2003 FORD EXPLORER

7 recalls, 1,369 complaints - 126 TSBs

EXTERIOR LIGHTING:HEADLIGHTS

Defect Description

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES... Read more

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.

42,540 vehicles affected

Manufacturer: DOPE, INC.

EXTERIOR LIGHTING

Defect Description

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES... Read more

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.

16,270 vehicles affected

Manufacturer: SABERSPORT

VISIBILITY:GLASS, SIDE/REAR

Defect Description

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDER... Read more

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.

Remedy

SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER... Read more

1,657 vehicles affected

Manufacturer: SAFELITE FULFILLMENT, INC.

EXTERIOR LIGHTING

Defect Description

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. ... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

27,176 vehicles affected

Manufacturer: CK MOTORSPORT, INC.

EXTERIOR LIGHTING

Defect Description

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE D... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

61,944 vehicles affected

Manufacturer: PRO-A MOTORS, INC.

STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS

Defect Description

ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.

Consequence

IF THE HINGE SHOULD FRACTURE, THERE IS A POTENTIAL FOR THE GLASS TO FALL AND ULTIMATELY BREAK AND PERSONAL INJURIES COULD OCCUR.

Remedy

DEALERS WILL HAVE THE LIFTGATE GLASS STRUT BRACKETS AND GLASS HINGES REPLACED. FOR THE VEHICLES BUILT FROM AUGUST 1, 2000 THROUGH MARCH 3, 2002, THE DEALERS WILL REPLACE THE HINGES AND LIFTGATE STRUT BRACKET. ON VEHICLES BUILT FROM MARCH 3, 2002 THROUGH JUNE 23, 2003, THE DEALERS WILL ONLY REPLACE... Read more

955,732 vehicles affected

Manufacturer: FORD MOTOR COMPANY

STRUCTURE

Defect Description

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EX... Read more

Consequence

THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy

DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-60... Read more

3,674 vehicles affected

Manufacturer: SOUTHERN COMFORT CONVERSIONS

Complaint Statistics

1,369 total complaints 70 crashes 10 fires 69 injuries 2 deaths

Top Reported Components

Component	Complaints
POWER TRAIN:AUTOMATIC TRANSMISSION	141
STRUCTURE:BODY	135
POWER TRAIN	110
STRUCTURE:BODY:HATCHBACK/LIFTGATE	90
STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS	55
UNKNOWN OR OTHER	44
STRUCTURE	44
ELECTRICAL SYSTEM	43
WHEELS	42
ENGINE AND ENGINE COOLING	33

Incident date: Sep 15, 2025

The driver and passenger windows intermittently skip and get stuck while moving up or down. They struggle to operate smoothly and don’t function properly.

Incident date: Jul 28, 2022

There is a crack down the middle section of the liftgate for quite some time. The liftgate has been unlocking and opening automatically by itself. On only rare occasions has the liftgate opened all the way while driving. On the morning of 7/28/2022 while the vehicle was parked in my driveway the lif... Read more

Incident date: Jul 28, 2022

Incident date: Nov 1, 2014

Head lights are cloudy given poor visibility. Back hatch door has a crack.

Incident date: Oct 25, 2021

The contact owns a 2003 Ford Explorer. The contact stated that while driving at approximately 25-35 MPH around a curb, the driver thought that the tire was flat. The contact pulled off the road and noticed that three of the wheel studs on the driver’s side rear wheel had sheared off. The vehicle w... Read more

Incident date: Oct 16, 2021

Hello my name is [XXX] just writing you cause my neighbors have program my vehicle meaning they hack my 2003 explore pretty much they want to take over my driving they trying to dominate me in this matter when in reality is not going to be possible that's why I come to your people's corporate plus ... Read more

Incident date: Nov 25, 2019

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. THE CONTACT STATED THAT THE FRONT DRIVER'S SIDE WHEEL DETACHED DUE TO THE CONTROL ARM BEING CORRODED. THE CONTACT CALLED ELDER FORD (777 JOHN R RD, TROY, MI 48083, (248) 825-8646) AND WAS ADVISED TO SCHEDULE AN APPOINTMENT. THE VEHICLE WAS LATER TAKEN TO AN... Read more

Incident date: Jul 5, 2019

SHIFTER BROKEN INSIDE STEERING COLUMN. STOPPED AT A GAS STATION WHEN PUTTING INTO PARK IT BROKE. HAD TO KEEP MY FOOT ON BRAKE PADDLE FOR 2 HOURS UNTIL TWO TRUCK ARRIVED

Incident date: Jan 20, 2019

2003 FORD EXPLORER. CONSUMER WRITES IN REGARD TO DEFECTIVE THROTTLE IN MODEL VEHICLE. *AS *TR

Incident date: Jan 20, 2019

2003 FORD EXPLORER. CONSUMER WRITES IN REGARD TO DEFECTIVE THROTTLE IN MODEL VEHICLE. *AS *TR

Incident date: Feb 10, 2019

VEHICLE WAS IN MOTION, MOVING THROUGH AN INTERSECTION ON A CITY STREET AND INVOLVED IN AN ACCIDENT. NO AIR BAGS DEPLOYED AT ALL.

Crash

Incident date: Oct 26, 2018

ENGINE STOPS WHILE DRIVING (STALLS IN MOTION WHILE TURNING ON STREET AND HIGHWAY) RESTARTS WITHOUT PROBLEM, HAS HAPPENED TWICE NOW 30 DAYS APART.

Incident date: Feb 28, 2017

2003 FORD EXPLORER. CONSUMER WRITES IN REGARD TO MALFUNCTION TO COMPANY'S REAR WHEEL BEARING. *AS *TR

Incident date: Aug 30, 2018

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WITHIN A MONTH OF OWNING THE VEHICLE, AN INDEPENDENT MECHANIC STATED THAT THE BRAKE SYSTEM NEEDED SERVICING, INCLUDING THE ROTORS AND BRAKE PADS. THE VEHICLE WAS NOT DIAGNOSED BY A DEALER. THE MANUFACTURER WAS NOTIFIED AND HAD NOT ISSUED ANY BRAKE SYSTEM RE... Read more

Incident date: Mar 14, 2018

THE PROBLEM THE SEAT BELTS DOES NOT HAVE ENOUGH TENSION TO RETRACT CONSEQUENTLY GETTING ON THE DOOR LOCK MECHANISM, CAUSING THE DOOR NOT TO LOCK, TO STAY OPEN UNSECURED ALSO DAMAGING THE SEAT BELT, IT DOES NO HAVE A WAY TO INCREASE THE TENSION WHICH IT SHOULD HAVE. IT DAMAGED MY DOOR SEAL, MY LOCK M... Read more

Incident date: Jan 3, 2018

REAR WINDOW LOWER PANEL PLASTIC CRACKING UP, REPLACED THREE TIMES, STILL CRACKING DUE TO NO SUPPORT AND BENDING TOO MUCH, I CALLED FORD DOES NOT CARE IF CONTINUES CRACKING UP, IT LOOKS UGLY ALSO PANELS CAN CAUSE AN ACCIDENT TO OTHER CARS GETTING INTO THEIR WINDSHIELDS LOOSE PARTS. THEY KNOW ABOUT TH... Read more

Incident date: May 3, 2018

THIS SUV'S ARE GETTING HOT DURING THE TEXAS WEATHER, WHY ARE NOT INCLUDING A SOLAR FAN INSTALLED TO KEEP THE AIR CIRCULATING IN THE SUV, TECHNOLOGY IS CHANGING WHY ARE NOT ADDING THE SYSTEM ???

Incident date: Jun 2, 2018

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHEN ATTEMPTING TO CLOSE THE REAR WINDOW, THE CONTACT NOTICED THAT THE REAR LIFTGATE WINDOW HINGES WERE CRACKING AND WERE TILTED ON ONE SIDE. THE CONTACT, A CERTIFIED MASTER TECHNICIAN, STATED THAT THE WINDOW NEEDED TO BE REPLACED. THE CONTACT CALLED FORT M... Read more

Incident date: Jun 2, 2018

Incident date: Jan 20, 2018

EXHAST MANAFOLD HAS CRACK IN IT AND SCREWS CAME LOSE AND FELL OUT WIHICH CREATED FUMES IN CAR.

Incident date: Feb 22, 2018

ALL SIDE AIRBAGS DEPLOYED WITHOUT ACCIDENT. DEPLOYMENT HAPPEND WHILE MY WIFE AND 4 YEAR OLD SON WAS IN THE VEHICLE DRIVING APPROXIMATELY 30-40 MILES PER HOUR DOWN A STRAIGHT ROAD IN LONG VALLEY NEW JERSEY. THIS ROAD IS SMOOTH, LEVEL AND FREE OF POT HOLES ETC. UNABLE TO SEE BECAUSE OF THE DOWNED AIRB... Read more

Incident date: Jan 8, 2018

WHENEVER WE ARE DRIVING IN THE CAR, MY WIFE AND I GET DIZZINESS AND NAUSEA. MY WIFE AND DAUGHTER SAY THERE IS AN EGGY SMELL SOMETIMES. MOSTLY, NO ODOR BUT AN OVERWHELMING SENSE OF DIZZINESS ONLY WHEN WE ARE IN THAT CAR TO THE POINT WE AVOID DRIVING AS MUCH. THIS HAS BEEN ONGOING FOR YEARS. I THOUGH... Read more

Incident date: Dec 22, 2017

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHILE DRIVING 65 MPH, THE TEMPERATURE GAUGE INCREASED TO HIGH AND THE VEHICLE CAUGHT FIRE UNDER THE HOOD WITHOUT WARNING. THE AIR BAGS DID NOT DEPLOY. THERE WERE NO INJURIES DUE TO THE FIRE. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO AN INDEPENDENT... Read more

Fire

Incident date: Nov 28, 2017

VEHICLE WAS PARKED WHEN REAR WINDOW EXPLODED AFTER DOOR CLOSED. SHARDS OF GLASS FLEW OUTWARD

1 injured

Incident date: Sep 21, 2017

BROKEN GEAR SHIFTER

Incident date: Aug 16, 2017

SHIFT LEVER BROKE OFF INSIDE STEERING COLUMN OF MY WIFE'S EXPLORER WHEN CHANGING FROM PARK TO DRIVE TO EXIT FROM A BOAT LAUNCH RAMP WITH NO BOAT ON THE TRAILER. VEHICLE WAS TOWED ON A FLATBED WRECKER TO MY GARAGE. BROKEN ELEMENT ( SEE PHOTOS) WAS NOT REPLACEABLE BY ITSELF. STEERING COLUMN HAD TO BE ... Read more

Incident date: Aug 16, 2017

Incident date: Jun 18, 2016

I CONTACTED FORD REGARDING RECALL WITH THE LIFT GATE. THERE WAS RECALL IN 2004 FOR MY VEHICLE THAT WAS TAKEN CARE OF IN 2005. IN 2016 THE SAME THING HAPPEN WHERE THE LIFT GATE BOLTS BROKE AND THE GATE FELL AND THE GLASS SHATTERED ALL OVER ME. I WENT THROUGH MY INSURANCE COMPANY AND GOT IT REPAIRE... Read more

Incident date: Aug 1, 2017

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 10 MPH, THE VEHICLE STALLED WITHOUT WARNING AND CRASHED INTO A DITCH. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT AND FOUR BYSTANDERS PUSHED THE VEHICLE INTO... Read more

Crash

Incident date: May 17, 2006

GREETINGS THE PROBLEM THE CABIN NOT WELL SEALED FROM ANY FUMES PLUS THE A/C DOOR INSIDE TO KEEP THE AIR RECYCLE FALLING OFF NOT WELL SECURE CONSEQUENTLY GETTING FUMES FROM THE OUTSIDE AND ALSO I CAN SMELL THE CABIN IN THE MORNING WHEN I GET INSIDE FROM EITHER OIL LEAKS AND EXHAUST BURNS, IT NEEDS AT... Read more

Incident date: Jul 13, 2017

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHILE DRIVING 55 MPH, THE LUG NUTS BECAME DETACHED FROM THE REAR PASSENGER WHEEL, WHICH CAUSED THE VEHICLE TO SHAKE VIOLENTLY. THE CONTACT PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND WAITED FOR A TOW TRUCK. THE CONTACT STATED THAT THE FAILURE OCCURR... Read more

Incident date: May 10, 2017

AWOKE THE MORNING OF MAY 10, 2017 TO FIND THE ENTIRE BACK LIFTGATE AND WINDOW EXPLODED OUTWARDS AND INWARDS OF OUR FORD EXPLORER. THE VEHICLE WAS PARKED IN FRONT OF OUR HOME, WE ARE RURAL, SO NO EVIDENCE OF SOMEONE PURPOSELY BREAKING IT. OUR SHERIFF IN CASCADE COUNTY, MONTANA, STATED IT APPEARS TO ... Read more

Incident date: Nov 2, 2012

TRANSMISSION SHIFTS HARD AND CLUNKS, IS NOT SAFE TO DRIVE. THE ESTIMATE REPAIR IS AROUND $ 3,400. WILL NEVER BUY A FORD AGAIN.

Incident date: Dec 27, 2012

THE BACK LIFT GATE HAS A CRACK. I HAVE NOTICED THIS ON PRACTICALLY EVERY OTHER EXPLOER OF THIS YEAR. I CONTACTED FORD SEVERAL YEARS AGO AND THEY SAID SINCE IT WAS A DEFECT THAT WAS NOT A DANGER THEY WOULD NOT RECALL OR REPAIR IT.

Incident date: Feb 18, 2003

CHAT CONVERSATION START 5:57PM GREETINGS, I SAW YOU COMMENTARY ABOUT THE FORD EXPLORER EXHAUST FUMES INSIDE THE CABIN, WELL I HAVE A 2004 FORD EXPLORER WITH THE SAME PROBLEM, I AM A MECHANIC I FIGURED MAY BE THE FILTER WAS CLOGGED WELL IT WAS NO FILTER, WHAT I FOUND THE VENT DOOR FELL OFF FROM THE... Read more

Incident date: Feb 18, 2003

Incident date: Jan 28, 2016

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHILE DRIVING AT LOW SPEEDS, THE VEHICLE BEGAN TO EXPERIENCE A JERKING MOTION AND THE ABS INDICATOR ILLUMINATED. THE FAILURE WAS PERSISTENT. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE WHEEL SPEED SENSORS, ABS SENSORS, A... Read more

Incident date: Nov 4, 2016

TL* THE CONTACT OWNED A 2003 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 10 MPH, THE VEHICLE SUDDENLY ACCELERATED AND THE PASSENGER SIDE AIR BAG IMMEDIATELY DEPLOYED WITHOUT WARNING. THE CONTACT STATED THAT THE POWDERY DUST FROM THE DEPLOYED AIR BAG CLOUDED HIS VISION AND CAUSED THE VEHICLE TO REAR E... Read more

Crash 1 injured

Incident date: Jan 8, 2017

THE REAR PANEL OF MY 2003 EXPLORER CRACKED TODAY FOR NO REASON. NOT SURE IF THIS IS A SAFETY CONCERN. WHEN I "GOOGLED" THE PROBLEM, IT SEEMS THIS IS A COMMON PROBLEM THAT FORD ONCE ADDRESSED.

Incident date: Nov 13, 2016

BACK GLASS EXPLODED. WHEN I PRESSED THE GATE RELEASE BUTTON, GLASS EXPLODED ON MY AND MY FOSTER CHILD I WAS HOLDING.

Incident date: Dec 6, 2016

WHILE DRIVING THIS VEHICLE, THE SPARK PLUGS HAVE BLOWN OUT OF THE ENGINE SIX TIMES REQUIRING SIX DIFFERENT TOWS HOME. THE VEHICLE IS UNRELIABLE FOR ME (DISABLED, SINGLE MOM) WHO HAS TO TAKE MY DAUGHTER AND I TO DOCTORS APPOINTMENTS. I FEEL UNSAFE AND IT IS NOT SAFE FOR MY DAUGHTER, BUT I CAN'T AFF... Read more

Incident date: Sep 1, 2009

TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHEN OPERATING THE VEHICLE, THE REAR HATCH DOOR AND THE REAR HATCH WINDOW BECAME UNSECURED AND OPENED DUE TO A CRACK NEAR THE REAR WINDOW WIPER. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE F... Read more

Incident date: Sep 1, 2009

Incident date: Jul 28, 2016

TL* THE CONTACT OWNED A 2003 FORD EXPLORER. WHILE DRIVING AT AN UNKNOWN RATE OF SPEED ON A HIGHWAY, THE CONTACT WAS INVOLVED IN A HEAD ON COLLISION WITH ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY. THE OTHER VEHICLE ROLLED OVER AND THE CONTACT'S VEHICLE STOPPED AT THE MEDIAN. A POLICE REPORT WAS FI... Read more

Crash 1 injured

Incident date: Aug 10, 2015

"TAKATA RECALL"I BROUGHT THE TRUCK AND THE AIRBAG LIGHT WAS FLASHING 4X4 LIGHTS FLASHING ALSO, SMELLING OIL COMING FROM THE DEFERENTIAL ON THE BACK AXLE. NOW, THE TRANSMISSION STARTED SLIPPING AND HE CHANGED A PART . THEN, THE TRANSMISSION STARTED TO SLIP AGAIN. ALSO,I WANTED TO SWITCH TO ANOTHER V... Read more

Incident date: Aug 10, 2015

Incident date: Jun 22, 2016

THE REAR LIFT-GATE HAS A CRACKED PANEL.

Incident date: Jun 12, 2016

MY TRANSMISSION LIGHT HAS BEEN COMING ON. I WAS ONLY AT 117K MILES WHEN IT HAPPENED. THAT'S TO SOON FOR A TRANSMISSION TO BE ACTING UP ESPECIALLY SINCE IT'S ANEW ONE ACCORDING TO CARFAX THIS IS THE SECOND TRANSMISSION FOR MY EXPLORER. THE FIRST ONE WAS PUT IN ONLY AT 3 YEARS OLD. IT WILL SOMETIMES J... Read more

Showing 50 of 1,369 complaints.

Technical Service Bulletins, 2003 FORD EXPLORER

126 manufacturer communications from 123 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
061000 ENGINE AND ENGINE COOLING:ENGINE	18
106000 POWER TRAIN:AXLE ASSEMBLY	17
110000 ELECTRICAL SYSTEM	15
100000 POWER TRAIN	8
090000 FUEL SYSTEM, OTHER	6
160000 STRUCTURE	3
162000 STRUCTURE:BODY	3
105000 POWER TRAIN:DRIVELINE	3

160000 STRUCTURE

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

160000 STRUCTURE

350000 EQUIPMENT

106200 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

106220 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

061000 ENGINE AND ENGINE COOLING:ENGINE

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

106000 POWER TRAIN:AXLE ASSEMBLY

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT

091200 FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT

190000 TIRES

LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT

060000 ENGINE AND ENGINE COOLING

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

081100 FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH

021600 SUSPENSION:FRONT:WHEEL BEARING

NOISE FROM REAR WHEEL HUB BEARINGS. *TT

090000 FUEL SYSTEM, OTHER

MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT

106220 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL

AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT

105000 POWER TRAIN:DRIVELINE

DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE. *TT

151300 SEAT BELTS:FRONT:RETRACTOR

SAFETY BELT RETRACTION SPEED. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE SEAL LEAKS. *EH

060000 ENGINE AND ENGINE COOLING

NO START/HARD START N HOT SOAK RESTART. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE NOISE REPAIR. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT

220000 SEATS

FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT UPDATE. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE HOWL. THIS INCLUDES 1997-05 FORD VEHICLES. *EH

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE HOWL SERVICE WITH INDIVIDUAL PARTS INSTEAD OF AN AXLE ASSEMBLY. *EH

133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

REAR POWER WINDOW(S) INOPERATIVE. *TT

162000 STRUCTURE:BODY

LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED. SERVICE PROCEDURE. *TT

110000 ELECTRICAL SYSTEM

OPEN FUSE F2.20 (5 AMP) AND/OR F2.1 (30 AMP) WHICH MAY RESULT IN LOSS OF FUNCTION OF SEVERAL SYSTEMS INCLUDING POWER SEATS, ADJUSTABLE PEDALS AND POWER DOOR LOCKS. *TT

022000 SUSPENSION:REAR

REAR AXLE NOISE REPAIR. *SC

061000 ENGINE AND ENGINE COOLING:ENGINE

HARD START/NO START CONDITION DURING COLD AMBEINT TEMPERATURES AFTER SHORT HOT SOAK PERIOD-4.0L ENGINE. *SC

132000 VISIBILITY:GLASS, SIDE/REAR

BACKGLASS DIFFICULT TO CLOSE AND AN INTERMITTENT DOOR AJAR LAMP. *TT

110000 ELECTRICAL SYSTEM

WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT

162000 STRUCTURE:BODY

ALUMINUM CORROSION - SERVICE TIP. *TT

138200 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REAR WINDOW

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

103300 POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)

GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004. *TT

162300 STRUCTURE:BODY:DOOR

BROKEN REAR CARGO STORAGE DOOR LIFT HANDLE. VARIOUS MODELS INCLUDING 2005 EXPLORER/MOUNTAINEER. *TT

090000 FUEL SYSTEM, OTHER

MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE NOISE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, MOUNTAINEER AND AVIATOR. *TT

090000 FUEL SYSTEM, OTHER

RUNS ROUGH OR MISFIRE - DIAGNOSTIC TROUBLE CODES P0300-P0308 OR P0316. *TT

180000 VEHICLE SPEED CONTROL

SPEED CONTROL INOPERATIVE OR NOT HOLDING THE SET SPEED. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, SPORT TRAC, MOUNTAINEER AND AVIATOR. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

CHATTER, SHUDDER, A BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS ON VEHICLES EQUIPPED WITH THE 9.75 INCH OR 8.8 INCH LIMITED SLIP REAR AXLE. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

FRONT AXLE TUBE LEAK. *EH

091200 FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

FUEL GAUGE SLOW TO UPDATE. *TT

100000 POWER TRAIN

UPDATED REAR HALFSHAFT REMOVAL PROCEDURE. *TT

113000 ELECTRICAL SYSTEM:STARTER ASSEMBLY

NO CRANK/NO START CONDITION WHEN VEHICLE TEMPERATURE IS BELOW FREEZING (32F/0C). *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04.

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *TT

110000 ELECTRICAL SYSTEM

STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401. ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY.

063130 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

CUSTOMER SATISFACTION PROGRAM 02M01 SUPPLEMENT #4. CERTAIN FORD 2000 THROUGH 2003 VEHICLES EQUIPPED WITH A TUBE-MOUNTED EGR PRESSURE SENSOR - ADDITIONAL EGR PRESSURE SENSOR WARRANTY COVERAGE. *TT SUPPLEMENT #3. *MJ SUPPLEMENT #6

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE DATE CODE INSPECTION AND SERVICE. VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPER MIX OF REAR AXLE LUBRICANT AND FRICTION MODIFIER ADDITIVE. IF SO, THE CUSTOMER MAY EXPERIENCE NOISE AND VIBRATION WHILE DRIVING. *TT *MJ

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS. *TT

353000 EQUIPMENT:ELECTRICAL

MESSAGE CENTER DISPLAYS COMPUTING FUEL INSTEAD OF DISTANCE TO EMPTY. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE NOISE. *TT

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

TIRE PRESSURE MONITORING SYSTEM (TPMS) LOW TIRE OR TIRE VERY LOW MESSAGE AND/OR THE TPMS LIGHT ON. *TT

141000 AIR BAGS:FRONTAL

POOR FIT BETWEEN DRIVER AIR BAG AND STEERING WHEEL. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR 3.55 AXLE NOISE. CERTIFIED REAR AXLE OR IMPROVED GEAR SET AVAILABLE. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

GENERATOR NOISE IN COLD AMBIENT TEMPERATURES. *MJ

100000 POWER TRAIN

CERTIFIED REAR AXLE AVAILABLE. *MJ

110000 ELECTRICAL SYSTEM

INTERMITTENT AIR BAG WARNING LAMP ON, MEMORY SEAT, AND/OR ADJUSTABLE PEDAL CONCERNS. *MJ

100000 POWER TRAIN

REAR AXLE NOISE. ALSO INCLUDES LINCOLN AVIATOR 2002. *MJ

090000 FUEL SYSTEM, OTHER

DISTANCE TO EMPTY NOT DISPLAYED. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

TIRE PRESSURE MONITORING SYSTEM (TPMS) MODULE CONFIGURATION - SERVICE TIP. *MJ

090000 FUEL SYSTEM, OTHER

FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE AUXILIARY OIL COOLER LINE AND THE RIGHT SIDE MOTOR MOUNT SQUEAKING NOISE FROM FRONT EXTERIOR WHILE DRIVING OVER BUMPS. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ON AND HARD START/LONG CRANK. *TT

110000 ELECTRICAL SYSTEM

INSTRUMENT CLUSTER LOCKING UP AND ACCESSORIES SUCH AS THE RADIO, POWER WINDOWS, POWER LOCKS AND MOONROOF INOPERATIVE. *TT

162000 STRUCTURE:BODY

A POPPING OR CREAKING NOISE THAT APPEARS TO BE COMING FROM THE FRONT EXTERIOR OF THE VEHICLE. *TT

112000 ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

GENERATOR WHISTLE/HOOT NOISE IN COLD AMBIENT TEMPERATURES. *TT

110000 ELECTRICAL SYSTEM

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

105000 POWER TRAIN:DRIVELINE

DRIVELINE VIBRATION ON DRONE/BOOM AT HIGHWAY SPEEDS. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

MULTIPLE VEHICLES WITH 3.0L OR 4.0L ENGINES LACKS POWER/RUNS ROUGH/BLACK SMOKE. 2004 SPORT TRAC INCLUDED. *TT

046600 SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT

THE AMBER ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LIGHT ON WITH DIAGNOSTIC TROUBLE CODES C1235, C1236/C1237 STORED IN MEMORY. *TT

162610 STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS

BREAKAGE OF A LIFTGATE WINDOW HINGE. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

AIR CONDITIONER HOOTING NOISE DURING LIGHT LOAD ACCELERATION AT LOW SPEEDS, FROM 1000-1300 RPM. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

SOME VEHICLES, EQUIPPED WITH THE 4.6L 2V ENGINE, WITH AN ENGINE BUILD DATE PRIOR TO 8/29/03 MAY EXHIBIT AN ENGINE TICK NOISE THAT IS PRESENT AT ALL TEMPERATURES DURING IDLE. 2004 MODELS INCLUDED. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND DIAGNOSTIC TROUBLE CODES (DTC'S) P0171, P0172, P0174, OR P0175. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ROUGH IDLE / ENGINE SHAKE. *TT

100000 POWER TRAIN

TCIL FLASHING WITH DIAGNOSTIC TROUBLE CODE P0741 AND/OR NOISE FROM THE CONVERTER HOUSING. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE AT CRUISE OR DURING ACCELERATION/ DECELERATION. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ROUGH/ROLLING IDLE OR HESITATION AFTER FIRST STARTUP OR A ROUGH/ROLLING ENGINE SPEED WHEN RETURNING TO IDLE AFTER A SHORT TRIP. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE MISFIRE OR ROUGH RUNNING CONDITION WITH COIL ON PLUG (COP) IGNITION SYSTEMS MAY BE MORE ACCURATELY DIAGNOSED USING THE OPTIONAL WORLDWIDE DIAGNOSTIC SYSTEM (WDS) COIL ON PLUG (COP) KIT. 2003 SUPER DUTY F SERIES INCLUDED. *TT

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT

110000 ELECTRICAL SYSTEM

NO CRANK CONDITION. SERVICE TIPS. *TT

036100 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE

ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED AND DIAGNOSTIC TROUBLE CODE (DTC) C1235, C1236, C1237 ON VEHICLES WITH DIFFERENTIAL-MOUNTED RAR WHEEL SPEED SENSOR. *TT

093000 FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM

ROUGHNESS/ROLLING RPM WHEN RETURNING TO IDLE (I.E., COMING TO A STOP) AFTER A SHORT TRIP. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE VIBRATION/DRONE ABOVE 60 MPH. *TT

110000 ELECTRICAL SYSTEM

CLUSTER LOCKING UP & VARIOUS ACCESSORIES SUCH AS THE RADIO, POWER WINDOWS, POWER LOCKS AND MOONROOF BEING INOPERATIVE. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

DRIVEABILITY CONDITIONS DUE TO CALIBRATION VEHICLES EQUIPPED WITH THE 4.0L SOHC ENGINE. IDLE AIR CONTROL (IAC) VALVE REPLACEMENT FOR THESE SYMPTOMS IS TYPICALLY NOT EFFECTIVE. *TT

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

A FLUID LEAK COMING FROM WITHIN THE CONVERTER HOUSING ON VEHICLES WITH 5R55S TRANSMISSION. *TT

110000 ELECTRICAL SYSTEM

AN INTERMITTENT OR CONTINUOUS OPEN OF FUSE 1.15. *TT

162600 STRUCTURE:BODY:HATCHBACK/LIFTGATE

LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED - SERVICE PROCEDURE. *TT

100000 POWER TRAIN

TCIL FLASHING WITH DIAGNOSTIC TROUBLE CODE P0741 (TCC SLIPPAGE DETECTED) AND/OR NOISE FROM THE TORQUE CONVERTER HOUSING. *TT

100000 POWER TRAIN

A WHINE NOISE ON TIP-IN AT SPEEDS OF 45 TO 65 MPH. THIS MAY BE DUE TO DRIVELINE STACK-UP TOLERANCE WITH THE DRIVESHAFT AND REAR AXLE. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE ROUGHNESS / ROLLING RPM WHEN RETURNING TO IDLE (I.E., COMING TO A STOP) AFTER A SHORT TRIP. *TT

046600 SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT

ANTI-LOCK BRAKE SYSTEM (ABS) INDICATOR LAMP ON WITH CODES C1235 AND C1236 OR C1237. *TT

Showing 100 of 126 bulletins.

NHTSA Safety Investigations, FORD EXPLORER

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

DP, Closed , Model Year: 2020

Underbody shields detachment

The Office of Defects Investigation (ODI) received a petition on August 22, 2025, requesting a defect investigation into an alleged defect of the “underbody shields” on model year (MY) 2020 Ford Explorer vehicles. The petition alleges premature degradation and detachment of the plastic underbody... Read more

RQ, Closed , Model Year: 2020

Rear Axle Bolt Failure

On July 17, 2023, the Office of Defect Investigation (ODI) opened this Recall Query (RQ) after receiving 2 consumer complaints alleging loss of vehicle forward power and/or loss of transmission torque of the rear wheels in model year (MY) 2020-2022 Ford Explorer vehicles (subject vehicles). The RQ w... as opened to focus on the effectiveness of the remedies of Recalls 22V-255 and 23V-199 related to the alleged problem. Recall 22V-255 involved replacing the bushing and axle cover in the following subject vehicles: 3.3L FHEV Police built before October 14, 2020, and 3.3L Gas Police vehicle built before January 31, 2021. For 2.3L RWD, 3.0L PHEV, 3.3LFHEV, and 3.0LST retail (non-police) vehicles, the recall provided an PCM software update to engage the Electronic Park Brake (EPB) when Park is commanded. The recall addressed a breakage of the rear axle bolt that can cause the driveshaft/half shafts to disconnect, resulting in a loss of transmission torque to the rear wheels necessary to hold park. If the parking brake is not applied, the loss of the primary park torque will allow the vehicle to roll in park increasing the risk of crash and injury. Recall 23V-199 addressed 674 of the subject vehicles produced from February 2, 2019 to April 4, 2022, which received an incorrect remedy under Recall 22V-255. The affected vehicles had received a previous Powertrain Control Module (PCM) update which did not include an automatic EPB engagement when vehicle is shifted to park. On October 17, 2023, Ford filed a new safety recall (Recall 23V-675) covering 238,364 MY 2020-2022 Explorer vehicles with the following powertrains: 3.3L FHEV Police, 3.3L Gas Police, 3.0L Gas Police, 2.3L RWD, 3.0L PHEV, 3.3L FHEV, 3.0L RWD and 3.0L AWD, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. Ford stated that the cause of the bolt fracture is due to joint design not robust to peak axle input torques and manufacturing variability. The primary contributor is insufficient bearings for maximum joint loads. This can result in bearing deformation, increasing bending stress on the bolt, which may lead to fatigue failure. On January 19, 2023, Ford amended Recall 23V-675 to add 1,942 MY 2020-2022 Explorer vehicles with the following powertrain: 3.0L RWD Platinum and King Ranch variant, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. In addition to the safety recall, Ford will conduct a customer satisfaction program for the following MY 2020-2022 Explorer vehicles with the following powertrains: 2.3L AWD, 3.3L Gas Retail, 3.0L Gas AWD Platinum and King Ranch, produced from October 22, 2018 to July 6, 2022. Ford stated that the Explorer powerpack variants not covered under Recalled 23V-675 do not present an unreasonable risk to motor vehicle safety due to the combination of lower peak torque levels and torque management strategies to share inputs between front and rear axles, reducing occurrence of higher torque. According to Ford, this is also evidenced by the lower current and projected failure rates. In view of the recall action being taken by Ford, ODI is closing this RQ. NHTSA will continue to monitor complaints from the customer satisfaction program vehicles and reopen this issue, if necessary. 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.Read more

PE, Closed , Model Year: 2011

Windshield trim molding Item detachment

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 fail... ure. 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.Read more

AQ, Open , Model Year: 2018

Hertz/Vehicles Rented with Open Recalls

NHTSA is opening this audit query to investigate whether The Hertz Corporation (Hertz) has complied with the requirements of the National Traffic and Motor Vehicle Safety Act (Safety Act). The Safety Act requires, among other things, that a rental company shall not rent a vehicle subject to a safety... Read more

EA, Closed , Model Year: 2011

Exhaust Odor in Passenger Cab

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 oc... cupational 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 inveRead more

PE, Closed , Model Year: 2011

Ford Explorer Exhaust Odor

During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 ... Read more

EA, Closed , Model Year: 2013

Front Brake Hose Failure

On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate a report alleging incidents of front brake hose failure in model year (MY) 2015 Ford Explorer Police Interceptor vehicles used by the Sacramento Police Department in its pursuit driving training program (VOQ ... Read more

PE, Closed , Model Year: 2015

Front brake hose failure

On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate reports of low-mileage failures of front brake jounce hoses in model year (MY) 2015 Ford Explorer Police Interceptor vehicles operated as training vehicles by the City of Sacramento, California (ODI VOQ No. 1... 0705832). To date, the Sacramento police fleet has reported a total of 7 front hose failures in 5 different Explorer Police Interceptor vehicles used for its Emergency Vehicle Operation Course (EVOC) training. Most of the failures occurred within the first few miles of service on a closed course used for the EVOC program, which includes evasive accident avoidance and pursuit maneuver training. The hose assemblies either leaked at, or pulled completely free from, the caliper-end attachment where the hose is crimped to the steel end fitting. Most of the failures resulted in a sudden loss of braking performance that caused the vehicle to run off the intended course. None of the failures resulted in any crashes, injuries or property damage.The subject MY 2015 hose assemblies are similar in design to hoses used on MY 2013 through 2014 Explorer Police Interceptor and civilian vehicles. The 5 vehicles used by Sacramento EVOC have all been repaired using MY 2016 front hose assemblies that have been changed to incorporate a short steel tube attached to the caliper end banjo block. No failures have been experienced by the Sacramento fleet to date in the other 37 MY 2014-2015 Explorer Police Interceptor vehicles (2 MY 2014 and 35 MY 2015) used by the fleet in regular law enforcement duty cycles unrelated to the EVOC training. In its response to ODI's information request letter for PE15-017, Ford provided information about 2 additional failures reported by other fleets, including 1 involving a Sacramento Regional Transit vehicle that occurred while being driven on the street.Based on its analysis of failed parts returned from the Sacramento fleet and the fleet's EVOC training duty cycle, Ford attributes the Sacramento fleet hose failures to excessive temperatures produced during hot-soak portions of the EVOC training duty cycle (when the vehicles are stationary after hard braking exercises, with no cooling air flow through the brake rotor vents and across the other brake components). During testing conducted to replicate the EVOC duty cycle, Ford measured temperatures at the subject crimp fittings that exceeded the design limits of the brake hose material after several successive training intervals and hot soaks. Ford has provided the Sacramento fleet with modified replacement hose assemblies for all of its MY 2014-15 Explorer Police Interceptor vehicles. The replacement hose assemblies were developed for use in MY 2016 Explorer vehicles and were modified slightly to accommodate the addition of a ride height sensor in those vehicles. The revised assemblies have an additional length of brake pipe between the caliper end connection and the subject crimp ferrule that results in additional heat dissipation and makes the assemblies more robust to the severe thermal effects experienced during the EVOC testing (the hose material is the same in both assemblies). Ford believes that the excessive temperatures experienced at the crimp fitting in the subject vehicles are unique to the EVOC duty cycle, have not been observed in the standard on-road severe duty cycle testing performed by Ford and police fleets who routinely conduct such testing and are not likely to occur in service usage for on-road Explorer Police Interceptor vehicles.This preliminary evaluation is closed, an Engineering Analysis (EA15-005) has been opened to conduct testing and furtherRead more

PE, Closed , Model Year: 2013

Front brake hose failure

The Office of Defects Investigation (ODI) opened PE14-027 based on a report of 13 front brake hose (jounce hose) failures in 11 vehicles in the District of Columbia Metropolitan Police Department (DCMPD) fleet of 46 model year (MY) 2013 Ford Explorer Police Interceptor (PI) vehicles (VOQ 10621634).T... he DCMPD fleet provided Ford with 71 jounce hoses for analysis, including 4 of the 13 failed hoses.Inspection of each of the failed hoses identified a small tear in the outer cover on the body end of the hoses on the outboard side. Ford?s lab analysis of these hoses identified splits in the inner liners 1.5-2.0mm from the end of the nipple (outside of the crimped ferrule joint).Ford conducted pressure testing of 10 randomly selected samples of the remaining 67 hoses that had not experienced leaks and 9 of the samples leaked at 6,000 psi.Ford?s examination of the 9 hoses that leaked in the pressure tests found 4 that failed on the outboard side of the hose (similar to the 4 leaking field parts) and 5 that failed on the body end of the hose on the inboard side.Four additional non-leaking hoses were sent to the hose supplier, Hitachi, for analysis.Broken yarn was observed in scanning electron microscope examinations at both the body side and caliper side hose to ferrule crimps, indicating severe bending stress had occurred at these locations. Hitachi supplied an additional set of non-leaking field return hoses and a brand new set of hoses to an outside laboratory (Element Materials Technology) for analysis.The lab did not identify any manufacturing or material deficiencies in the hoses and concluded that the hose failures were caused by excessive bending stresses.Based on the examinations of the returned jounce hoses, Ford conducted durability testing on new hoses that were the same design as those found on the subject vehicles.Ford first determined the worst case conditions for the hoses; jounce bumpers removed, internal rebound stops fully compressed, and shock absorbers attached. With the jounce hose installed, the steering was rotated to the maximum turn angle while the suspension was translated from full jounce to full rebound.This determined the maximum hose length of 13.0in (331mm) and a minimum hose bending radius of 1.6in (40mm).Using these conditions hoses tested on a Suspension Motion Simulator far surpassed Ford?s performance specifications. Twenty (20) complaints of front brake jounce hose failure were identified on a total of 18 Explorer PI vehicles, including the 13 hose failures in 11 vehicles from the DCMPD fleet that prompted PE14-027.The remaining 7 complaints included 3 from one fleet that reportedly occurred on the banjo block end of the hose assembly and single complaints from 4 other fleets.Only two brake hose assemblies were used in the subject and peer Explorer vehicles, with the BB53 level hose used until June 20, 2012, and an updated DB53 level hose used thereafter.No pattern of failures was observed by hose assembly, with 15 of failures involving the BB53 hose assembly (including the 13 from DCMPD manufactured in March 2012) and 5 the DB53 hose assembly built after June 20, 2012. No root cause was determined for the reported Explorer PI jounce hose failures, but Ford identified improper service repair procedures (e.g., hanging the brake caliper from the brake hose during brake pad replacement) as a possible contributor to higher than expected rate of front brake jounce hose leaks. ODI?s analysis of field data, hose inspection and test data did not identify evidence of any defects in hose material, manufacture or vehicle installation.The closing of this investRead more

PE, Closed , Model Year: 2011

Electric power steering failure

On May 27, 2014 and amended June 2, 2014, Ford Motor Company (Ford) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 179,027 model year (MY) 2011 through 2013 Ford Explorer vehicles equipped wit... h electric power assisted steering (EPAS), including 82,328 MY 2011 Explorersthat are the subject of PE12-017.Ford has assigned the recall number 14S06.The NHTSA recall number is 14V-286.Ford's DIR indicates that loss of power steering assist while driving would require higher steering effort at lower vehicle speeds, which may result in an increased risk of a crash.Sudden loss of power steering assist while driving can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe mode, which removes power from the EPAS motor and defaults to manual steering.Ford's DIR indicates that the majority of steering assist failures in the recalled vehicles have been caused by an intermittent electrical connection in the Power Steering Control Module (PSCM) that can lead to a loss of the motor position sensor signal.Ford's remedy instructs dealers to check the PSCM for diagnostic trouble codes (DTC).If upon initial inspection a loss of steering assist DTC is present, dealers will replace the steering gear at no charge to the owner and update the PSCM with revised software.Following detection of a motor position sensor signal fault, the revised software will provide audible and visual warnings to the driver that a power steering system fault has been detected and will maintain steering assist for the remainder of that drive cycle.If no DTC is present, dealers will reprogram the PSCM with the revised software. Analysis of information from all sources identified a total of 969 complaints and 4,059 warranty claims related to loss of power steering assist while driving in the MY 2011 through 2012 Explorer vehicles, resulting in a complaint rate of 5.4 incidents per thousand vehicles and a warranty claim rate of 2.3 percent.ODI identified 15 crashes with evidence indicating loss of power steering assist may have been a factor.All 15 crashes involved low-speed impacts with roadside objects during turning maneuvers, resulting in minor vehicle damage or no damage.In one incident that occurred in a low-speed curve, the driver attempted to brake in response to the sudden increase in steering effort and inadvertently applied the accelerator pedal instead.This caused the vehicle to run off the side of the road and strike a wooden pole at approximately 15 mph.Another incident occurred when the driver was unable to to negotiate a left-turn at an intersection and ran off the road into a shallow ditch, resulting in moderate front-end damage to the vehicle and minor injuries to the driver that did not require medical treatment. This investigation is closed.All ODI complaints associated with this closing resume are listed in the Attachment 1.Read more

EA, Closed , Model Year: 2002

Vehicle Rollaway Allegations

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of... Read more

PE, Closed , Model Year: 2002

VEHICLE ROLLAWAY ALLEGATIONS

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM ... Read more

RQ, Closed , Model Year: 2004

REAR LIFTGATE GLASS HATCH FAILURE

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS ... Read more

PE, Closed , Model Year: 2002

STUCK ENGINE THROTTLE

ON JULY 7, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE COMPLAINTS IN CERTAIN MODEL YEAR (MY) 2002 FORD EXPLORER AND MERCURY MOUNTAINEER VEHICLES EQUIPPED WITH THE STANDARD AVAILABLE 4.0L SOHC V6 ENGINE.AT THAT TIME, ODI WAS AW... ARE OF 15 COMPLAINTS THAT ALLEGED STUCK ENGINE THROTTLE CAUSING UNWANTED VEHICLE ACCELERATION AND 1 ALLEGED CRASH AS A RESULT.SIX COMPLAINANTS REPORTED THAT THROTTLE CONTROL CABLE REPLACEMENT REMEDIED THE ALLEGED STUCK THROTTLE CONDITION.ADDITIONALLY, ODI WAS AWARE OF A TECHNICAL SERVICE BULLETIN ISSUED BY THE MANUFACTURER THAT REFERRED TO AN ACCELERATOR CABLE DESIGN CHANGE.ODI SENT A LETTER TO THE MANUFACTURER ON JULY 18, 2005 REQUESTING CERTAIN INFORMATION ABOUT THESE VEHICLES. ACCORDING TO FORD, APPROXIMATELY 234,092 SUBJECT VEHICLES BUILT FROM AUGUST 14, 2000 (?JOB 1?) THROUGH OCTOBER 31, 2001 USED A PARTICULAR ACCELERATOR CABLE KNOWN AS A 16 LAY WIRE DESIGN.THIS DESIGN IS COMPRISED OF THE THROTTLE CABLE SURROUNDED BY A CONDUIT MADE OF SEVERAL CONCENTRIC LAYERS INCLUDING A TEFLON LINER, A NYLON TUBE EXTRUDED OVER THE TEFLON LINER, 16 LAY WIRES WRAPPED AROUND THE NYLON TUBE, AND FINALLY A NYLON JACKET EXTRUDED OVER AND AROUND THE LAY WIRES. FORD REPORTS THAT THROTTLE CONTROL CONCERNS RELATED TO THE ACCELERATOR CABLE ARE LIKELY CAUSED BY A MIGRATION OF THE INNER TEFLON LINER OUT OF THE CONDUIT AT THE DASH PANEL FITTING.SHOULD THE TEFLON LINER MIGRATE OUTWARD SUFFICIENTLY TO CONTACT THE ACCELERATOR PEDAL ARM IT COULD INTERFERE WITH THE PEDAL?S ABILITY TO RETURN TO IDLE.IN NOVEMBER 2001, FORD BEGAN USING A NEW 12 LAY WIRE DESIGN ACCELERATOR CABLE.THIS CHANGE WAS IMPLEMENTED TO ALLOW FOR INSTALLATION OF OPTIONALLY AVAILABLE POWER-ADJUSTABLE PEDALS. FIELD DATA SUGGESTS THAT THE CONDITION WITH THE SUBJECT CABLE IS MORE PREVALENT IN COLD (WINTER) CLIMATES.OF THE 396 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT, NEARLY 68% OCCURRED IN WINTER MONTHS AND MOST WARRANTY CLAIMS ARE ASSOCIATED WITH VEHICLES SOLD IN THE NORTHEASTERN, NORTHERN INTERIOR (MIDWEST), AND ROCKY MOUNTAIN REGIONS OF THE UNITED STATES.THIS SEASONAL TREND APPEARS TO BE IN DECLINE WITH FEWER WARRANTY CLAIMS PAID IN WINTER 2005 THAN IN PREVIOUS WINTERS.THERE ARE NO KNOWN CRASHES RELATED TO THE ALLEGED DEFECT ON THE SUBJECT VEHICLES, THE COMPLAINT RATE IS LOW AFTER APPROXIMATELY FOUR YEARS IN SERVICE (3.0 INCIDENTS PER 100,000 VEHICLES) AND THE FAILURE TREND IS DECLINING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2005.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.ODI WILL CONTINUE TO MONITOR ITS COMPLAINT DATABASE AND WILL RECEIVE UPDATED COMPLAINT AND WARRANTY DATA FROM FORD IN SPRING 2006 TO VERIFY THE TREND ANALYSIS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.Read more

PE, Closed , Model Year: 2002

REAR LIFTGATE GLASS ASSEMBLY

COMPLAINTS REPORT FAILURE OF THE REAR LIFTGATE GLASS SUPPORT WHILE THE OPERATOR IS OPENING OR CLOSING THE GLASS.THE FALLING GLASS CAN STRIKE THE OPERATOR OR BYSTANDER.THE INJURIES REPORTED ARE BRUISES TO THE HEAD, NECK OR BACK, CUTS TO THE FACE, ARM OR HAND.ON SEPTEMBER 9, 2004, FORD NOTIFIED THE AG... Read more

PE, Closed , Model Year: 1998

FRONT SEAT BACK RECLINER ATTACHMENT

BY LETTER DATED AUGUST 4, 2003, FORD NOTIFIED THE AGENCY THAT IT IS CONDUCTING A VOLUNTARY SAFETY RECALL (NHTSA RECALL NO. 03V281) INVOLVING CERTAIN MODEL YEAR (MY) 1998-2001 FORD EXPLORER / MERCURY MOUNTAINEER 4-DOOR, MY 1998-2000 FORD EXPLORER 2-DOOR AND MY 2001-2002 FORD EXPLORER SPORT AND SPORT ... Read more

EA, Closed , Model Year: 2002

MIS-ASSEMBLED AIRBAG CLOCKSPRING

IN JULY 2001, FORD ISSUED A SPECIAL SERVICE MESSAGE ANNOUNCING THAT SOME AIR BAGCLOCKSPRING DEVICES MAY PRODUCE NOISE WHEN THE STEERING WHEEL IS TURNED FULL LEFT OR RIGHT.FORD WAS AWARE THAT SOME CLOCKSPRINGS MAY HAVE BEEN IMPROPERLY INSTALLED.THE IMPROPER INSTALLATION MAY ALSO CAUSE AN OPEN CIRCUIT... Read more

EA, Closed , Model Year: 1995

SAFETY BELT ASSEMBLY FAILURE

ODI RECEIVED 18 CONSUMER COMPLAINTS AND FORD IDENTIFIED ANOTHER FOUR REPORTS ASSOCIATED WITH THE ALLEGED DEFECT.MOST OF THE COMPLAINTS INDICATE INABILITY TO LATCH THE DRIVER SEAT BELT BUCKLE CAUSED BY A BROKEN LATCH RELEASE SPRING.NONE OF THESE 22 REPORTS RESULTED IN ANY INJURIES OR CRASHES.NO COMPL... Read more

PE, Closed , Model Year: 1995

SAFETY BELT ASSEMBLY

SQ, Closed , Model Year: 2002

INOPERATIVE AIR BAG SYSTEM

EA, Closed , Model Year: 1999

SEAT BELT WEBBING

ODI OPENED PE00-044INVESTIGATION ON NOVEMBER 3, 2000, BASED ON A REPORT REGARDING THE DEATH OF THE OCCUPANT OF THE RIGHT FRONT SEAT IN A 2000 MODEL YEAR FORD EXPLORER XLS INVOLVED IN A ROLL-OVER CRASH.IT IS ALLEGED THAT THE WEBBING OF THE BUCKLE PORTION OF THE SEAT BELT ASSEMBLY FAILED DURING THE CR... Read more

PE, Closed , Model Year: 2000

SEAT BELT WEBBING

ODI OPENED THIS INVESTIGATION ON NOVEMBER 3, 2000, BASED ON A REPORT REGARDING THE DEATH OF THE OCCUPANT OF THE RIGHT FRONT SEAT IN A 2000 MODEL YEAR FORD EXPLORER XLS INVOLVED IN A ROLL-OVER CRASH.IT IS ALLEGED THAT THE WEBBING OF THE BUCKLE PORTION OF THE SEAT BELT ASSEMBLY FAILED DURING THE CRASH... Read more

PE, Closed , Model Year: 1995

FRONT SUSPENSION STABILIZER BAR LINK

There is no summary currently available

EA, Closed , Model Year: 1991

SPARE TIRE WINCH CABLE

There is no summary currently available

PE, Closed , Model Year: 1991

SPARE TIRE WINCH CABLE

FROM THE BEGINNING OF THE 1991 MODEL YEAR PRODUCTION UNTIL THE MIDDLE OF THE 1994 MODEL YEAR PRODUCTION, FORD USED A GALVANIZED STEEL CABLE TO LIFT AND HOLD IN STORED POSITION, THE EXPLORER SPARE TIRE.ON MAY 19, 1994, BASED ON THE RESULTS OF FORD DURABILITY TESTING , FORD CHANGED TO A 4.00MM STAINLE... Read more

SQ, Closed , Model Year: 1999

AIRBAG SYSTEM'S LIGHT DYSFUNCTIONAL

There is no summary currently available

PE, Closed , Model Year: 1995

ACCELERATOR PEDAL

There is no summary currently available

RQ, Open , Model Year: 1991

LIFTGATE SUPPORT BRACKET FAILURE

SUMMARY:ON AUGUST 22, 1995, FORD CONDUCTED SAFETY RECALL, 95V-164, ON 1992 AND 1993 MODEL YEAR EXPLORER DUE TO LIFTGATE FAILURES.THE REAR LIFTGATE HYDRAULIC CYLINDER BRACKET CAN BECOME UNATTACHED ALLOWING THE LIFTGATE TO SUDDENLY DROP.THE RECALL REMEDY WAS TO INSTALL REINFORCEMENTS ON THE BRACKETS.F... Read more

PE, Closed , Model Year: 1997

WINDSHIELD WIPER MALFUNCTION

There is no summary currently available

PE, Closed , Model Year: 1997

STEERING KNUCKLE SEPARATIONS

There is no summary currently available

SQ, Closed , Model Year: 1998

VEHICLE HESITATION/STALLING

There is no summary currently available

EA, Closed , Model Year: 1992

BLOWER ASSEMBLY FIRES

BASED ON THE RELATIVELY LOW FAILURE FREQUENCY MEASURED OVER AN EXTENDED EXPOSURE TIME AND THE FACT THAT THE GREAT MAJOITY OF INCIDENTS ARE CONFINED WITHIN THE BLOWER HOUSING, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF THE AGENCY RESOURCES DOES NOT APPEAR TO... Read more

EA, Closed , Model Year: 1997

THROTTLE STICKING

ON JANUARY 23, 1997, FORD MOTOR COMPANY ISSUED SPECIAL SERVICE MESSAGE (SSM) 10240, ANNOUNCING THAT A REVISED THROTTLE BODY WOULD BE AVAILABLE DURING THE FIRST QUARTER OF 1997 FOR 1997 MODEL YEAR FORD EXPLORERS EQUIPPED WITH THE 4.0L SINGLE OVERHEAD CAM (SOHC) ENGINE.THE SSM STATED THE REVISED THROT... Read more

RQ, Closed , Model Year: 1997

FUEL LINE DAMAGE FROM JUMP STARTING

There is no summary currently available

DP, Closed , Model Year: 1992

HEATER BLOWER ASSEMBLY FIRE

There is no summary currently available

PE, Closed , Model Year: 1992

BLOWER ASSEMBLY FIRES

There is no summary currently available

SQ, Closed , Model Year: 1997

THROTTLE STICKING

There is no summary currently available

DP, Closed , Model Year: 1991

HEAVY LATERAL VIBRATION

NHTSA WAS PETITIONED TO COMMENCE A DEFECT INVESTIGATION OF THE SUBJECT VEHICLES ON JANUARY 6, 1998.THE PETITION ALLEGES THAT EARLY MODEL FORD EXPLORER SPORT UTILITY VEHICLES DEVELOP HEAVY LATERAL VIBRATIONS AT SPEEDS ABOVE 55 MPH AND WHEN ENCOUNTERING BUMPS AT LOW SPEEDS.THE PETITION FURTHER ALLEGES... Read more

EA, Closed , Model Year: 1991

SUNROOF SHATTERING AND SEPARATION

There is no summary currently available

PE, Closed , Model Year: 1995

ELECTRICAL FIRE IN CENTER CONSOLE

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 VEHICL... Read more

PE, Closed , Model Year: 1992

SUNROOF (AIR ROOF) SHATTER

THE SUNROOF SHATTERED OR WAS BLOWN OFF.IN ALL BUT ONE CASE THIS OCCURRED WHILE DRIVING.

PE, Closed , Model Year: 1993

DRIVER DOOR ELECTRICAL FIRE

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... Read more

EA, Closed , Model Year: 1993

BRAKE SYSTEM MALFUNCTION

There is no summary currently available

PE, Closed , Model Year: 1993

WHEEL LOCKUP WITH ANTILOCK BRAKE SYSTEM

ODI HAS RECEIVED OND HUNDRED SEVENTY-THREE (173) CONSUMER COMPLAINTS OF ALLEGED FAILURES OR MALFUNCTIONS IN THE BRAKING SYSTEM ON CERTAIN 1993 AND 1994 FORD EXPLORERS.THESE ALLEGED FAILURES OR MALFUNCTIONS ARE REPORTED TO HAVE CAUSED THIRTY-SIX (36) ACCIDENTS RESULTING FROM VEHICLE LOSS OF DIRECTION... Read more

EA, Closed , Model Year: 1991

SEPARATION OF MASTER CYLINDER

FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY.LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS.IF EVIDENCE INDICATES THE SCOPE SHOULD ... Read more

PE, Closed , Model Year: 1991

BRAKE MASTER CYLINDER/BOOSTER SEPARATION

There is no summary currently available

PE, Closed , Model Year: 1991

ENGINE COOLING FAN CRACKS

There is no summary currently available

EA, Closed , Model Year: 1992

AUTO TRANS PRNDL MISALIGN

There is no summary currently available

EA, Closed , Model Year: 1991

THROTTLE STICKING

There is no summary currently available

PE, Closed , Model Year: 1992

AUTO TRANS.PRNDL MISALIGN

There is no summary currently available

EA, Closed , Model Year: 1991

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

EA, Closed , Model Year: 1991

THROTTLE RELEASE FAILURE

There is no summary currently available

PE, Closed , Model Year: 1991

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

PE, Closed , Model Year: 1991

THROTTLE RELEASE FAILURE

There is no summary currently available

FORD EXPLORER - All Years Overview

Complete safety history for the FORD EXPLORER across all model years (1991, 2027).

386 Total Recalls

43,121 Total Complaints

54 Investigations

2,520 Reported Crashes

1,069 Reported Fires

301 Reported Deaths

FORD EXPLORER - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2027	1	0	View
2026	11	29	View
2025	19	135	View
2024	10	26	View
2023	15	147	View
2022	24	342	View
2021	26	532	View
2020	33	1,638	View
2019	6	328	View
2018	7	864	View
2017	14	2,021	View
2016	15	3,007	View
2015	9	2,190	View
2014	7	2,040	View
2013	12	2,781	View
2012	7	1,027	View
2011	8	1,495	View
2010	2	155	View
2009	1	49	View
2008	3	216	View
2007	3	271	View
2006	4	788	View
2005	3	604	View
2004	4	1,647	View
2003 (current)	7	1,369
2002	10	4,096	View
2001	12	503	View
2000	15	1,203	View
1999	15	1,737	View
1998	14	2,374	View
1997	12	2,150	View
1996	11	1,818	View
1995	12	1,048	View
1994	7	1,531	View
1993	9	1,151	View
1992	7	848	View
1991	11	764	View
1990	0	12	View
1989	0	1	View
1988	0	7	View
1987	0	3	View
1986	0	3	View
1985	0	1	View
1984	0	1	View
1977	0	2	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-150	692	46,142	View
F-450 SD	692	624	View
F-250 SD	638	3,635	View
F-550 SD	578	603	View
EXPEDITION	555	11,534	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2003 FORD EXPLORER

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 2003 FORD EXPLORER

Most Affected Components

NHTSA Safety Investigations, FORD EXPLORER

FORD EXPLORER - All Years Overview

FORD EXPLORER - Year by Year

Other FORD Models