2016 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

The B pillar, that has a recall for it for almost 2yrs while waiting for the part to be available, fell off while driving on the freeway. The piece was barely holding on when we pulled over on the freeway. With that piece falling off it has tripped the electrical with the rear lift door now not working and forever now have the warning light on the dash that shows the door not closed and to lock the vehicle is difficult and the lights won’t shut off for over 20min which is now affecting the vehicle battery. Ford has been called and still will not fix the issue which has progressed to affecting other parts of the vehicle unless we pay out of pocket with quotes over $2,000!! There is a recall and it’s close to 2yrs waiting for the “part” but now the part has actually fallen off it’s causing more electrical and costly issues. Ford needs to pay for these repairs now with no more excuses. I need help please.

NHTSA ID

11776742

Incident

Aug 3, 2026

On approximately June 13, 2025, while driving my 2016 Ford Explorer Sport on the highway, the driver's-side exterior B-pillar trim appliqué came loose. There were no warning lights, messages, or other symptoms before the failure. The trim did not completely detach because it remained connected by the exterior keypad wiring. The failure created a risk to other motorists because the trim could have completely detached at highway speed and entered the roadway. I stopped at a gas station and temporarily secured the loose component with black duct tape to prevent it from completely detaching. Just a few days after the incident, I received Ford's recall notice involving this same B-pillar trim condition, Safety Recall 25S53/NHTSA Recall 25V347. The rear liftgate also stopped operating immediately following the incident. I presented the vehicle to an authorized Ford dealership for service. Ford repaired the liftgate issue, but the dealership was unable to complete the permanent recall repair for the failed B-pillar component. As of November 7, 2026, nearly 17 months after the recalled component actually failed while I was driving, Ford still has not completed the permanent recall repair. Ford's recall information continues to show Recall 25S53 as incomplete and states that Ford has a remedy but parts are not available. The failed recalled component remains temporarily secured to the vehicle with black duct tape because Ford has been unable to provide the permanent recall remedy. I have contacted and escalated the matter with Ford seeking a permanent resolution. The vehicle and failed component remain available for inspection upon request.

NHTSA ID

11776500

Incident

Jun 16, 2025

The contact owns a 2016 Ford Explorer. The contact stated that while driving 60 MPH, the front windshield trim detached and flapped across the front windshield. In addition, the contact received notification of NHTSA Campaign Number: 25V347000 (Structure); however, the part to do the recall repair was not yet available. The manufacturer was contacted and made aware of the failure. The failure mileage was approximately 120,000.

NHTSA ID

11773644

Incident

Oct 26, 2026

Mileage

120,000 mi

THE DASHBOARD COVER HAS SEPARATED FROM THE DASH JUST UNDER THR WINDSHIELD CLOSE TO THE BOTTOM OF THE WINDSHIELD BUT JUST IN FRONT OF THE AIR VENT. THE SEPARATION HAS CAUSED THE COVERING TO DRAW UP EXPOSING WHITE INSULATION FOAM UNDERNEATH TO CAUSE A GLARE ON THE WINDSHIELD THAT CREATES A VISIBILITY ISSUE DURING THE DAY. I HAVE RECEIVED REPAIR ESTIMATES IN THE $3,000.00 RANGE BUT AFTER RESEARCHING THIS IT SEEMS THIS IS AN OFTEN REPORTED ISSUE THAT I BELIEVE FORD SHOULD ADDRESS. THERE WAS NO WARNING AS ONE DAY I NOTICED THE GLARE AND REALIZED WHAT HAPPENED.

NHTSA ID

11773614

Incident

Aug 20, 2026

The b pillar is coming apart and may cause an incident. They put out recall in May of 2025 but still no remedy. .

NHTSA ID

11772860

Incident

Oct 3, 2026

2016 Ford Explorer, Falling pedal to the floor. acceleration of high speed. No physical obstuction. Noted that 2016 Ford Exployers have been highly documented for widw spread issue, which involves a defective EIB. Noted that automobile will be sent to dealership.

NHTSA ID

11771979

Incident

Oct 18, 2026

manufacturer has failed or is unable to remedy this safety recall for your vehicle in a timely manner. They have only repaired 1 side of the trim. Dealer states driver side is on back order

NHTSA ID

11769388

Incident

Oct 6, 2026

On approximately 09/02, I took my 2016 Ford Explorer to an authorized Ford dealership for recall-related PCM service. After the recall service was completed, I experienced additional problems with the vehicle and returned on 09/4 and I also called the same dealership that same day because I believed something was wrong following the repair. The dealership replaced the battery but did not perform additional diagnostics unless I paid out of pocket. I was unable to immediately afford those diagnostic charges, so I later sought additional diagnosis. The vehicle continued to experience drivability/electrical problems, including misfire symptoms and eventually a no-start condition. After further testing, another authorized Ford dealership diagnosed the PCM as faulty. I contacted Ford Motor Company because I am concerned that the recall service, programming, or work performed during the recall may have contributed to the PCM failure. Ford closed my case because the recall was marked completed and stated that my vehicle is outside its warranty period. I returned the vehicle two days after servicing dealership as the recall repair to report problems. I am requesting that this be reviewed as a possible recall-repair-related safety issue. The PCM failure and associated engine/electrical problems could affect drivability and the vehicle’s ability to operate safely. The vehicle and related repair records are available for inspection.

NHTSA ID

11769014

Incident

Sep 2, 2026

25E10-S1 Owner letter

NEW VEHICLE DELIVERY HOLD - Emissions Recall 25E10 - Supplement #1 Certain 2018-2020 Model Year F-150 Vehicles With 3.3L Engines and 2016-2019 Model Year Explorer, Taurus, and Flex Vehicles With 3.5L Engines Powertrain Control Module (PCM) Reprogramming

Certain 2021-2024 Model Year Bronco, 2021-2024 Model Year Bronco Sport, 2020-2022 Model Year Corsair and Escape, 2016-2024 Model Year Explorer, 2019-2020 Model Year Fusion, 2016-2018 Model Year Focus RS, 2022-2024 Model Year Maverick, 2016-2019 Model Year MKC and 2019-2024 Model Year Ranger Vehicles Equipped with a 2.0L or 2.3L Engine and Engine Block Heater System Block Heater Replacement

Advance Notice – Customer Satisfaction Program 25N17 Certain 2015-2025 Model Year Multiple Vehicle Lines Rear View Camera Replacement If Required After Dealer Evaluation

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

Some 2015-2021 Ford and Lincoln vehicles may exhibit an illuminated MIL with diagnostic trouble codes (DTCs) P0011, P0012, P0014, P0015, P0016, P0017, P0018, P0019, P0021, P0022, P0024 and/or P0025. Pinpoint test HK in the Powertrain Control and Emissions Diagnosis (PC/ED) or in Section 303-14 of the Workshop Manual (WSM) has been updated to address this concern.