2016 Ford Explorer Fuel system Problems

Truck turns off

NHTSA ID

11753172

Incident

Jul 3, 2026

Gas filler neck is loose, making it difficult to fill the gas tank without spillage. I don't recall how long this has been an issue, but it has been a problem for multiple years. There have been no incidents that preceded this problem.

NHTSA ID

11703582

Incident

Dec 1, 2025

The contact owns a 2016 Ford Explorer. The contact stated that while driving 70 MPH, the vehicle unintendedly started to decelerate. Additionally, while depressing the accelerator pedal, the brakes unintendedly engaged. The “Scheduled Maintenance” light was illuminated. The contact pulled over to the side of the road and depressed the accelerator pedal seven times, and the vehicle started to operate as intended. The contact stated that a dealer was contacted. The vehicle was taken to the dealer and was test-driven, and the dealer informed the contact that the vehicle was operating as designed. The contact related the failure to the results of a Google search on the throttle body. The vehicle was not repaired. The manufacturer was notified of the failure and opened a case. The approximate failure mileage was 136,000.

NHTSA ID

11683940

Incident

Aug 26, 2025

Mileage

136,000 mi

On June 14, we drove our 2016 Ford Explorer from Tallahassee, FL to Boone, NC without issue. However, on [XXX], upon starting the vehicle, we noticed a gasoline smell. Concerned for our safety, we checked the car before leaving the neighborhood and discovered fuel pouring from the front. We parked the vehicle in a safe location and coordinated a tow to the local Ford dealership and were informed our fuel line had ruptured. The vehicle had 41,000 miles at the time of the incident. We were not given a clear explanation for the fuel line rupture, leaving us apprehensive about the safety and reliability of Ford vehicles. The ordeal cost $4,000 in repairs, and the service experience made us feel taken advantage of after we were routinely asked if we were local. Our Ford mechanic in Tallahassee later mentioned that labor charged by the Boone dealership seemed excessive. Additionally, they refused to replace the gasoline-covered cabin air filter and engine cover, raising further concerns about the service provided. The rupture of the fuel line posed a severe safety risk as it could have led to a fire or explosion, endangering the lives of the occupants and others nearby. The problem has not been reproduced but was confirmed by the local Ford dealership. No inspections have been conducted by the manufacturer, police, or insurance representatives to our knowledge. There were no warning lamps, messages, or other symptoms of the problem prior to the failure. Our gas tank was nearly full the morning of June 17, and it was empty when we picked it up from the Ford dealership after repairs were completed. Given the serious nature of the fuel line failure, the potential risks involved, and the financial burden of the repairs, we believe this issue warrants a recall investigation to prevent future incidents and to ensure the safety of Ford customers, especially given the multiple recalls already issued and the shared “significant safety concern” shared by the NHTSA on this. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF

NHTSA ID

11596120

Incident

Jun 17, 2024

The power transfer unit is broken. Symptoms are vehicle shuddering, vehicle sounds like it is going to stall. This could cause a major accident at any moment.

NHTSA ID

11592838

Incident

May 29, 2024

In August 2023, my vehicle began to make a popping noise and began to lose power when attempting to accelerate. It was diagnosed by the repair shop as a turbo going bad. I repaired the turbo. In December 2023, the check engine light came on. The repair shop indicated that the lifters and cam shafts were bad and caused scoring to the engine block, requiring the engine to be replaced. The repair shop asked if I had been changing the oil regularly. I indicated that I did change the oil per when the vehicle would notify me it was time. The repair shop noted that I changed the oil every 10k miles. Per the repair shop, not changing the oil regularly (because the Ford vehicle system designed to tell me when to change the oil) ultimately caused me to need to replace the turbo and the engine. All because the oil was not changed more frequently 3-5k miles per the repair shop. I've spent $15k in repair costs since August 2023 because I was relying on the Ford vehicle's notifications as to when it needed oil. The vehicle is not even worth this much blue book. For a 8.5 year old vehicle that has been well cared for, I do not think these parts should have failed and I think Ford should have set the timing for oil change notifications more frequently if this is what is needed by the engine to keep it in good repair. It literally indicates the % of time before the oil needs to be changed.

NHTSA ID

11578895

Incident

Aug 9, 2023

My check engine light keeps reading a evap code. I have replaced the evap throttle 3x’s. My car smells of a gas leak coming from somewhere. I have taken it to Ford, and to two other mechanics. They claim that the check engine code is wrong and they cannot find where the fuel smell is coming from without the proper code. My check engine light turns on and off with the same error everytime. The evap code is not the problem. I have made a complaint months ago, and still nothing. Not sure what else I can do.

NHTSA ID

11524738

Incident

Dec 1, 2022

Mileage

122,490 mi

The contact owns a 2016 Ford Explorer. The contact stated that while driving approximately 65-70 mph, there was an abnormal exhaust odor entering the vehicle. When the accelerator pedal was released, the odor dissipated. There were no warning indicator lights illuminated. The driver and passenger sustained a headache due to the odor but medical attention was not provided. The vehicle was taken to an independent mechanic who stated that the seal was broken. Additionally, the mechanic informed her to use premium or Chevron fuel. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted, who opened a case, and referred her to the NHTSA hotline. The failure mileage was approximately 112,000.

NHTSA ID

11520907

Incident

Nov 1, 2022

Mileage

112,000 mi

Everytime my ac/heat is on it affects my engine as I’m driving. My speedometer fast jumps. As soon as I turn it off it seems to run better. I made a complaint a week ago about something going on with my fuel and fan running high speed. I have a foul smell in my car. I thought for awhile it was something outside but now I believe it’s coming from my car. It smells like fuel/rubber/sewer if that makes sense.

NHTSA ID

11518316

Incident

Feb 15, 2023

Mileage

1,176,658 mi

My fuel evap pump check engine light keeps coming on. I’ve owned this vehicle since July 2022 and I have paid for the evap pump 3x’s. My fan constantly runs in the engine. My engine has a stutter when I press the gas. Ford absolutely dropped the ball with this vehicle. I have already paid thousands of dollars (water pump, evap pumps and more) please help on getting this car serviced. I still owe like 20k on this car. I cannot afford to keep getting it fixed. I have 121k miles on it.

NHTSA ID

11516956

Incident

Oct 3, 2022

Mileage

117,658 mi

Every since I bought this vehicle back in December 2016. I've had major problems that consist of the battery lasting a year an half. In 2018, Ford had it for two weeks due to a major problem that they repaired but never told me what the issue was. Still, to this day, I don't know what they repaired. In 2021, My water pump went out, something is wrong with he fuel injection that may be causing the engine light to be on. Every year since 2016 there's been something going wrong with my Explorer, including the radio panel/cameras monitor. Last year, 2022, I was driving down the highway when my windshield trim panels flew off! I thought it was something from another car until I stopped and realized, my windshield didn't have a cover on the driver side. I'm hoping I didn't caused harm or almost caused harm to any drivers behind me! Nonetheless, since my incident, I have noticed other Explorers missing a windshield cover.

NHTSA ID

11505134

Incident

Oct 10, 2022

Water pump failure which causes the car to stall immediately when it overheats. This appears to be a common issue with 2016 Ford Explorers

NHTSA ID

11486926

Incident

Sep 27, 2022

My purge valve was stuck open and had strong fuel vapors leaking inside of the car cabin. I became lightheaded and went to the ER. This was before the check engine light came on. It was very concerning.

NHTSA ID

11486796

Incident

Sep 1, 2022

There is a VERY STRONG sulfur odor emiting into the cabin without an engine warning light. Tested for error codes and inspected by Ken Towery in Louisville and the seriviceperson couldn't detect the source of the odor. The defect appeared at 98458. The smell causes me to gag and feel light headed. Please advise.

NHTSA ID

11456981

Incident

Mar 15, 2022

Fuel pump fail

NHTSA ID

11447664

Incident

Jan 16, 2022

The contact owns a 2016 Ford Explorer. The contact stated that the vehicle constantly smelled of gasoline. The contact stated that the odor occurred when the vehicle was in motion but was stronger when the vehicle was idle. The vehicle was taken to an independent mechanic who was not able to properly diagnose the vehicle. The mechanic sealed several locations where the odor might have been coming from. The vehicle was taken to the dealer because the gasoline odor was stronger on the outside of the vehicle. The dealer was not able to determine the cause of the failure and referred the contact to NHTSA for assistance. The contact stated that the failure had gotten progressively worse. The manufacturer was not notified of the failure. The failure mileage was 90,000

NHTSA ID

11443329

Incident

Nov 1, 2021

Mileage

90,000 mi

Exhaust leaks into cab under moderate to heavy acceleration with windows closed it is even worse when accelerating with the windows open

NHTSA ID

11435312

Incident

Nov 2, 2020

ON MULTIPLE OCCASIONS TRANSMISSION WAS SLIPPING WHICH LED TO AN EVENTUAL COMPLETE FAILURE. EXPLORER WAS ON CA HIGHWAY 76 GOING WESTBOUND WHEN TRANSMISSION FAILED. DRIVER WA FORCED TO DODGE TRAFFIC AND COAST TO AN EMERGENCY STOP AT THE RIGHT SIDE OF THE HIGHWAY. EXPLORER HAD TO BE TOWED.

NHTSA ID

11407741

Incident

Feb 11, 2021

Mileage

123,519 mi

DURING ACCELERATION CAR SMELLS LIKE ROTTEN EGGS ALL WINDOWS NEED TO BE OPEN TO VENT CAR AND ALL PASSENGERS GET NAUSEOUS. DEALER TRIED TWICE TO FIX PROBLEM BUT WITH NO SUCCESS.ITS GETTING IMPOSSIBLE TO DRIVE THE CAR ON HIGHWAY.FORD NEEDS TO DO SOMETHING ASAP.

NHTSA ID

11389705

Incident

Jan 3, 2021

Mileage

59,000 mi

TL* THE CONTACT OWNS A 2016 FORD EXPLORER. WHILE DRIVING THE CONTACT TURNED ON THE HEAT IN THE VEHICLE AND SMELT AN DISTINCT ODOR COMING FROM THE VEHICLE. THE ODOR WAS STRONG THE CONTACT HAD TO ROLL DOWN THE WINDOW IN THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THE FAILURE AS A CARBON MONOXIDE LEAKAGE. THE VEHICLE WAS REPAIRED BUT THE FAILURE PERSISTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 66,000.

NHTSA ID

11389036

Incident

Dec 20, 2020

Mileage

66,000 mi

THE VEHICLE WITHOUT WARNING , JUST SHUTS OFF. EVEN WHILE GOING 65 MPH ON A HIGHWAY. IF YOUR LUCKY, YOU CAN COAST OFF THE HIGHWAY BEFORE YOU ARE HIT . FORD REFUSED TO FIX EVEN THOUGH UNDER WARRANTY. SO I HAD TO SELL IT SO I WOULDN'T BE KILLED. HUNDREDS IF NOT THOUSANDS HAVE COMPLAINED ABOUT THE SAME THING.

NHTSA ID

11377948

Incident

Apr 16, 2020

Mileage

68,000 mi

EXHAUST IS GETTING INTO THE CAB OF VEHICLE WHEN UNDER MODERATE ACCELERATION TO PASS VEHICLES AND WHEN THE WINDOW OR WINDOWS ARE OPEN IT IS EVEN WORSE.

NHTSA ID

11343765

Incident

Apr 1, 2020

PERSISTENT EMISSIONS SMELL IN CABIN CAUSING HEADACHES FOR THE DRIVER. ROESCHE FORD IN ELMHURST ILLINOIS CONDUCTED WARRANTY WORK WHICH CONSISTED OF "REPROGRAMMING" THE CAR. THE FIX DID NOT WORK AND ROESCH FILED AN APPEL TO FORD - WHO IS DENYING LIABILITY AND CLAIMING THE "REPROGRAMMING" IS THE FIX. I HAVE ALSO FILED A CLAIM WITH FORD CAS24714279. THIS IS THE EXACT SAME PROBLEM THE POLICE INTERCEPTOR EXPLORERS IS HAVING AND IS WELL DOCUMENTED - FORD HAS EVEN SET UP A HOTLINE FOR THE POLICE - BUT IGNORE THE INDIVIDUAL OWNER.

NHTSA ID

11278835

Incident

Oct 28, 2019

Mileage

55,000 mi

WAS DRIVING DOWN 95 @ 65 MPH WHEN ALL OF A SUDDEN, THE CAR JERKED AND LOST ALL POWER. WRENCH LIGHT, CHECK ENGINE, AND AIRBAG LIGHT ALL CAME ON. NO POWER. NO GAS, LIMP MODE. CODE READER DETERMINED THROTTLE BODY ISSUE. LOOKED ONLINE, APPEARS TO BE KNOWN ISSUE IGNORED BY FORD. I COULD HAVE BEEN KILLED

NHTSA ID

11267269

Incident

Oct 8, 2019

Mileage

47,000 mi

GAS SMELL OCCUR IN THE CABIN. MAKES ME HEADACHE AND SHICK

NHTSA ID

11258578

Incident

Sep 3, 2019

Mileage

69,000 mi