2005 FORD EXPLORER

3 recalls, 604 complaints - 77 TSBs

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.

Complaint Statistics

604 total complaints 30 crashes 8 fires 16 injuries 1 deaths

Top Reported Components

Component	Complaints
STRUCTURE:BODY	107
POWER TRAIN	49
POWER TRAIN:AUTOMATIC TRANSMISSION	40
FUEL SYSTEM, GASOLINE	38
VEHICLE SPEED CONTROL	34
ELECTRICAL SYSTEM	32
STRUCTURE	25
FUEL/PROPULSION SYSTEM	17
UNKNOWN OR OTHER	17
STRUCTURE:BODY:HATCHBACK/LIFTGATE	16

Incident date: Feb 21, 2024

My 2019 Suburu Forester battery will not hold a charge. Whenever I want to use it, my husband must jump the Forester with cables from his car's battery. I am careful not to park it for long and use it for trips to dentist, doctor, and other necessities. We bought the Suburu Forester brand new off t... Read more

Incident date: Jan 12, 2022

ABS module sticking brake pedal soft Must press hard to stop , brake feel like they don’t work ABS Lights come on traction control disengagement Took to mechanic for verification.

Incident date: Nov 5, 2015

The contact owns a 2005 Ford Explorer. The contact stated that on several occasions while attempting to shift into reverse, the vehicle jerked backwards while the brake pedal was depressed. No warning lights were illuminated. The vehicle was taken to the dealer where the failure could not be duplica... Read more

Incident date: Sep 1, 2022

The contact owns a 2005 Ford Explorer. The contact stated that there was a crack on the top panel of the rear liftgate. The contact was concerned that the rear liftgate would fracture if she opened the liftgate. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The man... Read more

Incident date: Oct 23, 2021

I sitting on a incline put it in reverse and started backing up and the transmission just let loose and started rolling forward it's done this several times and sometimes it want back up at all even on level ground had it checked it was full of fluid but done a fluid and filter changed. And it still... Read more

Incident date: May 19, 2010

2005 FORD EXPLORER TRANSMISSION ISSUES. VERY COMMON ON THIS MODEL, BASED ON CUSTOMER/CAR OWNERS COMPLAINTS. REVERSE IS AFFECTED. COULD NOT REVERSE QUICKLY, ALMOST HIT BY ONCOMING CAR. VERY DANGEROUS. I HAVE CHILDREN!!!!

Incident date: May 19, 2010

Incident date: Mar 1, 2020

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT WHILE ATTEMPTING TO ACCELERATE FROM A STOP LIGHT, THE REAR DRIVER'S SIDE WHEEL DETACHED FROM THE VEHICLE AND ROLLED AWAY FROM THE VEHICLE INTO ONCOMING TRAFFIC. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DETERMINED THAT FOU... Read more

Incident date: Sep 25, 2020

SEVERAL TIMES OVER THE PAST TWO YEARS WHILE DRIVING AT HIGH SPEEDS ALL THE ELECTRICAL TURNS OFF LIKE THE KEY IS TURNED OFF. IT IS ALMOST IMPOSSIBLE TO STEER AS THERE IS NO POWER STEERING. IT ALMOST CAUSED AN ACCIDENT AS THE CAR SLOWED QUICKLY. I AM CONCERNED AS THIS HAS BEEN REPORTED SEVERAL TIMES A... Read more

Incident date: Jul 12, 2020

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT SHORTLY AFTER REFUELING, THE VEHICLE FAILED TO ACCELERATE WITH THE ACCELERATOR PEDAL DEPRESSED. THE CONTACT STATED THAT THE VEHICLE THEN ABRUPTLY ACCELERATED AT A HIGH RATE OF SPEED WITHOUT THE ACCELERATOR PEDAL BEING DEPRESSED. ALSO... Read more

Incident date: Jul 12, 2020

Incident date: Jan 1, 2014

METAL SEAT FRAME BAR COMING THROUGH OUTSIDE OF DRIVERS SEAT.. I AM 5' 3" TALL, 125 LBS...NOT FROM OVER WEIGHT DRIVER.. VERY PROMINENT METAL BAR MAKES SEAT ALMOST IMPOSSIBLE TO SIT ON. LUMBAR SUPPORT DIDNT LAST 5 YEARS...SEAT DANGEROUS TO ANYONE SITTING ON IT.

Incident date: Mar 24, 2019

REAR WHEEL WELL SHOCK TOWER MOUNT IS RUSTED OUT. THERE IS NO REASON THIS SHOULD BE HAPPENING. THIS IS A MAJOR SAFETY ISSUE.

Incident date: Mar 24, 2019

REAR WHEEL WELL SHOCK TOWER MOUNT IS RUSTED OUT. THERE IS NO REASON THIS SHOULD BE HAPPENING. THIS IS A MAJOR SAFETY ISSUE.

Incident date: Mar 24, 2019

REAR WHEEL WELL SHOCK TOWER MOUNT IS RUSTED OUT. THERE IS NO REASON THIS SHOULD BE HAPPENING. THIS IS A MAJOR SAFETY ISSUE.

Incident date: Mar 1, 2019

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. WHILE THE CONTACT WAS REVERSING OUT OF THE DRIVEWAY, THE VEHICLE WAS PLACED INTO DRIVE AND ACCELERATED ON ITS OWN. THE ACCELERATOR PEDAL BECAME STUCK AT 60 MPH. THE VEHICLE WENT THROUGH A BACKYARD, DROVE OVER A CURB, DROVE THROUGH A NEIGHBOR'S BACKYARD, AND... Read more

Crash 1 injured

Incident date: Mar 1, 2019

Crash 1 injured

Incident date: Oct 19, 2018

I TRIED TO PUT THE CAR IN DRIVE AND THE SHIFTER BROKE OFF/

Incident date: May 11, 2018

1) ABS, BRAKE, AND WRENCH FAILURE LIGHTS FLASHED ON FOR ABOUT 3 SECONDS AND TURNED OFF WHEN DECELERATING WITH CRUISE CONTROL FROM 55 MPH TO 45 MPH ZONES AT COURLAND, VA. VEHICLE MANUAL PROVIDES NO GUIDANCE ON THIS FAILURE MODE; ONLY 'WARNING LIGHTS TURN ON AND CONTINUE FLASHING, REDUCE SPEED AND TA... Read more

Incident date: May 11, 2018

Incident date: May 25, 2018

NEED TO RECALL THE GASKET HEADS. THERE ARE HUNDREDS OF COMPLAINTS OF THE SAME ISSUE. LITTLE HOLES MELTED ON THE HEAD. OVERHEATING VEHICLE AND SMOKING OUT ANTIFREEZE WHILE DRIVING. WHY IT'S THIS MATERIAL PLASTIC?

Incident date: May 20, 2018

SOMETHING WRONG WITH THE TIRE PRESSURE THE LIGHT STAYS ON IN THE MESSAGE BOARD AND A MESSAGE WITH THE BRAKE SYSTEM ALSO STAYS ON AND IT STALLS WHILE IM IN MOTION ON THE HWY AND STREETS AND TAKES AWHILE TO MOVE FOWARD AGAIN. I

Incident date: May 20, 2018

Incident date: Nov 6, 2017

ABOUT 7 MONTHS AGO I STARTED HAVING AN ISSUE WHILE DRIVING ON A CITY STREET, THAT SHIFTING FROM 2ND TO 3RD GEAR IT WOULD REV AND HESITATE AND WHEN IT DOES IT TO MANY TIMES WHILE DRIVING THE CHECK TRANSMISSION MESSAGE APPEARS ON THE DISPLAY AND ALSO THE O/D LIGHT BLINKS AND MY TRUCK WILL ACT FUNNY U... Read more

Incident date: May 1, 2018

FROM PARK, DELAY FROM 1 TO 7 SECONDS FOR ENGAGEMENT FOR REVERSE (AUTOMATIC TRANS), WORSE IN WARM WEATHER. SERIOUS SAFETY ISSUE, AS YOU MAY PRESS ON GAS THINKING YOU'RE IN REVERSE, AND THEN ACCELERATE!! HEARD 1ST HAND FROM FORD DEALER THIS IS WELL KNOWN, AND SOMETIMES SEVERE. SOMETHING WITH SOLENOID ... Read more

Incident date: Apr 1, 2018

ABS LIGHT AND ADVANCE TRACKING LIGHT AND 4X4 LIGHT AND CAR WITH TRACKING LIGHT ALL COMES ON AND THE BRAKING JERK WHEN STOPPING. ALSO LOW OIL PRESSURE LIGHT COMES ON EVEN AFTER OIL CHANGE

Incident date: Apr 1, 2018

ABS LIGHT AND ADVANCE TRACKING LIGHT AND 4X4 LIGHT AND CAR WITH TRACKING LIGHT ALL COMES ON AND THE BRAKING JERK WHEN STOPPING. ALSO LOW OIL PRESSURE LIGHT COMES ON EVEN AFTER OIL CHANGE

Incident date: Apr 1, 2018

ABS LIGHT AND ADVANCE TRACKING LIGHT AND 4X4 LIGHT AND CAR WITH TRACKING LIGHT ALL COMES ON AND THE BRAKING JERK WHEN STOPPING. ALSO LOW OIL PRESSURE LIGHT COMES ON EVEN AFTER OIL CHANGE

Incident date: Aug 15, 2017

2005 FORD EXPLORER. FRAME IS ROTTING ALONG THE WELDS. NOT UP AND DOWN. LENGTH WISE RUNNING WITH THE FRAME. OBVIOUSLY A FACTORY WELD ISSUE AND A BIG ISSUE AT THAT AS THE ISSUE COULD HAVE THE FRAME FAIL AND ENTIRE HUB/AXLE/WHEEL ASSEMBLY RIP RIGHT OFF THE VEHICLE. THIS IS ALSO A VERY COMMON ISSUE WITH... Read more

Incident date: Apr 3, 2018

TAKATA RECALL. FUEL GAUGE STOPPED WORKING CHANGED THE FUEL PUMP IN THE TANK 2 TIMES STILL DID NOT WORK. CHECKED FOR GROUND CONNECTIONS ALL SEEMED WELL. THE FUEL GAUGE STILL DOES NOT WORK

Incident date: Feb 27, 2018

WHEN USING THE CRUISE CONTROL AND THE 2005 FORD EXPLORER IS GOING DOWN HILL OR WHEN PRESSING COAST BUTTON, THE 2005 FORD EXPLORER STALL, ENGINE CUTS OUT. STEERING AND BRAKING BECOMES DIFFICULT.

Incident date: Feb 22, 2018

I WAS BACKING UP FROM MY DRIVEWAY AND MY CAR ACCELERATED WHEN PUT INTO REVERSE AND IT PEELED OUT AND HAD TO HIT THE BRAKES REALLY HARD.SOMETIMES THE ENGINE SHAKES WHEN GOING FORWARD FOR A FEW SECONDS THEN IT GOES AWAY.

Incident date: Jan 30, 2018

DRIVING ON THE INTERSTATE AT ABOUT 70 MPH, SUNROOF WAS TILTED IN VENT POSITION WHEN MY SUNROOF EXPLODED. GLASS REIGNED DOWN ON ME. I THOUGHT SOMETHING HAD SMASHED THROUGH, BUT I COULD NOT FIND ANYTHING. LOOKS LIKE IT ACTUALLY BLEW OUTWARD IN THE CENTER. IT'S POSSIBLE SOMETHING HIT IT, BUT I DID NOT... Read more

Incident date: Nov 18, 2017

MY EXPLORER TRANSMISSION JUST STOPPED WORKING GOING DOWN THE HIGHWAY, ALMOST GOT HIT BY A TRUCK. ELECTRICAL SYSTEM KEPT GOING IN AND OUT. CHECKED WITH A FORD DEALERSHIP THEY SAID IT WAS A COMMON PROBLEM WITH EXPLORERS AND THERE WAS NO RECALL. I CHECKED ONLINE AND THERE WAS OVER 10,000 COMPLAINTS MAD... Read more

Incident date: Nov 18, 2017

Incident date: Jul 31, 2017

WHILE USING CRUISE CONTROL, WHEN THE VEHICLE DECELERATE GOING DOWN HILL THE ENGINE STALLS ALL WARNING LIGHT COMES ON AND ENGINES DIES. THIS HAPPEN ALL THE TIME WHEN I OR WIFE ARE DRIVE WITH OUR FAMILY

Incident date: Oct 15, 2017

BRAKE LIGHTS DO NOT WORK. REAR TURN SIGNALS DO NOT WORK. IT IS NOT THE FUSE BECAUSE THE REAR BACK UP LIGHTS WORK AND THE HIGH CENTER BRAKE LIGHT WORKS AND THE REAR LIGHTS TURN ON WHEN I TURN ON THE HEADLIGHTS. JUST WHEN I PRESS THE BRAKES AND TURN SIGNALS (REAR) DO NOT WORK. RESEARCHING ONLINE, L... Read more

Incident date: Aug 26, 2017

THE BACK LIFT GATE PANEL CRACKED ON THE BACK OF OUR FORD EXPLORER AND WHEN WE WENT TO SHUT THE LIFT GATE THE WHOLE BACK WINDOW SHATTERED. FORD WON'T REPLACE IT BECAUSE THEY SAY ITS NOT A SAFETY ISSUE AND OUR YEAR OF OUR FORD WAS NOT APART OF THE RECALL OF THESE PANELS BEING CRACKED. PLEASE BE AWARE... Read more

1 injured

Incident date: Aug 25, 2017

WHILE DRIVING DOWN THE INTERSTATE AT NIGHT MY VEHICLES DASHBOARD BEGAN TO ACT ERRATIC. THEN THE BATTERY GAUGE RAPIDLY DROPPED INTO THE RED ZONE. WITHIN ABOUT 3 MILES I LOST MY INTERIOR POWER, HEADLIGHTS, TAILLIGHTS, AND SIGNALS INCLUDING MY HAZARD LIGHTS. WHEN LIMPING OFF THE INTERSTATE MY TRUCK... Read more

Incident date: Aug 25, 2017

Incident date: Aug 26, 2017

WE HAVE A 2005 FORD EXPLORER AND THE BACK LIFT GATE PANEL WAS CRACKED RIGHT BY THE FORD SYMBOL. WHEN WE WENT TO OPEN THE BACK LIFT GATE AND THE PANEL WHERE IT WAS CRACKED BROKE IN HALF AND SHATTERED THE WHOLE BACK WINDOW AND INJURED US. FORD WANTS TO CHARGE ME $140.00 TO JUST LOOK AT IT. COME ON FOR... Read more

1 injured

Incident date: Aug 23, 2017

MY GAUGES GO HAYWIRE THE NEEDLES SHAKE WHILE DRIVING AND WHEN CAR IS OFF NO KEY IN IGNITION. THE LIGHTS FLASH AS WELL. CAR WILL STALL IN TRAFFIC AT A STOP, THE RPM WON'T GO ABOVE 2 EVEN WHEN HWY GOING 60 MPH. MECHANIC SAID IT'S ELECTRICAL, THE DEALER TOOK OUT TOP COUNSEL AS A WORK AROUND FOR THIS EL... Read more

Incident date: Aug 23, 2017

Incident date: May 20, 2016

WE'VE REPLACED THE FUEL SENSOR IN OUR 2005 FORD EXPLORER XLT TWICE IN THE PAST TWO YEARS. WE HAD 68,000 MILES WHEN WE FIRST REPLACED THE FUEL SENSOR. IT IS A COSTLY FIX. NOW, AUGUST 2017, THE FUEL SENSOR IS NOT WORKING AND OUR SERVICE ENGINE SOON LIGHT IS ON. THIS IS A SAFETY ISSUE BECAUSE WE NE... Read more

Incident date: Aug 23, 2017

FUEL GAUGE DROPS TO EMPTY AFTER FILLING THE TANK UP AND STARTING IT. THE FUEL GAUGE REMAINS ON EMPTY. SERVICE ENGINE LIGHT COMES ON AND STAYS ON. IT IS UNSAFE NOT KNOWING HOW MUCH FUEL IS IN THE TANK BECAUSE YOU COULD RUN OUT OF GAS AT 70+MPH AND CAUSE A CRASH. SEARCHING THE ISSUE ONLINE BROUGHT ME ... Read more

Incident date: Jul 8, 2017

I HAVE A 2005 FORD EXPLORER AND UPON OPENING MY REAR TAILGATE, THE SCREWS ON THE TWO HINGES BROKE FROM THE GLASS. TTHE ONLY THING HOLDING IT HALFWAY UP IS THE HYDRAULIC POWER LIFTERS. GLAD I WAS PARKED AND NOT ON THE HIGHWAY

Showing 50 of 604 complaints.

Technical Service Bulletins, 2005 FORD EXPLORER

77 manufacturer communications from 55 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
060000 ENGINE AND ENGINE COOLING	7
110000 ELECTRICAL SYSTEM	6
106000 POWER TRAIN:AXLE ASSEMBLY	5
061000 ENGINE AND ENGINE COOLING:ENGINE	4
060000 ENGINE (PWS)	3
160000 STRUCTURE	3
100000 POWER TRAIN	3
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	2

350000 EQUIPMENT

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

061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

060000 ENGINE AND ENGINE COOLING

061000 ENGINE AND ENGINE COOLING:ENGINE

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061110 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

063110 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

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

060000 ENGINE (PWS)

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

060000 ENGINE (PWS)

FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD

111000 ELECTRICAL SYSTEM:12V/24V/48V BATTERY

060000 ENGINE (PWS)

FORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE HARD STARTS AND ENGINE IDLE RPM FLUCTUATION AND EXHIBIT DIAGNOSTIC TROUBLE CODES (DTCS) P0505, P0506, P2111 AND P2112. *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

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

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

100000 POWER TRAIN

NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT

190000 TIRES

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

210000 TRAILER HITCHES

NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *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

110000 ELECTRICAL SYSTEM

SERVICE ENGINE SOON LAMP ON WITH PCM DTC P0463, INSTRUMENT CLUSTER DTC B1201 AND OR FUEL GAUGE DROPS TO EMPTY-VEHICLES BUILT 8/2/2004 THROUGH 4/7/2005. *SC

021600 SUSPENSION:FRONT:WHEEL BEARING

NOISE FROM REAR WHEEL HUB BEARINGS. *TT

104000 POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. *TT

060000 ENGINE AND ENGINE COOLING

NO START/HARD START ON COLD SOAK - 4.0L ENGINE. *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

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) AND ELECTRONIC THROTTLE CONTROL (ETC) LAMPS ON WITH BOTH DIAGNOSTIC TROUBLE CODE (DTC) P2106 AND P2135. *TT

151300 SEAT BELTS:FRONT:RETRACTOR

SAFETY BELT RETRACTION SPEED. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

IMPROPERLY FORMULATED TRANSMISSION FLUID THAT, OVER TIME, MAY CAUSE DELAYED/HARSH REVERSE ENGAGEMENTS. CUSTOMER SATISFACTION PROGRAM 04B22. 5R55S/E & 5R44E TRANSMISSION FLUID ADDITIVE. *TT SUPPLEMENT #1. *TT SUPPLEMENT #2. *TT SUPP

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE SEAL LEAKS. *EH

110000 ELECTRICAL SYSTEM

WRENCH LAMP ON AND NO DIAGNOSTIC TROUBLE CODE (DTC) STORED. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT

100000 POWER TRAIN

DELAYED OR HARSH REVERSE ENGAGEMENTS - 5R55S TRANSMISSION - VEHICLES BUILT PRIOR TO 09/23/2004. *TT

060000 ENGINE AND ENGINE COOLING

NO START/HARD START ON COLD SOAK. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE NOISE REPAIR. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT UPDATE. *TT

220000 SEATS

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

106000 POWER TRAIN:AXLE ASSEMBLY

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

061000 ENGINE AND ENGINE COOLING:ENGINE

MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM). *TT

010000 STEERING

INCREASED TURNING EFFORT DURING LOW SPEED SHARP TURNS FALSE 4X4 ENGAGEMENT. *EH

060000 ENGINE AND ENGINE COOLING

MIL ON AND/ OR RUNS ROUGH/MISFIRE DTCS P0300-P0308 P0316 AND OR P0171/P0174 4.6L ENGINE. *EH

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

5R55S TRANSMISSION FLUID LEAKS FROM CONVERTER HOUSING AREA. DIAGNOSTIC TROUBLE CODE P1783 ON VEHICLES BUILT PRIOR TO 12/12/2004. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

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

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

190000 TIRES

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

022000 SUSPENSION:REAR

REAR AXLE NOISE REPAIR. *SC

110000 ELECTRICAL SYSTEM

MIL ON WITH DTC P0191 WITH OR WITHOUT VARIOUS DRIVABILITY SYMPTOMS AND/OR ADDITIONAL DTCS. *TT

200000 WHEELS

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

132000 VISIBILITY:GLASS, SIDE/REAR

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

100000 POWER TRAIN

INCREASED EFFORT DURING LOW SPEED SHARP TURNS ON 4X4 VEHICLES. *TT

160000 STRUCTURE

WELD BONDING PROCEDURE. *TT

060000 ENGINE AND ENGINE COOLING

THROTTLE PEDAL RESPONSE ON TIP IN VEHICLES BUILT BEFORE 10/4/2004 EQUIPPED WITH A 4.0L ENGINE. *EH

162000 STRUCTURE:BODY

ALUMINUM CORROSION - SERVICE TIP. *TT

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

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

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

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

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

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

110000 ELECTRICAL SYSTEM

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

060000 ENGINE AND ENGINE COOLING

ROUGH IDLE IN DRIVE. *EH

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.

091200 FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

MIL ON WITH P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB

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 (current)	3	604
2004	4	1,647	View
2003	7	1,369	View
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

2005 FORD EXPLORER

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 2005 FORD EXPLORER

Most Affected Components

NHTSA Safety Investigations, FORD EXPLORER

FORD EXPLORER - All Years Overview

FORD EXPLORER - Year by Year

Other FORD Models