2006 FORD EXPLORER

4 recalls, 788 complaints - 66 TSBs

EQUIPMENT

Defect Description

MARATHON IS RECALLING CERTAIN SEAT COVERS, BRAND SUPERHIDES WITH PART NUMBERS 593, 594, 578, 960, 228, 228-09, 267-08, 333, 625, AND 630, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE SEAT COVERS ARE MADE OF HEAVIER THREAD AND ARE NOT COMPATIBLE WITH SEATS CONTAINING S... Read more

Consequence

AN IMPROPERLY DEPLOYED AIRBAG COULD RESULT IN SERIOUS INJURY.

Remedy

MARATHON WILL NOTIFY OWNERS OF RECORD AND REPLACE THE SEAT COVER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 14, 2010. OWNERS MAY CONTACT MARATHON AT 1-800-735-2769.

294 vehicles affected

Manufacturer: MARATHON SEAT COVERS, INC.

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.

VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

Defect Description

ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.

Consequence

AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.

Remedy

DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.

199,942 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

788 total complaints 18 crashes 8 fires 17 injuries

Top Reported Components

Component	Complaints
POWER TRAIN	172
POWER TRAIN:AUTOMATIC TRANSMISSION	114
ENGINE AND ENGINE COOLING:COOLING SYSTEM	75
ENGINE	59
ENGINE AND ENGINE COOLING	55
ELECTRICAL SYSTEM	34
VEHICLE SPEED CONTROL	28
UNKNOWN OR OTHER	20
SERVICE BRAKES, HYDRAULIC	18
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY	18

Incident date: May 27, 2025

The GM bulletin N19227110 indicates that they are aware of over 10% of Chevrolet Spark models from the years 2014-2015 experiencing transmission problems. Although this bulletin expired last year, it is important to note that they do not provide coverage for vehicles purchased used with fewer than 1... Read more

Incident date: May 27, 2025

Incident date: Sep 5, 2023

Failing Brake Actuator Assembly. This is known issue by Toyota and they issued a brief warranty repair program, but have since stopped and refuse to fix the issue or provide assistance.

Incident date: Jul 16, 2023

Car smells like gas inside the cabin. Many people have posted throughout varies forums about the occurrence. I took the vehicle to my Nissan dealership and they had a bulliten saying replace the PVC blower hose assembly. Part is on order until next week when I will have it installed. One person in ... Read more

Incident date: Mar 31, 2023

Honda Rebel 1100 motorcycle footrest has too much vibration at 55 to 70 miles/ hour speed. thus after an hour or more makes the feet num. When i took it to the honda dealer they said that the engine will vibrate due to balance problem. this is dangerous. Look at youtube and other facebook sites and ... Read more

Incident date: Jun 4, 2022

Complete failure of the powertrain electrical harness. Heat degradation to wire insulation has exposed all conductors. Several other owner operators have experienced the same issue wherein the Dealer has attempted repair of existing trouble codes, by replacing sensors, modules and components. Pro... Read more

Incident date: Jun 4, 2022

Incident date: Jun 12, 2019

THE TRANSMISSIONS HAVE A PROBLEM AND HAVE HAD A PROBLEM FOR YEARS. THEY CAN FAIL WITHOUT NOTICE AND CAUSE A VEHICLE TO LOSE MOMENTUM WHILE GOING DOWN THE ROAD. YES THIS IS AN OLDER VEHICLE BUT IF YOU LOOK UP OLDER COMMENTS ON THIS VEHICLE ON OTHER REPORTING SITES THERE ARE MANY REPORTS OF TRANSMIS... Read more

Incident date: Jan 8, 2021

DRIVING ON SPEED LIMIT I STOPPED AT A LIGHT, CAR ENGINE WENT DEAD. I TURNED KEY OFF AND WAITED A FEW MINUTES, TURNED KEY ON, CAR STARTED AS NOTHING WAS WRONG. IT HAS HAPPENED 3 TIMES IN THE PAST YEAR. BATTERY AND ALTERNATOR ARE PRETTY NEW. DECIDED TO TAKE TO AN AUTHORIZED MECHANIC DEALER, COULDN'T ... Read more

Incident date: Jan 8, 2021

Incident date: Feb 18, 2018

THE UNIT HAS ISSUES WITH THE SEAT BELTS. I CALLED THE DEALER BUT THEY SAID THAT THEY DON'T HAVE ANY RECALL CAMPAIGN REGARDING THIS ISSUE, AND NO GUARANTY CAN BE APPLY.

Incident date: Feb 18, 2018

THE UNIT HAS ISSUES WITH THE SEAT BELTS. I CALLED THE DEALER BUT THEY SAID THAT THEY DON'T HAVE ANY RECALL CAMPAIGN REGARDING THIS ISSUE, AND NO GUARANTY CAN BE APPLY.

Incident date: Oct 27, 2020

I WAS TURNING FROM TURNING LANE INTO WAL-MART AND WHEN I GAVE IT GAS THE TRANSMISSION SLIPPED AND WOULDN'T MOVE. LUCKILY NO CARS WERE COMING AND IT FINALLY KICKED IN AND LET ME PULL INTO THE PARKING LOT. I JUST BOUGHT THIS AND WAS LOOKING UP THE ISSUE AND FOUND OUT THIS IS A PROBLEM WITH FORD EXPLOR... Read more

Incident date: Aug 25, 2020

I TOO HAD THE SAME PROBLEM AS I WAS COMING TO A FOUR WAY INTERSECTION. AS I WAS DRIVING ALL OF A SUDDEN A WRENCH TOOL CAME UP AND I COULD NOT ACCELERATE SO I HAD TO PULL OFF IN A PARKING LOT BEFORE I GOT TO THE INTERSECTION. I DID NOT WANT MY VEHICLE TO STALL AND I TURNED THE VEHICLE OFF AND PUT IT ... Read more

Incident date: Jun 8, 2020

RADIATOR FLUID EXPLODED ALL OVER ENGINE AND FLOOR MASSIVE LEAK . SEARCHED IT UP ON INTERNET AND SEEMS THIS IS A COMMON PROBLEM WITH THIS VEHICLE . I STARTED VEHICLE AND FLUID STARTED GOING EVERYWHERE .I DROVE MAYBE 10 FEET AND SHUT THE CAR OFF IMMEDIATELY . *TR

Incident date: Jun 6, 2020

STATIONARY-TURNED KEY ON,EXPLORER STARTED-PUT IN REVERSE- LIGHTLY TAPPED ACCELERATOR-EXPLORER WENT FULL THROTTLE.I APPLIED BRAKE WHITE TURNING KEY OFF. RESTARTED 3 TIMES WITH THE SAME RESULTS-THEN THE EXPLORER STARTED AND OPERATED IN A NORMAL WAY. 2 ACCIDENTS ONE WITH15,000 & ONE 5,000 PROPERTY DAM... Read more

Crash

Incident date: Oct 31, 2019

I HAVE NOW HAD 2 PROBLEMS WITH THIS DEALERSHIP, AND PERSONALLY I BELIEVE EVERYONE DESERVES SECOND CHANCES, THE FIRST VEHICLE THE SELLER SOLD ME HAD MAJOR ISSUES WITH GAS TANK HAD A HOLE IN IT AND EXPOSED WIRES RIGHT NEXT TO IT SO THAT TRUCK WAS A TICKING TIME BOMB, NOW I HAVE A 2006 FORD EXPLORER WI... Read more

Incident date: Oct 31, 2019

Incident date: May 1, 2017

I PURCHASED A 2006 FORD EXPLORER, EDDIE BAUER. I NEEDED THE TRANSMISSION REBUILT AND PAID AAMCO ALMOST $4,000. NOT EVEN A YEAR LATER THE TRANSMISSION FAILED AND HAD TO BE RE-BUILT AGAIN BUT IT WAS UNDER WARRANTY. BACK IN MARCH 2019, I TOOK IT BACK TO AAMCO AND WAS TOLD NOTHING WRONG WITH THE TRANSMI... Read more

Incident date: Nov 29, 2018

MY CHECK ENGINE LIGHT CAME ON. I STOPPED TO HAVE THE PARTS STORE GET THE CODES IT WAS THROWING OUT. TWO OF THE CODES HAVE TO DO WITH THE AIR BAG HAVING A MALFUNCTION IN THE SYSTEM. NEED TO KNOW IF THIS IS A MANUFACTURING ISSUE. I HAVE KIDS THAT RIDE IN THE VEHICLE SO TRYING TO TAKE PRECAUTIONS. THE ... Read more

Incident date: Sep 25, 2018

WHEN THE CAR IS PUT IN REVERSE AND YOU GIVE IT GAS, IT SHIFTS REALLY HARD AND JERKS AND SLIPS. I THINK THAT SOMETHING IS WRONG WITH THE TRANSMISSION. THIS HAPPENED WHILE I WAS LEAVING WORK AND PUT THE CAR INTO REVERSE TO LEAVE THE PARKING LOT.

Incident date: Oct 2, 2018

1. REAR WIPER QUIT WORKING SEVERAL YEARS AGO. SLUGGISH AND NOW FROZE UP. HASN'T WORKED FOR A LONG TIME. 2. REPLACED RADIATOR SEVERAL YEARS AGO. REPLACED THERMOSTAT SEVERAL TIMES OVER THE YEARS. THEN... 2018, SEPTEMBER,-- DISAPPEARING COOLANT FROM RADIATOR FOR LAST 6 MONTHS WITH NO OBVIOUS L... Read more

Incident date: Oct 2, 2018

Incident date: Mar 20, 2018

TRANSMISSION BEEN SLIPPING ON 2ND OR 3RD GEAR I BELIEVE I NEVER TOWED OR CARRY HEAVY LOADS AT ALL IT'S BEEN DOING THIS SINCE THE FIRST MONTH I PURCHASE IT AND IT'S BEEN GETTING WORST SINCE

Incident date: Aug 20, 2018

ENGINE SHUT DOWN WHILE DRIVING APPROXIMATELY 10- 15 MILES WITHOUT NOTICE

Incident date: Jun 13, 2018

TAKATA RECALL-2ND ROW PASSENGER SEAT BELT IS LOCKED UP. MY GRANDKIDS RIDE IN THIS AREA AND I DESPERATELY NEED TO GET THIS REPAIRED AND WANTED TO KNOW IF THIS IS AN ISSUE WITH ANYONE ELSE

Incident date: Jun 19, 2018

2006 FORD EXPLORER, EDDIE BAUER EDITION. THE ELECTRONIC THROTTLE BODY (ETB) FAILS, BECOMES DEFECTIVE, AND HAS BEEN REPLACED FIVE TIMES IN LESS THAN TWO YEARS. WITHOUT WARNING, THE VEHICLE WILL DISPLAY POOR PERFORMANCE, ERRATIC RPM'S, LOOSE POWER, AND EVEN STALL. ALL INDICATIONS POINT TO THE ETB; CO... Read more

Incident date: Jun 13, 2018

SHIFT STUCK IN PARK AND KEYS STUCK IN IGNITION

Incident date: May 4, 2018

AFTER PLACING THE VEHICLE IN PARK, AFTER REMOVING FOOT FROM BRAKE, THE CAR ROLLS FORWARD. THIS HAPPENS EACH TIME IT'S BEING PARKED, MORE NOTICEABLE OVER THE LAST 6 MONTHS. ALSO FREQUENTLY MISFIRES WHEN STARTING; DIAGNOSTICS USUALLY PRODUCE 8 - 13 CODES, NONE OF WHICH PRODUCE A COMPLETE FIX.

Incident date: Apr 20, 2018

DRIVERS POWER SEAT IS LOOSE. PROBLEM APPEARS TO BE RELATED TO TRACK. SEAT FEELS LOOSE AND MOVES FORWARD OR BACKWARD DEPENDING ON ACCELERATION OR BRAKING. THE BIGGEST PROBLEM IS HOW DISTRACTING THIS IS. THE AMOUNT OF MOVEMENT SEEMS TO BE GETTING GREATER AND GREATER.

Incident date: Feb 1, 2016

TL* THE CONTACT OWNS A 2006 FORD EXPLORER. THE CONTACT STATED THAT VARIOUS WARNING INDICATORS FLASHED AND THE VEHICLE STALLED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE FLY BY WIRE PEDAL AND THE THROTTLE BODY WERE REPLACED, BUT THE FAILURE CONTINUED. THE VEHICLE WAS NO... Read more

Incident date: Feb 1, 2016

Incident date: Jan 4, 2017

TL* THE CONTACT OWNS A 2006 FORD EXPLORER. WHILE REVERSING OUT OF THE DRIVEWAY, THE VEHICLE MADE A LOUD ABNORMAL NOISE. SUDDENLY, THE VEHICLE WOULD NOT SHIFT INTO REVERSE OR DRIVE. THE VEHICLE WAS TOWED TO AN INDEPENDENT TRANSMISSION SHOP. THE MECHANIC DIAGNOSED THAT THE TRANSMISSION NEEDED TO BE RE... Read more

Incident date: Jul 3, 2017

MY EXPLORER'S TRANSMISSION IS STARTING TO EXHIBIT HARD SHIFTS THAT RATTLE THE ENTIRE CAR. I KNOW THIS IS NOT A NEW PROBLEM AS A FAMILY MEMBER HAD TO REPLACE THE TRANSMISSION IN THEIR 2006 EXPLORER AND CYBER COMMUNITY IS FULL OF EXAMPLES. THIS IS A MAJOR SAFETY ISSUE AS THE TRANSMISSION HESITATES WHI... Read more

Incident date: Aug 25, 2017

TRANSMISSION IS SLIPPING BAD AND CAR NOT SHIFTING INTO DRIVE

Incident date: Aug 25, 2017

TRANSMISSION IS SLIPPING BAD AND CAR NOT SHIFTING INTO DRIVE

Incident date: Aug 25, 2017

TRANSMISSION IS SLIPPING BAD AND CAR NOT SHIFTING INTO DRIVE

Incident date: Feb 1, 2014

ON MY 2006 EXPLORER I AM UNABLE TO FILL THE TANK WITH GASOLINE. IT ALMOST IMMEDIATELY BACKS UP THE FILL TUBE AND TURNS THE FUEL PUMP OFF. IT'S BEEN TO MANY MECHANICS WHO HAVE TOLD ME THAT THE PROBLEM IS WITH THE FUEL TANK ITSELF. THEY HAVE SAID THAT IT SHOULD HAVE BEEN A RECALL ON FORD'S PART LONG A... Read more

Incident date: Jul 21, 2017

POWER TRAIN WARNING LIGHT COMES ON AS DRIVING DOWN THE HIGHWAY AT 75 MPH. CAR ACTED AS IF IT WOULD STOP AND AS IF TRANSMISSION WAS SLIPPING. WE SLOWED CAR DOWN, AND MOVED IT AT A RATE OF 30 MPH, BUT THEN CAR BEGAN ACTING NORMALLY. WE STOPPED AS SOON AS POSSIBLE AND TURNED CAR OFF AND TURNED BACK ON.... Read more

Incident date: Nov 10, 2015

I OWN A 2006 FORD EXPLORER EDDIE BAUER , BOUGHT USED IN 2011/61000K. SINCE 2012 THE CAR STARTED SHOWING PROBLEMS WITH THE POWER STEERING AND /OR ENGINE. WHEN DRIVING AT 35-40 MPH ON A HIGHWAY THE CAR STARTED TO SURGE FORWARD, THEN BACK, KEEPING SURGING UNTIL THE CAR REACHED A HIGHER SPEED OF 60. IF ... Read more

Incident date: Nov 10, 2015

Incident date: Jul 9, 2017

REAR WINDOW HINGE FRACTURED, WINDOW FELL. VEHICLE WAS STATIONARY.

Incident date: Dec 3, 2016

THE CAR WAS SOLD WITH LIMITED WARRANTY, USED, BUT HAD WRITTEN COLD START ISSUE. THE VEHICLE GETS WARM IF WARM OUTSIDE AND WILL JUST COMPLETELY SHUT OFF ANYWHERE AT ANYTIME. RIDING DOWN INTERSTATE, WILL LOSE POWER THEN SHUT OFF AND LEAVE YOU WITH NO POWER STEERING TO CONTROL VEHICLE GOING HIGH SPEEDS... Read more

Incident date: Dec 3, 2016

Incident date: Jun 1, 2017

THE AUTOMATIC TRANSMISSION IS BANGING INTO GEAR. IT JOLTS THE VEHICLE BACK AND FORTH AS IT SHIFTS. TRIED REPLACING TRANSMISSION FLUID BUT CONTINUES TO DO IT. FEELS LIKE I'VE BEEN REAR-ENDED AT TIMES. ITS A CONSISTENT OCCURRENCE.

Showing 50 of 788 complaints.

Technical Service Bulletins, 2006 FORD EXPLORER

66 manufacturer communications from 39 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
061000 ENGINE AND ENGINE COOLING:ENGINE	5
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	4
060000 ENGINE (PWS)	3
036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	2
117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL	2
062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS	2
190000 TIRES	2
063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE	2

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-J

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

010000 STEERING

This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly ma

060000 ENGINE (PWS)

Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only cam

350000 EQUIPMENT

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

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

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

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

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

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

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

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

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061000 ENGINE AND ENGINE COOLING:ENGINE

060000 ENGINE AND ENGINE COOLING

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

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)

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

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)

036500 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:WHEEL SPEED SENSOR

FORD/MERCURY: TO PREVENT HARNESS DAMAGE, ON SOME VEHICLES, RESULTING IN CONTACT WITH TIRE OR SUSPENSION COMPONENTS, PROPER ROUTING OF WIRING HARNESS FOR WHEEL SPEED SENSOR IS KEY. 2006-2010 EXPLORER, MOUNTAINEER, EXPLORER SPORT TRAC.

114000 ELECTRICAL SYSTEM:WIRING

046300 SERVICE BRAKES, AIR:ANTILOCK:WHEEL SPEED SENSOR

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

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD/MERCURY/LINCOLN: VEHICLES MAY EXHIBIT ONE OR MORE OF THE FOLLOWING SYMPTOMS: DRIVE AWAY HESITATION, LOSS OF RPM ON DECELERATION, DIFFICULTY STARTING, AND/OR IDLE RPM LESS THAN DESIRED. THE F53 MOTORHOME CHASSIS IS INCLUDED. *

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

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

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

FORD/MERCURY: 4.0L/4.6L HARD START/ROUGH RUNNING; AFTER LONG HOT SOAK/DIP IN RPM WHEN COMING TO A STOP; BUILT ON OR BEFORE 4/2/08. MAY EXHIBIT A DIP IN RPM BELOW NORMAL IDLE LEVEL OF 600 RPM ON DECELERATION. *PE

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

IMPROVED BRAKE PEDAL FEEL AND FIRMNESS. *NJ

072200 FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

FUEL FILL--SLOW OR EARLY SHUT OFF--BUILT BEFORE 11/28/2007. *NJ

102000 POWER TRAIN:MANUAL TRANSMISSION

FORD/MERCURY: SOME VEHICLES EQUIPPED WITH 6R60 TRANSMISSIONS MAY EXHIBIT VARIOUS TRANSMISSION PERFORMANCE ISSUES. WHEN COMPARED TO OTHER TRANSMISSIONS, SOME OF THE SHIFT CHARACTERISTICS ARE DIFFERENT THAN PREVIOUS MODELS DUE TO THE 100% S

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

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

980000 UNKNOWN OR OTHER

MALFUNCTION INDICATOR LAMP (MIL) MAY NOT ILLUMINATE AND DIAGNOSITC TROUBLE CODES (DTC'S) MAY NOT BE SET WHEN A CERTAIN SENSOR OR NETWORK FAILURES OCCUR. *KB

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

THE LOWER RADIATOR HOSE CLAMPS MAY DEVELOP CRACKS OR BREAK DUE TO A CONCERN WITH THE CLAMP COATING. CUSTOMER SATISFACTION PROGRAM 06B38 - LOWER RADIATOR HOSE CLAMP REPLACEMENT. *TT SUPPLEMENT I. *TT

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

MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P202 - 4.6L 3V. *TT

135200 VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR

LIMITED OR RESTRICTED INWARD MOVEMENT OF EXTERIOR REAR VIEW MIRROR GLASS. *TT

210000 TRAILER HITCHES

NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

HARSH OR DELAYED 1-2, 2-1 AND/OR 3-2 SHIFT. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODES P0340/P0344/P0345/P0349 - 4.6L 3V AND 5.4L 3V. *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

030000 SERVICE BRAKES, HYDRAULIC

BRAKE DRAG CONDITION. *TT

190000 TIRES

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

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

NO START WITH INSTRUMENT CLUSTER INOPERATIVE. *TT

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440. *TT

100000 POWER TRAIN

NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT

116000 ELECTRICAL SYSTEM:IGNITION

IGNITION DIAGNOSTICS. TO INCLUDE LINCOLN ZEPHYR 2006. *TT

081100 FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH

200000 WHEELS

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

190000 TIRES

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

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

COOLANT LEAK -- HEATER HOSE CONNECTIONS. *TT

036400 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT

ABS LIGHT WITH DTC C1440. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

DIAGNOSTIC TROUBLE CODES (DTC) P0340, P0344, P0345, P0349. ARE FOUND. *KB

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

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

061000 ENGINE AND ENGINE COOLING:ENGINE

CALIBRATION UPDATE 4.0L - VARIOUS SYMPTOMS - SURGE, HESITATION, TORQUE CONVERTER CYCLING, NO UP SHIFT AFTER FORCED DOWNSHIFT, AND POOR A/C PERFORMANCE. *KB

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

CALIBRATION UPDATE 4.0L - VARIOUS SYMPTOMS - SURGE, HESITATION, TORQUE CONVERTER CYCLING, NO UP SHIFT AFTER FORCED DOWNSHIFT, AND POOR A/C PERFORMANCE. *KB

091200 FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

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

220000 SEATS

FRONT SEAT MANUAL LUMBAR INOPERATIVE. *KB

138800 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:FAN/MOTOR

THUMPING/LOUD FLUTTER - BEHIND DASH IN DEFROST MODE - LACK OF AIRFLOW TO FLOOR - MANUAL A/C. *KB

012000 STEERING:COLUMN

LOWER STEERING COLUMN SHAFT POP/CLUNK NOISE. *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 (current)	4	788
2005	3	604	View
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

2006 FORD EXPLORER

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 2006 FORD EXPLORER

Most Affected Components

NHTSA Safety Investigations, FORD EXPLORER

FORD EXPLORER - All Years Overview

FORD EXPLORER - Year by Year

Other FORD Models