2016 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.

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 occupational 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 inve

The contact stated that the Police Department owns a 2016 Ford Explorer. The contact stated that while a Police Officer was attempting to drive the vehicle; however, the steering wheel seized. There was no warning light illuminated. The vehicle was towed to the Government mechanic who previously diagnosed the vehicle and stated that the steering rack had failed. The contact stated that two other Police Department vehicles had recently experienced the same failure with the steering rack. The manufacturer was notified of the failure and stated there was no recall on the vehicle. The failure mileage was approximately 49,000.

NHTSA ID

11579478

Incident

Mar 26, 2024

Mileage

49,000 mi

TL* THE CONTACT OWNS A 2016 FORD EXPLORER POLICE INTERCEPTOR. THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE DOWNSHIFTED INDEPENDENTLY WITH THE RPMS INCREASING RAPIDLY. THE CONTACT STATED HE WAS UNAWARE IF THERE WAS ANY WARNING LIGHT ILLUMINATED. THE CONTACT STATED PULLED OVER TO THE SIDE OF THE ROADWAY, RESTARTED THE VEHICLE AND CONTINUED TO DRIVE TO HIS DESTINATION. THE CONTACT ALSO STATED ON AUGUST 25, 2020, WHILE SHIFTING GEAR TO REVERSE HE HEARD AN ABNORMAL NOISE COMING FROM THE TRANSMISSION. THE CONTACT STATED NO WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATE HE SHIFTED GEARS TO DRIVE AND HEARD AN ABNORMAL NOISE AND THE VEHICLE STARTED TO JERK FORWARD. THE CONTACT STATED HE CONTINUED TO DRIVE TO HIS RESIDENCE. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER MARK MCLARTY FORD LOCATED AT 4400 LANDERS RD, NORTH LITTLE ROCK, AR 72117, (501) 945-1200, WHERE THE VEHICLE WAS DIAGNOSED AND THE CONTACT INFORMED THAT A TRANSMISSION FLUSH WAS NEEDED. ADDITIONALLY, THE TRANSFER CASE ALSO NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS INFORMED OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 99,603.*DT*JB

NHTSA ID

11354281

Incident

Aug 23, 2020

Mileage

99,603 mi

THE DRIVER AND PASSENGER "A" AND "B" PILLARS ARE COMING OFF.

NHTSA ID

11195911

Incident

Mar 1, 2019

Mileage

38,944 mi

THE PLASTIC PIECES ON THE "A" AND "B" PILLAR, DRIVER AND PASSENGER SIDE ARE COMING OFF.

NHTSA ID

11195900

Incident

Mar 1, 2019

Mileage

38,944 mi

THE PLASTIC PIECES ON THE "A" PILLAR ARE COMING OFF

NHTSA ID

11195897

Incident

Mar 1, 2019

Mileage

35,257 mi

I STARTED MY VEHICLE AND PUT IN DRIVE MY STEERING WHEEL WAS LOCKED IN ONE POSITION I WAS UNABLE TO TURN THE WHEEL LEFT OR RIGHT I STARTED GETTING SEVERAL LIGHTS ON MY DASH FROM HILL START ASSIST, SERVICE ADVANCETRAC, STEERING ASSIST FAULT. I WAS UNABLE TO TURN MY VEHICLE & HAD TO BACK IN THROUGH THE PARKING LOT BACK INTO A SPOT, AFTER SEVERAL ATTEMPTS OF TURNING VEHICLE ON AND OFF I WAS ABLE TO GET THE STEERING COLUMN TO RELEASE BUT THERE WAS NO POWER AND VEHICLE WAS OPERATING LIKE AN OLDER VEHICLE WITH NO POWER STEERING, IT TOOK A LOT OF MUSCLE TO GET THE WHEEL TO TURN AND MULTIPLE WARNING LIGHTS WERE COMING ON VEHICLE WAS PARKED NEGATIVE BATTERY TERMINAL WAS DISCONNECTED TO TRY AND RESET SYSTEM AND STEERING IS STILL LOCKED IN PLACE FORD DEALERSHIPS ADVISED THEY HAVE HAD MULTIPLE EXPLORERS WITH THIS ISSUE AND THE COST IS AROUND $3,000 AND NOT COVERED UNDER THE WARRANTY VEHICLE HAS 26000 MILES AND HAS BEEN PROPERLY MAINTAINED.

NHTSA ID

11166639

Incident

Jan 10, 2019

Mileage

26,406 mi

THE SEAT MANUAL TILT LEVER FOR THE DRIVER SIT IS BUSTED. IT LOCKS AND DOES NOT ALLOW ADJUSTMENT. THE LOCAL DEALERSHIP SAID IT WAS NOT COVERED UNDER WARRANTY. THE COST TO REPLACE THE UNIT WAS EXTREME. WE HAVE HAD THREE 2016 EXPLORERS POLICE PACKAGE FALL VICTIM TO THE SAME ISSUE. THE ISSUE BEGAN ABOUT A YEAR INTO IT'S USE. IS THERE A RECALL FOR THIS ISSUE?

NHTSA ID

11140555

Incident

Jul 1, 2017

Mileage

30,000 mi

FUEL PUMP ASSEMBLY, SENDING UNIT. FUEL GAUGE STOPPED WORKING. VEHICLE HAD 38,000 MILES ON IT. DEALER CHARGED 600.00 PLUS TO FIX, NOT COVERED UNDER RECALL OR WARRANTY.

NHTSA ID

11121271

Incident

Jul 16, 2018

Mileage

38,297 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.

Certain 2016-2018 Model Year Explorer Vehicles High-Speed Cooling Fan Motor Relay; Reason for supplement: Vehicles Covered by this Program: all open / unrepaired vehicles from 21B05 (Police Interceptor Utility Vehicles) have been added to 21N01 as 21B05 expires August 31, 2022. Owner Notification: Police Interceptor Utility owners who have not completed 21B05 will be mailed a letter describing this change.