2015 Ford Explorer Police Intercept

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 failure. 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.

The contact owns a 2015 Ford Explorer Police Intercept. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer and diagnosed with catalytic converter failure. The dealer performed an oil change and reprogrammed the computer; however, the failure recurred. The dealer was made aware of the failure and informed the contact that the catalytic converter needed to be replaced. The vehicle was not repaired. The dealer directed the contact to file a complaint with the NHTSA. The manufacturer was made aware of the failure and a case was opened. The manufacturer informed the contact that the warranty on the vehicle had expired. The failure mileage was approximately 111,000. The VIN was unavailable. The consumer has provided the VIN. They also stated that the dealer spoke with a Ford tech to inform them to replace the part and Ford refuses to do so.

NHTSA ID

11456600

Incident

Mar 14, 2022

Mileage

111,000 mi

EXHAUST MANIFOLDS WERE LEAKING CAUSING DRIVER HEADACHES. NEEDED TO BE REPAIRED BY REPLACING BANK 1 AND BANK 2 MANIFOLDS. VEHICLE IS A POLICE INTERCEPTOR AND HAS BEEN USED ON PATROL.

NHTSA ID

11170308

Incident

Nov 1, 2018

Mileage

112,000 mi

VECHILE SHIFTS DOWN INTO FIRST WHILE DRIVING STEERING WHEEL POPS WHEN TURNING AND LOCKS UP

NHTSA ID

11090523

Incident

Apr 11, 2018

Mileage

90,000 mi

THIS VEHICLE IS USED AS A POLICE VEHICLE. COMPLAINTS OF EXHAUST FUMES IN CABIN. INSPECTION SHOWED EXHAUST MANIFOLD CRACKED. ALREADY RECALLED FOR EXHAUST FUMES AND WAS INSPECTED FOR THIRD PARTY HOLES. THIS IS RELATED TO NHTSA COMPLAINT #'S 11072716 AND 11072719. FORD FLEET SERVICES HAS BEEN CONTACTED AND HAS ASSIGNED CASE # CAS14109974. THEY HAVE STATED THEY ARE AWARE BUT NO RECALL FOR MANIFOLDS. WE ARE A SMALL DEPARTMENT WITH 5 POLICE VEHICLES AND WE ARE DOWN THREE ALL IN THE LAST 3 WEEKS. WE HAVE NO CHOICE BUT TO GET THEM FIXED AT A COST OF BETWEEN $1200-$1500. I HAVE ASKED FOR FINANCIAL ASSISTANCE FROM FORD. THEY ADVISED THEY WILL LOOK INTO THAT.

NHTSA ID

11072853

Incident

Jan 29, 2018

Mileage

155,000 mi

THIS VEHICLE IS USED AS A POLICE VEHICLE. COMPLAINTS OF EXHAUST FUMES IN CABIN. INSPECTION SHOWED RIGHT EXHAUST MANIFOLD CRACKED. ALREADY RECALLED FOR EXHAUST FUMES AND WAS INSPECTED FOR THIRD PARTY HOLES.

NHTSA ID

11072719

Incident

Feb 8, 2018

Mileage

112,000 mi

THIS VEHICLE IS USED AS A POLICE VEHICLE. COMPLAINTS OF EXHAUST FUMES IN CABIN. INSPECTION SHOWED LEFT EXHAUST MANIFOLD CRACKED. ALREADY RECALLED FOR EXHAUST FUMES AND WAS INSPECTED FOR THIRD PARTY HOLES.

NHTSA ID

11072716

Incident

Feb 1, 2018

Mileage

135,000 mi

For 2015-2024 Ford and Lincoln vehicles equipped with turbocharged engines and customer concern of an engine oil leak, refer to Workshop Manual (WSM), Section 303-00 for oil leak inspection and testing methods. Ford has evaluated turbochargers replaced for oil leak symptoms and although oil may collect on the external surface of a turbocharger, it is extremely rare for a turbocharger assembly to be the root cause of the oil leak. Careful inspection of the turbocharger oil feed and drain tubes should be performed along with the recommended WSM procedures as needed. Warranty claims for turbocharger replacement going forward will be assessed.

During service and repair requiring removal and replacement of a crankshaft bolt and/or crankshaft damper, achieving proper torque of the crankshaft pulley bolt is critical. Incorrect torque may allow the bolt to loosen resulting in the timing gear breaking and engine damage. Replacement of the bolt is critical to the repair and accurately following the installation procedure in the Workshop Manual (WSM) Section, 303-01 is extremely important. The bolt torque procedure can be found in the crankshaft front seal removal and installation procedure or in the engine assembly procedure.

Certain 2013-2019 Model Year Explorer Police Interceptor Vehicles - Owner Guide Update

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.

Some 2013-2019 Police Interceptor Utility vehicles, equipped with spotlights, require left and/or right windshield applique/moulding modification if these parts are replaced. Spotlight mounting holes are not present on new replacement windshield appliques/moldings and must be cut using a rotary tool or equivalent. Left and/or right windshield applique/moulding spotlight mounting hole templates are available on the Professional Technician Society (PTS) at Service Tips/Technical Communications and can be printed on an 11X17 inch sheet of paper. Refer to Workshop Manual, Section 501-08 for windshield applique/moulding replacement procedures.

Some 2015-2016 vehicles equipped with 6F50/6F55 transmission and built on 2-Nov-2015 and through 1-Feb-2016 may exhibit no reverse, 3rd and 5th gear with diagnostic trouble codes (DTCs) P0715,P0717,P0756 and/or P2701. This may be caused by the direct clutch cylinder/tone wheel (7F283) inadvertently forcing the snap ring out of position resulting in damage to the direct clutch hub (7G384). Service part (7J250) complete rotating 3-5-R clutch module is now available. Refer to Workshop Manual (WSM), Section 307-01. For claiming, use causal part 7F283 and applicable labor operations in Section 7 of the Service Labor Time Standards (SLTS) manual.