2017 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 contact owns a 2017 Ford Explorer. The contact received notification of NHTSA Campaign Number: 25V347000 (Structure); however, the part to perform the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that the driver's side and passenger's side B-pillar trims detached from the vehicle. The contact used tape and hot glue to reattach the B-pillar trims to the vehicle. The dealer was notified of the failure and confirmed that the part was not yet available. The failure mileage was approximately 160,000.

NHTSA ID

11764718

Incident

May 23, 2025

Mileage

160,000 mi

See attached document for complaint.

NHTSA ID

11764479

Incident

Jul 15, 2026

The contact owns a 2017 Ford Explorer. The contact stated that while driving 70 MPH on the interstate, the engine light illuminated and the vehicle stopped in the middle lane. The contact was able to maneuver and coasted the vehicle over to the side of the road. The instrument panel was illuminated afterwards. The contact stated that the failure was like NHTSA Action Number: DP26008 (Engine and Engine Cooling). The vehicle was towed by Firestone and then towed to the local dealer, where the engine was replaced. The manufacturer was contacted, and two letters were sent, three emails were sent to the CEO, and two phone calls were made to Ford Customer Service, who opened a case, but no further assistance was provided. The failure mileage was 55,000.

NHTSA ID

11763586

Incident

Sep 6, 2026

Mileage

55,000 mi

The contact owns a 2017 Ford Explorer. The contact stated that while driving, the driver's side B-Pillar trim detached and was hanging off the vehicle with the wiring exposed. The contact used a bungee cord to secure the driver's side B-Pillar trim to the vehicle. The dealer was contacted by phone and made aware of the failure. The vehicle was taken to the dealer, and the contact was informed that the parts to repair the vehicle were unavailable. The contact was informed that the parts were unavailable until July 2027. The contact received notification of NHTSA Campaign Number: 25V347000 (Structure); however, the part to do the recall repair was unavailable. The manufacturer was contacted by phone and made aware of the failure, and a case was filed. The failure mileage was approximately 63,500.

NHTSA ID

11763185

Incident

Aug 9, 2026

Mileage

63,500 mi

Ford diagnosed the A-Pillar recall (Ford Recall Notice 24S02) condition on January 13, 2026, confirmed that the vehicle requires the recall repair, and placed the vehicle in the repair queue. The obstacle preventing completion of the repair is not the dealership. Rather, it is Ford Motor Company's continued inability to provide sufficient replacement parts to its dealer network. I have been advised that the waiting list for this repair is approaching 300 customers and the dealer is receiving only a very limited number of replacement parts from Ford. Based on the information provided to me, the dealership is receiving approximately three to four replacement parts at a time. As a result, the inability to complete the repair is attributable to the supply of parts from Ford, not the actions of the dealership. Ford's suggestion that I simply return to the dealer does not address the underlying issue. The dealer has already diagnosed the defect, identified the required repair, and acknowledged that the repair cannot be completed until Ford supplies sufficient replacement parts. Further, the current allocation of parts suggests that the delay may be substantial. Assuming a waiting list of approximately 300 customers and replacement parts being supplied at a rate of only three to four units at a time, many customers could potentially face wait times measured in years rather than weeks or months. While actual delivery schedules may vary, this demonstrates why directing affected owners back to the dealership does not provide a meaningful resolution when the necessary parts remain unavailable. The Ford dealer used tap to temporary repair the condition as seen in photos which keeps the A-Pillar covers from detacting while driving the vehicle.

NHTSA ID

11763126

Incident

Jan 13, 2026

There is a driver's safety-restraint malfunction with a failure mode such that the tongue (male end of seat-belt) will not insert normally into the buckle (female end) unless the red release button is depressed. The driver buckle failure results in a failure in the vehicle's personal safety system. The component has not been inspected or confirmed by a dealer, as Ford Motor Company has indicated this will be an out-of-pocket cost replacement due to the extended warranty on this buckle no longer being applicable - Ford issued voluntary special field action 23L06 related to the driver's side buckle that expired March 31 2025.

NHTSA ID

11763003

Incident

Sep 8, 2026

The contact owns a 2017 Ford Explorer. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 21V316000 (Structure); however, the failure recurred with the front and rear driver's side roof rail covers detaching. The contact also received notification of NHTSA Campaign Number: 25V347000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that the driver’s and front passenger’s side door B-pillar trims had detached. The contact duct-taped the front and rear driver's side roof rail covers and the driver’s and front passenger’s side door B-pillar trims. The vehicle was taken to the dealer, and it was confirmed that parts were not yet available for the recall repair. The contact had to pay for the front and rear driver's side roof rail covers to be replaced. The manufacturer was notified of the failure by phone, and a case was filed. The failure mileage was approximately 122,000.

NHTSA ID

11762786

Incident

Aug 1, 2026

Mileage

122,000 mi

Ever since my B pillar came off my car my cabin lights stay on longer than usual and my trunk cant be opened, both being an inconvenience. Dealer agreed the lights stay on because of what broke off but since theres no remedy they cant do anything about it. Ive already had to purchase a battery and will soon prob going to need to again but ford will not pay for one despite it being they're fault.

NHTSA ID

11762396

Incident

Mar 13, 2026

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

This article supersedes TSB 24-2165 to update the TSB Service Procedure. Some vehicles listed in the Model statement above may exhibit various SYNC performance related concerns including but not limited to:  Display operation concerns  Navigation inoperative  Voice recognition concerns  Phone connection issues  Dropped phone connections  Applink related performance  Travel Link not present or showing incorrect traffic  Slow system response NOTE: Ford has found some of the APIMs replaced and returned for inspection contained an outdated software level and the APIM did not require replacement. The customer concern may have been resolved by updating the APIM with latest level of software. The SYNC 3 universal thumb drive will be able to update the APIM software without the use of a scan tool and does not require the process to be monitored. Ford will be monitoring APIM replacements to confirm TSB directed software updates have been performed.

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.