2011 Ford Explorer

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

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 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness ? all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).

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 with 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.

The power steering has fully stopped working , the car cannot be steered, this started to happen on the road, I had to steer the entire weight of the car myself, at fast speed it was difficult but not impossible, at slow speed and zero speed or while the vehicle is stationary it was impossible or unmovable to steer. there were no warning lamps about this, the Ford dealer has not detect this in my vehicle's previous recall, further vehicle has two more recalls this year, that have been cited this year by the dealer. this needs to be addressed on their recalls because this can cause a very severe problem on the road

NHTSA ID

11753984

Incident

Jul 31, 2026

On Friday 7/24/2026, I was driving and all the sudden my steering went out. Dash flashed No Power Steering Assist / AdvanTrac System Fail. I pulled over immediately to turn around & get home with zero power steering. The amount of strength to steer/control was extreme. To turn was almost impossible. I took my car to Ford AutoNation on Arapahoe in Centennial on 7/27/26, they ran full diagnostics & it came back that the car suffered a hard internal failure (DTC U3000) of the electronic Power Steering Control Module, creating an immediate, dangerous loss of steering assist while driving. This vehicle was subject to Federal Safety Recall 14S06 (NHTSA Campaign 14V286000). According to official Ford OASIS data, Ford attempted to remedy this safety defect in 2014 using a software reflash shortcut (Labor Code 14S06A) rather than replacing the physical defective hardware. I have a text (via their service dept) from the service manager as well stating "it was a reflash" when I asked which labor code was done under the 14S06; "was it the software reflash or the full rack replacement?". I have a formal case with Ford Corporate created 7/31/26, and have that number as well. IBecause Ford's software patch completely failed to prevent the component's internal hardware failure, the original federally mandated safety defect remains active, unresolved, and dangerous in this chassis. Ford Corporate is refusing to honor the recall remedy because the vehicle is past an arbitrary 10-year limit on their internal customer satisfaction extensions, violating the permanent nature of safety recalls. I stated I would be filing with the NHTSA and they pushed my information on to the Safety Auto Office on 7/31/26.

NHTSA ID

11753968

Incident

Jul 24, 2026

The contact owns a 2011 Ford Explorer. The contact stated that while attempting to start the vehicle, the message "Power Steering Assist Fault" was displayed and the vehicle failed to start. The contact stated that the failure reoccurred after starting the vehicle, and the steering wheel locked up. The dealer was contacted, but the vehicle was not diagnosed or repaired. The contact related the failure to NHTSA Campaign Numbers: 14V286000 (Steering) and 14E001000 (Steering); however, the VIN was not included. The manufacturer was not contacted. The failure mileage was approximately 140,000.

NHTSA ID

11751531

Incident

Jan 20, 2026

Mileage

140,000 mi

The contact owns a 2011 Ford Explorer. The contact stated that while driving 25 MPH, the steering wheel became difficult to turn to the left or the right. The contact stated that while depressing the brake pedal, there was an abnormal rumbling sound coming from the vehicle and the steering wheel started shaking. No warning light was illuminated. The vehicle was repaired under NHTSA Campaign Number: 14V286000 (STEERING); but the repair failed to fix the vehicle. The contact stated that the failure had occurred after the recall repair. The manufacturer was not notified of the failure. The failure mileage was 199,455.

NHTSA ID

11747972

Incident

Jun 15, 2014

Mileage

199,455 mi

The pillar covers fell of the vehicle when driving last week. Both plastic covers are on the side of the interstate. I was told and found there is a recall for the clips on these covers, but when I searched, they are not listed for this vehicle. There appears to be an issue with this recall and the explorer.

NHTSA ID

11745751

Incident

Jun 18, 2026

The contact owns a 2011 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the dealer and manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact stated that the trim piece was almost detached. The vehicle was not repaired. The failure mileage was unknown.

NHTSA ID

11744504

Incident

Mar 15, 2025

While stopped at a stop sign my engine suddenly died, before restarting a low oil pressure light came on but went out immediately. I was approximately 40 miles from home when I got to my destination. The car was showing no signs of issues, no warning lights or errors. When I went back out to start it and head home it would not start. I had to pay additional expense beyond my insurance road side coverage due to the distance. I have had an independent mechanic going over the vehicle since it died. Starter has been replaced because it appeared to be the issue. (the original was bad) Once replaced while attempting to start it he found out the engine had locked up. I bought the vehicle March 30, 2026 & this happened on June 10, 2026. The vehicle had 132,344 miles on it when bought and 135,716 when it seized up. After looking through other reports I have found this to be a reported issue.

NHTSA ID

11744176

Incident

Jun 10, 2026

I contacted chapman ford in phila to have the recall corrected and it has been almost 2 yrs and no parts or follow up. They told me for months that the parts were backordered. My trim is loose and the rubber around my windshield almost gone. I also contacted ford main and was told an advisor would follow up and they did not.

NHTSA ID

11742300

Incident

Oct 31, 2024

Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how to retrieve the master code. This guide is located under the Workshop Manual tab > Accessories > Installation > Wireless RF Keypad Diagnosis Guide > PPT C > Step C2.<br /><br /> Note: The only available keypad for some vehicles from the assembly plant is the accessory wireless keyless entry keypad. The integrated wired keypad cannot be installed on vehicles not equipped from the factory with a wired keyless entry k

All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during initial delivery. Unlike the integrated (wired) factory keypad, the accessory keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool. If the wallet card for an accessory keypad is lost, follow these steps to recover the code. Dealer Key Code access is granted through the Dealer Program Enrollment System (DPES); dealership management can authorize users. The authorized user must go to FMCDealer.com > Parts and Service > Parts Product Line Information > Keys/Entry Devices > Aftermarket Keyless Entry Keypad Code Access. Follow the instructions on the screen to obtain the master code for the accessory keypad.

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.

Certain 2011-2017 Model Year Explorer Vehicles Rear Wheel Knuckle Replacement REASON FOR THIS SUPPLEMENT Program Terms: added 21R01 and 21R02 REASON FOR PROVIDING A NO-COST, ONE-TIME REPAIR: added 21R01 and 21R02 OWNER NOTIFICATION MAILING SCHEDULE: added mailing schedule for 21R01 and 21R02 OASIS ACTIVATION: added 21R01 and 21R02

Certain 2011 - 2013 Model Year Explorer Vehicles with Rear Wheel Knuckles that have been Replaced Rear Toe Link Inspection/Replacement Under Safety Recall 21S43, some of the affected vehicles that have had one (or both) rear wheel knuckle(s) replaced and were sold or operated in certain traditional corrosion areas where road salt is used extensively during winter months, may experience a seized toe link ball joint resulting in a fracture of the outboard section of the rear suspension toe link

Certain 2011-2017 Model Year Explorer Vehicles Rear Toe Link Replacement Under Safety Recall 21S32, some of the affected vehicles exposed to a highly corrosive environment where road salt is used extensively during winter months, have experienced a seized toe link ball joint resulting in a fracture of the outboard section of the rear suspension toe link.