2017 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 DRIVER AND PASSENGER A PILLAR COVERS ARE COMING OFF.

NHTSA ID

11195982

Incident

Mar 1, 2019

Mileage

57,005 mi

THE PASSENGER SIDE A PILLAR COVER AND DRIVER'S SIDE B PILLAR COVER ARE COMING OFF.

NHTSA ID

11195981

Incident

Mar 1, 2019

Mileage

50,146 mi

THE DRIVER'S SIDE A PILLAR COVER IS COMING OFF.

NHTSA ID

11195979

Incident

Mar 1, 2019

Mileage

10,391 mi

THE PLASTIC IS COMING OFF ON THE "A" PILLAR ON THE PASSENGER SIDE.

NHTSA ID

11195908

Incident

Mar 1, 2019

Mileage

23,339 mi

LAW ENFORCEMENT VEHICLE RECEIVING HIGH CARBON MONOXIDE LEVEL READINGS (10+ PARTS PER MILLION) IN PASSENGER CABIN UPON HARD ACCELERATION (FROM COMPLETE STOP TO 100+ MPH) WITH THE AIR CONDITIONING SYSTEM ON WITH THE RECIRCULATION FUNCTION ACTIVATED. AD003

NHTSA ID

11012637

Incident

Jul 25, 2017

Mileage

3,500 mi

LAW ENFORCEMENT VEHICLE RECEIVING HIGH CARBON MONOXIDE LEVEL READINGS (10+ PARTS PER MILLION) IN PASSENGER CABIN UPON HARD ACCELERATION (FROM COMPLETE STOP TO 100+ MPH) WITH THE AIR CONDITIONING SYSTEM ON WITH THE RECIRCULATION FUNCTION ACTIVATED. 374

NHTSA ID

11012634

Incident

Jul 25, 2017

Mileage

1,000 mi

LAW ENFORCEMENT VEHICLE RECEIVING HIGH CARBON MONOXIDE LEVEL READINGS (10+ PARTS PER MILLION) IN PASSENGER CABIN UPON HARD ACCELERATION (FROM COMPLETE STOP TO 100+ MPH) WITH THE AIR CONDITIONING SYSTEM ON WITH THE RECIRCULATION FUNCTION ACTIVATED. 799

NHTSA ID

11012633

Incident

Jul 25, 2017

Mileage

3,000 mi

LAW ENFORCEMENT VEHICLE RECEIVING HIGH CARBON MONOXIDE LEVEL READINGS (10+ PARTS PER MILLION) IN PASSENGER CABIN UPON HARD ACCELERATION (FROM COMPLETE STOP TO 100+ MPH) WITH THE AIR CONDITIONING SYSTEM ON WITH THE RECIRCULATION FUNCTION ACTIVATED. 726

NHTSA ID

11012522

Incident

Jul 25, 2017

Mileage

2,500 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

The Service Awareness Newsletter is an informal communication that contains information that may not be presently available in a TSB, SSM, GSB, or other electronic communication. This article includes information on warranty, technical service tips and other service information.

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.