTROL SWITCH CIRCUIT BOARD AND CAUSE A FIRE IN THE DRIVER'S DOOR.FORD HAS INDICATED THAT CURRENT IN EXCESS OF 15 AMPS CAN OVERHEAT THE CIRCUIT BOARD ENOUGH TO CAUSE A FIRE.CIRCUIT PROTECTION IS PROVIDED BY A 30 AMP FUSE.FORD IS RECALLING ALL 1993-94 4-DOOR EXPLORER VEHICLES EQUIPPED WITH THE SUBJECT ELECTRONIC OPTION COMBINATION TO INSTALL AN IN-LINE 10 AMP FUSE IN THE POSITIVE BATTERY FEED TO THE REMOTE POWER MIRROR CONTROL SWITCH ASSEMBLY.NO 2-DOOR EXPLORER VEHICLES WERE BUILT WITH THE SUBJECT COMPONENTS.ACCORDING TO FORD, VEHICLES BUILT PRIOR TO THE RECALL PRODUCTION RANGE WERE EQUIPPED WITH LOWER CAPACITY CIRCUIT BOARDS FOR THE SUBJECT SWITCH ASSEMBLY THAT WOULD FAIL FROM AN OPEN CIRCUIT IF A SIMILAR SHORT OCCURRED.A NEW SWITCH ASSEMBLY WITH 10 AMP FUSE PROTECTION WAS INTRODUCED BEGINNING WITH THE 1995 MODEL YEAR EXPLORER.MAZDA WILL CONDUCT A PARALLEL COMPAIGN (97V-083.002) TO REMEDY THE SUBJECT CONDITION IN APPROXIMATELY 14,000 NAVAJO VEHICLES.THE NAVAJO VEHICLES WERE AVAILABLE IN ONLY THE 2-DOOR VERSION WHICH, UNLIKE THE EXPLORER VEHICLES, DID USE THE SUBJECT OPTION COMBINATION IN THAT BODY STYLE.