2021 Ford Explorer Hybrid

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

On July 8, 2026, I was traveling westbound on Highway 7 when another vehicle pulled right out in front of me from southbound Orchard Road, attempting to cross the highway. We collided and I struck the other vehicle at a 45° angle. My seatbelt was buckled. The impact caused me to be thrown forward into the windshield which I broke with my skull. I suffered a broken neck. The seatbelt did not operate properly to keep me secure in the seat. There's no way I should've struck the windshield if the seatbelt would've worked. Not only did the shoulder belt not work, but the lap belt did not work either because I came up and out of the seat. Also, the airbag did not prevent me from striking the windshield. There is something wrong with the seatbelt operation as well as the airbag. I have contacted Ford to inspect the vehicle. The vehicle was inspected by the Harrisonville Missouri Police Department.

NHTSA ID

11754258

Incident

Jul 8, 2026

The contact owns a 2021 Ford Explorer Hybrid. The contact stated that after restarting the vehicle, there was a burning odor present. The message "Pull Over Possible Powertrain Damage" was displayed. The vehicle was towed to the local dealer who determined that the high voltage junction box had overheated and was burned. The high voltage junction box and high voltage junction box wiring harness were replaced, and the vehicle was repaired. The manufacturer was notified of the failure and indicated that the VIN was not included in the NHTSA Campaign Number: 23V626000 (Electrical System). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 96,147.

NHTSA ID

11556636

Incident

Aug 23, 2023

Mileage

96,147 mi

A Police Officer's Ford Explorer Interceptor Hybrid SUV while driving had a vehicle malfunction where the rear wheels began to wobble/vibrate and while driving in a straight line with front wheels facing straight caused the vehicle to fishtail out of the control (loss of control to the rear wheels) and slam into a tree at approximately 50mph injuring the officer. Officer's injuries were broken left leg and two knee fractures. Upon further research, this incident may have been caused by the "rear bolt" fracture issue Ford is having with these specific Ford Explorers. This specific vehicle is under recall per the VIN. The Officer's safety was put at risk because the vehicle was most likely not recalled and fixed per the recall. The vehicle has not been inspected by manufacturer or any qualified/certified individual. No other issues or symptoms were present prior to this incident. The vehicle is available for inspection upon request with the BART Police Department in Oakland, CA.

NHTSA ID

11556088

Incident

Nov 4, 2023

I was making a slow speed u-turn to stop a speeding motorist. As I came out of the u-turn, the wheel did not come back to center and I continued the turn going up a curb and striking a chain link fence. When I realized what was occurring, I manually began to turn the steering wheel to the right to get back on the roadway. There is patrol car dash cam footage of this collision. Police report# 23-688.

NHTSA ID

11513540

Incident

Feb 11, 2023

The contact owns a 2021 Ford Explorer Hybrid. The contact stated that while driving at various speeds, the electronic "lift gate ajar" warning was activated; however, the liftgate was not open. The vehicle was taken to the local dealer who adjusted the liftgate striker, and the failure was remedied; however, the failure reoccurred. Additionally, while driving at speeds between 5 - 20 MPH, the vehicle started jerking and vibrating with the RPM’s extremely elevated. The vehicle was taken to the local dealer, but the cause of the failure was not identified. The dealer indicated that the jerking and vibration were normal for a hybrid vehicle. The manufacturer was notified of the failure. The failure mileage was 22,000.

NHTSA ID

11501484

Incident

Jan 12, 2023

Mileage

22,000 mi

Some 2020-2024 Explorer/Police Interceptor Utility hybrid vehicles may exhibit a "Refuel Error See Manual" message in the instrument panel cluster (IPC) after installing a replacement fuel filler door assembly (7827936). This may be due to a concern with the replacement fuel filler door assembly. If diagnostics in the Workshop Manual (WSM), Section 501-14 Body > Handles, Locks, Latches and Entry Systems > lead to fuel filler door switch replacement, install a new fuel filler door assembly ordered from depot stock to correct this condition. Suspect parts have been cleared from parts depot inventory.

Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine and 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable to enter electric-only drive modes as expected during normal drive cycles. This may be due to the software within the belt integrated starter generator (BISG). For vehicles with this condition, follow Pinpoint Test G located in the Workshop Manual (WSM), Section 303-06D and repair the vehicle as necessary. Note that the BISG is on backorder status at the time of this publication and Ford is working to make parts available. Engineering is investigating this concern. Monitor PTS for updates.

Some 2020-2026 Police Interceptor Utility hybrid vehicles may exhibit multiple warning messages, various drivability concerns and/or an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P061B stored in the powertrain control module (PCM). This may be due to the incorrect installation of additional police equipment. Equipment should only use the provided rear power access point and must not use the 12V cranking or 12V auxiliary batteries for power. The vehicle will go to sleep after the ignition key is removed and is not designed to power equipment when the vehicle is not running. If equipped, the Police Engine Idle feature can be used to allow the vehicle to securely remain idling and to power equipment. Refer to the Owners Manual.<br /><br /> If it is determined additional equipment has not been added to the 12V cranking or 12V auxiliary batteries, continue with normal Workshop Manual (WSM) diagnostics, Section 303-04C Engine > Fuel Charging and Controls > Diagnosis and Testing > Pinpoint Test QE.<br /><br /> For general upfitter installation guidelines, refer to:<br />

Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost hybrid engine, 2020-2023 Explorer vehicles equipped with a 3.3L hybrid engine and 2020-2023 Aviator vehicles equipped with a 3.0L hybrid engine may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM) and auto start/stop disabled. This may be due to a loose wiring connection to the belt integrated starter generator (BISG). The Workshop Manual (WSM) has recently been updated to provide new direction for DTC P0A1E. Refer to the WSM, Section 303-06 Starting System, Diagnosis and Testing, Starting System for applicable diagnosis.

2020-2023 Escape/Explorer, 2021-2023 F-150 and 2022-2023 Maverick vehicles equipped with a full hybrid electric vehicle (FHEV) powertrain may exhibit a cable connection error screen from the Midtronics xRC-3363 High Voltage Battery Rescue Charger. The xRC-3363 will prompt the technician to verify the low voltage connections, when no actual fault is present. This may be due to the software level of the Midtronics xRC-3363 High Voltage Battery Rescue Charger. To correct this condition, update the Midtronics xRC-3363 High Voltage Battery Rescue Charger to the latest software level by navigating to the Main Menu > Settings > About (i) then selecting the download button in the bottom right corner of the tool's screen.

Some 2020-2023 Explorer 3.3L full hybrid electric (FHEV) vehicles built on or before 12-Nov-2023 may exhibit an illuminated malfunction indicator lamp (MIL) and/or powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P084B stored in the powertrain control module (PCM). This may be due to the software thresholds in the PCM