2018 Ford Explorer Fuel system Problems

I own a Ford Explorer 2018 bought as second hand in July 2020. For the last three years, the investment in it has been exponential. Finally working with a proper car mechanic, I understood that all the fixes I have made, have been known for a while. I have received several recalls and searching for more, I found one that **I did not receiveD*** and I'm having an issue with it. It can be seen in the attached document. Research shows that "the 2018 Ford Explorer has significant, well-documented complaints, primarily regarding catastrophic water pump failure, transmission issues, and multiple recalls. The 3.5L engine's internal water pump often fails around 125,000 miles, causing engine destruction. Other common issues include rear suspension toe link fractures, exhaust smells, and electrical problems." My water pump failed way before 125K miles, as the previous statement states.. Mine is 94K. I fixed it last year and now it's broken again. And by the say of the mechanic, it could be because of the issue of the catalyst, of a recall I didn't get and that probably got the previous owner. I have tried to reach Ford through letter and phone and no one answers. I finally spoke to someone on Tuesday from the warranty department and told me he will reach me in 3 hours. Two days have gone by. I also did a complaint on BBB and the refuse to fix and reimbursed the recall I didn't received.

NHTSA ID

11730439

Incident

Feb 11, 2026

Fuel system evap leak just like the Safety Recall 18S35

NHTSA ID

11719427

Incident

Dec 22, 2025

See attached document for complaint.

NHTSA ID

11688337

Incident

Aug 23, 2025

The contact owns a 2018 Ford Explorer. While the contact's son was driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. No warning lights were illuminated. The vehicle was driven to the shoulder of the roadway. The contact stated another driver with a tow truck assisted and towed the vehicle off the highway to a safe location. The contact stated after the vehicle sat for three hours, the vehicle was restarted, and driven to the contact's residence. The contact stated that the failure had occurred twice within one week. The contact stated that after the vehicle sat for a while, the vehicle independently reset and the vehicle could be driven for a while; however, the failure reoccurred. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The dealer was made aware of the failure. The manufacturer was made aware of the failure and a case was filed. The contact referenced an unknown recall; however, the VIN was not included in the recall. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 60,000.

NHTSA ID

11673416

Incident

Jul 6, 2025

Mileage

60,000 mi

I was pulling into my apartment division I heard a loud pop and the vehicle then died. I tried starting it back up and it then caught on fire. My door locks were stuck in the locked position and I could not get them to unlock. Within a few seconds (which felt like several minutes) the doors did unlock and I was able to get out. There were no warning lights or messages prior to this. Fire department did arrive and put out the fire. The car was a total loss. Report has been filed with insurance company. I purchased this car from BX Fort Myers LLC. I just purchased this vehicle from them and had for a total of 32 days. I did purchase the 12 month/12,000 mile extended warranty. I also purchased Gap insurance and informed them of what had happened. The one GM gave me a loaner for a week, got in trouble for giving me one and got demoted. the new GM said "definitely not" will not give me a loaner. I drive over an hour daily for my job and do need a vehicle.

NHTSA ID

11659235

Incident

Apr 20, 2025

The contact owns a 2018 Ford Explorer. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. In addition, the contact stated that the vehicle jerked forward and backward. The contact stated that the vehicle was driven back onto the driveway. The contact turned off the vehicle and the vehicle failed to restart. The vehicle was towed to the dealer and was diagnosed with throttle body failure that was seized closed. The contact was informed that the throttle body needed to be replaced. The vehicle was not repaired. In addition, the contact stated that the purge valve had been replaced 26 days prior to the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 100,200.

NHTSA ID

11623531

Incident

Nov 3, 2024

Mileage

100,200 mi

Faulty throttle body after purge valve replacement. Car would not accelerate and had to be towed to the dealer. Throttle body is stuck in the closed position according to the dealer.

NHTSA ID

11623513

Incident

Nov 3, 2024

EXHAUST SAFTEY ISSUE / MY CEL CAME ON LEAVING WORK ON 9/25 , SCANED CODE AND GOT A CODE OF P0430 (CATALYTIC CONVERTER BANK 2) I FOUND A CUSTOMER SATISFACTION PROGRAM ISSUED ON 06/13/19 -(PROGRAM #19M01) ON THIS TO REPLACE UNDER AN EXTENDED WARRANTY. THE ISSUE IS WARRANTY COVERAGE IS 11 YEARS OR 120,000 MILES. THE CODE CAME UP AT 120,325 JUST OUTSIDE THE WARRANTY EXTENSION , FORD IS UNWILLING TO EXTEND THIS COVERAGE PAST THE 120 MILE MARK , tHIS CAR ALSO FALLS UNDER ANOTHER PROGRAM THAT WAS ISSUED 01/26/23 (PROGRAM# 22M06) STILL FORD REFUSES TO COVER UNDER WARRANTY FOR THIS SAFTY ISSUE

NHTSA ID

11546795

Incident

Sep 25, 2023

The gas gauge isn’t reading correctly. I’m a mother of a one year old son and I didn’t noticed that my car was reading wrong until I put in gas and it didn’t give me the correct reading. I have spoken to many people who owns a Ford Explorer and they have said the same thing. I don’t even know where to start on why it wouldn’t work. The problem has been reported and I didn’t get a warning. It just stopped reading correctly. There’s nothing on my dashboard, no sign or anything. I am confused.

NHTSA ID

11542408

Incident

Aug 31, 2023

I Drove Explorer directly to Mayo Clinic in MN shorty after the purchase. It would smell like sulpher at times, gasoline, exhaust and I was getting very poor fuel economy. Averaging 17-2. I got extremely sick and confused and had severe headaches and nausea, vertigo, congnitive impairments, burning eyes and all I wanted to do was sleep. I felt fluish and I got confused while going to Mayo for testing. Well, I didn’t make it to my appointment, I couldn’t even figure out how to book a hotel or get cash. I ended up lifeless and chose to stay in the Explorer overnight due to the severe fatigue and confusion. I slept in an open air parking garage and had an electric throw and would start the vehicle occasionally to get warm. Well I ended up so sick and mentally confused and cognitively exhausted my sister called the police to let them know something was wrong with me. I ended up in the hospital for a week. I felt like normal during my days in the hospital, I actually thought that I had been sick from the off gassing of the Explorer, but I couldn’t get away from the smells. I have MCS. After I was released I continued to drive down to Jacksonville Florida for my 3 week outpatient appointment. I was getting terrible fuel economy but I didn’t realize it until I was getting 12 miles a gallon and eventually it went as low as 5 miles per gallon. I was so sick from the odors I didn’t realize how much gas I was going through since I left CO. The Ford at that time in April 2019 had 5,000 miles on it and I was told the reason my fuel economy was so poor along with only getting 5-10 miles per gallon and the frightening smells and sickness were caused by the new emission set up and they refused to listen to my story and symptoms and charged me 500.00 to fix what looked to have been poorly installed. I now have a TBI and severe cognitive and an MRI that shows evidence of Carbon Monoxide Poisoning and things only got worse from there. Thank you.

NHTSA ID

11531793

Incident

Feb 18, 2019

Water pump failing, has leak

NHTSA ID

11519213

Incident

Apr 21, 2023

Around 4:45 , was unable to access cruise control the message rapidly flashed., loss of headlights and all lighting for a few seconds. Was going 70 mph. I exited the interstate to turn around and go to my work on southbound the wrench light came on and I lost power steering, power, acceleration in my turn on the on ramp and proceeded off the road onto the incline somehow avoiding a rollover and teetering sideways. Meanwhile no power to open my window etc. at an angle where I couldn’t open the door, took a minute to get out of the seatbelt. Suddenly got my window able to open and crawled out. The cops, and tow truck couldn’t believe I didn’t roll. The car was at a dealership the previous week for loss of power and terai. System problems/ no power steering and they replaced the throttle body 3 days before this happened. I’ve had multiple electrical/exhaust/power failures. I am terrified to drive this vehicle. It’s been to different dealerships and the ford ones and ford don’t care (only the dealership I purchased it at tries) it is at a fifth one now. We have forscan reports of the failures also. Multiple images at scene also. Car wouldn’t drive correctly and terrain management fault, unloaded itself from trailer too.

NHTSA ID

11511692

Incident

Mar 11, 2023

My car produces a sulfer/burning smell at hard acceleration. When I am merging into traffic at 3500-4000 and over RMP, an awful smell enters the cabin. I am very concerned that this is unsafe for my family and children in the vehicle, as well as the environment. I have had this vehicle looked by Ford and they claim everything looks normal. It is not normal to have this smell while accelerating.

NHTSA ID

11487040

Incident

Jun 1, 2022

THE FUEL PRESSURE SENSOR ALARM

NHTSA ID

11460557

Incident

Mar 3, 2022

The contact owns a 2018 Ford Explorer. The contact stated that while driving at various speeds, a strong, gas odor would emit through the vehicle without warning. Due to the fuel odor, he began to suffer from blurred vision, nausea, and headaches. The contact had sought medical attention for his symptoms. The contact had taken the vehicle to the dealer on two occasions and each time the dealer could not detect a failure. The contact also mentioned that once he began to drive a rental vehicle, his symptoms began to go away. The manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 20,000.

NHTSA ID

11436662

Incident

Oct 1, 2020

Mileage

20,000 mi

Strong exhaust smell in the front cabin while driving 40+ mph. Resulting dizziness and nausea symptoms. Vehicle taken to dealer for diagnosis. Odometer reading 10560

NHTSA ID

11424599

Incident

Jul 8, 2021

WE PURCHASED A BRAND NEW 2018 FORD EXPLORER IN SEPTEMBER OF 2018. AROUND OCTOBER/NOVEMBER 2018 I STARTED HAVING A LOT OF DIZZY SPELLS AND PANICKED ATTACKS WHILE I WAS DRIVING THE EXPLORER. I WAS IN AND OUT OF DRS WEEKLY SOMETIMES MORE THAN WEEKLY FOR THESE EPISODES. DRS THOUGHT IT WAS ANXIETY SO WOULD INCREASE MEDICATIONS, OR CHANGE MEDICATIONS AND I CONTINUED WITH SAME SYMPTOMS. I DROVE THE EXPLORER NUMEROUS TIMES A DAY AS I HAVE KIDS AND WOULD FEEL THIS WAY 90% OF MY DAY EVERY DAY. I WENT THRU PHYSICAL THERAPY, MENTAL THERAPY AND ALSO SENT TO A HEART DOCTOR UP UNTIL 2 MONTHS AGO WHEN WE PURCHASED ANOTHER VEHICLE AND I NEVER HAD A ISSUE WHILE DRIVING THAT. MY FIANC DROVE THE EXPLORER ONE DAY WHICH HE NEVER DID AS IT WAS MY VEHICLE AND HE HAD HIS VEHICLE AND HE SMELLED A GAS SMELL AND QUESTIONED ME ABOUT IT BUT I HAD BEEN SUFFERING RESPIRATORY ILLNESSES DURING THIS TIME AND COULD NEVER SMELL ANYTHING SO I NEVER NOTICED THE SMELL. MY SON WAS HAVING VOMITING SPELLS NUMEROUS TIMES A WEEK AND DRS SAID IT WAS A GENERALIZED VOMITING ISSUE. I CONTACTED THE DEALERSHIP WE PURCHASED THE EXPLORER AT AND THEY CAME AND PICKED IT UP. ONCE THEY CHECKED IT OVER THEY CALLED ME AND SAID THEY HAD TO ORDER A WHOLE NEW MUFFLER SYSTEM AS IT WAS LEAKING CARBON MONOXIDE INTO THE CABIN OF MY EXPLORER. I CONTACTED FORD MOTOR COMPANY AND THEY SAID THEY WOULD FIX IT IN WHICH THEY DID BUT THE DAMAGE WAS DONE I HAD BEEN SUFFERING PHYSICALLY AND MENTALLY FOR A YEAR AND DUE TO THE PAN NICK ATTACKS WHILE DRIVING I COULD BARELY DRIVE MOST DAYS AND STILL STRUGGLE DUE TO THE FEAR I'VE ENCOUNTER BEHIND THE WHEEL. FORD BASICALLY SAID I COULD TRADE IT OR KEEP IT THAT'S ALL THEY WOULD OFFER ME. I WANTED THEM TO BUY IT BACK AS I COULDN'T GET BACK IN IT. I'VE HAD NO ISSUES SINCE I STOPPED DRIVING IT NEITHER HAS MY SON. I DIDN'T GET ANY PAPERWORK WHEN IT WAS FIXED SO I CAN'T GIVE U THAT.

NHTSA ID

11298301

Incident

Nov 22, 2019

WHEN STARTING VEHICLE, THE INSIDE OF MY VEHICLE FILLS WITH A STRONG SMELL OF GAS. THIS IS AN ONGOING AND REOCCURRING ISSUE. I BELIEVE IT MAY BE THE CAUSE OF MY 6 YEAR OLDS CHILD'S FREQUENT HEADACHES AND BOUTS WITH NAUSEA THAT BEGAN AT THE SAME TIME I STARTED NOTICING THE GAS SMELL ISSUE.

NHTSA ID

11282968

Incident

Nov 1, 2019

Mileage

25,000 mi

STRONG SMELL OF EXHAUST AND ROTTEN EGGS ENTERED THE CABIN 5 TIMES DURING A 4 HOUR ROAD TRIP DURING ACCELERATION AND AT HIGHER SPEEDS. THE SMELL CAUSED HEADACHES AND NAUSEA. THE WINDOWS HAD TO BE OPENED TO RELIEVE THE SMELL. THE ISSUE WAS REPORTED TO THE FORD DEALERSHIP ON THE NEXT POSSIBLE BUSINESS DAY AFTER OCCURRING FOR REVIEW IN A SCHEDULED MAINTENANCE WITHIN 2 WEEKS OF THAT DATE. NUMEROUS TSB (FOR PREVIOUS MODEL YEARS 2011-2017) AND COMPLAINTS (FOR MODEL YEARS INCLUDING 2018) FOR THIS SAME PROBLEM CAN BE FOUND IN ONLINE SEARCHES. AT THE TIME OF RECORDING THIS COMPLAINT, MY TRUCK IS STILL WITH THE DEALERSHIP UNDER REVIEW.

NHTSA ID

11256371

Incident

Sep 1, 2019

Mileage

11,000 mi

FORD EXPLORER 2018 GOING FROM 50 MPH. AND TO DO FORCE, ENTERS A STRONG SMELL OF GAS CABIN IT SHOULD SLOW DOWN AND OPEN THE CRYSTALS TO LEAVE THE STRONG ODOR.

NHTSA ID

11203128

Incident

Feb 1, 2019

I HAVE BEEN SMELLING EXHAUST FUMES/ROTTEN EGG SMELL IN MY CAR WHEN ACCELERATING UP TO 60MPH. 1ST TIME IN SHOP THEY SAID BOLTS WERE MISSING ON ENGINE AND SOME WERE LOOSE.; THEY 'FIXED' IT. STILL SMELLED EXHAUST FUMES/ROTTEN EGGS, SO TOOK CAR BACK. THEY SAID FUEL GOT IN THE FUEL FILTER BUT THEY 'FIXED' THE PROBLEM. NO STILL SMELL EXHAUST/ROTTEN EGGS. TOOK BACK FOR 3RD TIME THEY HAD MY CAR FOR A MONTH AND THEY REPLACED THE WHOLE EXHAUST. NOW HAVE HAD CAR A WEEK AND A HALF AND I SMELL THE EXHAUST. I DON'T KNOW WHAT TO DO, I HAVE THIS BRAND NEW CAR COSTING ME $37000.

NHTSA ID

11181331

Incident

May 1, 2018

TL* THE CONTACT LEASED A 2018 FORD EXPLORER. THE CONTACT DETECTED AN ABNORMAL FUEL ODOR INSIDE THE VEHICLE THAT WAS SO STRONG, SHE COULD TASTE FUEL. TOWNE AUTO GROUP (3535 SOUTHWESTERN BLVD, ORCHARD PARK, NY 14127, (716) 662-6500) WAS NOTIFIED OF THE FAILURE, BUT WAS UNABLE TO REPLICATE, DIAGNOSE, AND PROVIDE A REMEDY AFTER SEVERAL VISITS. THE DEALER LATER REPLACED THE DOOR SEALS, BUT THE FAILURE CONTINUED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 18V807000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT A PASSENGER INSIDE THE VEHICLE EXPERIENCED NAUSEA AND HEADACHES WHILE THE VEHICLE WAS IN OPERATION. MEDICAL ATTENTION WAS NOT RECEIVED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA ACTION NUMBER: EA17002 (STRUCTURE, ENGINE AND ENGINE COOLING). IN ADDITION, THE CONTACT WAS UNABLE TO USE THE AIR CONDITIONER AND HEATING, AND HAD TO CLOSE THE VENTS DUE TO AN ASTHMA CONDITION. THE APPROXIMATE FAILURE MILEAGE WAS 4,278.

NHTSA ID

11166470

Incident

Aug 30, 2018

Mileage

4,278 mi

AFTER 4,000 REVOLUTION THE SUV COMES TO STOP THE ENGINE AND RUN QUICKLY AGAIN

NHTSA ID

11100425

Incident

May 13, 2018