2019 Ford Explorer Fuel system Problems

Fuel pump and module failure. Driving on the highway at 70 miles an hour and the fuel pump failed. Causing me to have zero acceleration. Thus losing speed rapidly in the center lane. No warning lights were present before or after. One previous symptom of a crank no start. Dealership was able to replicate the crank no start situation. Resulting in the problem being a fuel pump failure and module needing replaced, at 83,000 miles on the vehicle. Though I know normal wear and tear can and does happen, there was no warning. And losing engine power at high speeds on a highway is unsafe.

NHTSA ID

11749645

Incident

Jul 8, 2026

The contact owns a 2019 Ford Explorer. The vehicle was taken to the local dealer to be repaired under NHTSA Campaign Number: 26V101000 (Suspension). While retrieving the vehicle, the vehicle failed to start. The contact heard the mechanic revving the engine of the vehicle. The dealer determined that the fuel pump and fuel pump module needed to be replaced, and that the failure was not related to the recall repair. The vehicle was not repaired. The manufacturer was contacted and determined that the failure was not related to the recall. The failure mileage was approximately 50,000.

NHTSA ID

11730183

Incident

Apr 6, 2026

Mileage

50,000 mi

Vehicle fails to start intermittently. After having this happen on several occasions and waiting for 1-2 hours it would start. However, the last time, while traveling it would not start after taking brief stop. Had to leave the vehicle overnight and return the next day to haul it back home 300 hundred miles. That was Feb. 23, 2026 and still will not start. Vehicle has 70,000 miles.

NHTSA ID

11723731

Incident

Feb 22, 2026

Accelerator stuck wide open while entering freeway. I also have a safety recall notice 24S02/NHTSA recall 24V031

NHTSA ID

11718318

Incident

Feb 11, 2026

Blown engine due to ecoboost fuel issues. Vehicle quit and shut off on highway. Multiple issues with 2019 ford explorer that does not get resolved.

NHTSA ID

11704213

Incident

Dec 7, 2025

The catalytic converters for the Ford Explorer Utility Police Interceptor fail prematurely, degrading the emissions from the vehicle and causing the vehicle to fail emissions testing. Although Ford has implemented a Customer Satisfaction Campaign 22M06, they do not inform owners of the campaign or potential problem. My car was inspected by two Ford dealerships who simply cleared the error code (P0430) and made no mention of Campaign 22M06. The error code persisted as I replaced numerous other components (spark plugs, purge valve, oxygen sensors, Mass air flow sensor) trying to alleviate the problem over the last year. Only if you mention the campaign specifically will they inspect the vehicle for the purpose of replacing the the catalytic converters under warranty. Replacing these failing catalytic converters should be a recall because failure creates substandard emissions for thousands of vehicles.

NHTSA ID

11703219

Incident

Oct 23, 2024

The contact owns a 2019 Ford Explorer. The contact stated while driving approximately 75 MPH with the cruise control activated, the vehicle suddenly started sputtering and decelerated unintendedly. The vehicle was driven to the shoulder of the roadway, and the vehicle stalled. The vehicle failed to restart and was towed to the local dealer. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 52,000.

NHTSA ID

11678167

Incident

Aug 3, 2025

Mileage

52,000 mi

The contact owns a 2019 Ford Explorer. The contact stated that upon acceleration from a stop, the vehicle experienced a loss of automotive power. There were no warning lights illuminated. The vehicle was towed to a local dealer where it was diagnosed, and the contact was informed that the fuel pump and the fuel injectors were faulty and needed to be replaced. The vehicle was repaired; however, the failure persisted. The contact stated that on another occasion while driving 63 MPH, the vehicle lost automotive power. There were no warning lights illuminated. The vehicle was towed to a local dealer where it was diagnosed, and the contact was informed that the fuel pump and fuel injectors were faulty and needed to be replaced. The vehicle was repaired; however, the failure reoccurred while driving 72 MPH, and the vehicle lost automotive power. There was no warning light illuminated. The vehicle came to a complete stop and the contact called the Police for traffic control and the vehicle was towed to a local dealer to be diagnosed. The contact was informed that the fuel pump and the fuel injectors were faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 60,000.

NHTSA ID

11674610

Incident

Jul 17, 2025

Mileage

60,000 mi

Car would not start at certain times without warning. Sometimes putting us in an unsafe location. Finally vehicle was in a public parking and would not start and had to be towed to Ford dealer. The fuel pump and some other issues failed. Repair shop said it would happen with low gas, but we had over a half a tank. Total cost of bill without tow was $2132.02. Vehicle had 45,015 miles.

NHTSA ID

11673441

Incident

Jun 15, 2025

On 3 separate occasions my car has stalled when driving. All three were after driving for several hours in hot weather. 2 of the times I had a quarter of a tank of gas and pressed on the gas to pass someone and my car stalled out immediately after. Both very dangerous scenarios. 3 time just this week. Driving for over 5 hours in hot weather conditions, but 3 quarters of a tank of gas and stuck in traffic and the car just completely stalled. Again a dangerous scenario on the highway. All three times after waiting for about 45 minutes the car will start again. Sluggish at first and then drives normal. It’s giving indications that it could be a defect in the low pressure fuel pump that has been a recall in other 2019 ford explorers, but my vin #is not listed as one of them.

NHTSA ID

11672764

Incident

Jul 7, 2025

Operator law enforcement was idling for an extended time in this vehicle. He was found unconscious in the vehicle and diagnosed with acute carbon monoxide poisoning. He was hospitalised for 4 days, and suffers continuing neurological deficits. Post-incident testing by engineer instructed by operator indicated two improper or incomplete welds on exhaust system, allowing exhaust to pool under vehicle and enter passenger compartment through HVAC fresh air intake. Post-incident testing recreated rising CO levels in passenger compartment. Vehicle has also been inspected by manufacturer. There were no warning lamps or messages.

NHTSA ID

11568138

Incident

Mar 22, 2021

When the vehicle is in outside in the direct sunlight, the extreme heat causes the fuel pump driver module to fail. When this module fails, it cause the vehicles fuel pump to stop sending fuel to the motor which causes the vehicle to turn off or run extremely rough, while driving and or stationary. The moduel has been replaced by world ford Pensacola once, and twice by an ASE Certified Master Mechanic, on 3 separate occasions.

NHTSA ID

11539478

Incident

Aug 18, 2023

At 53,000 miles I was driving down the highway and my vehicle sputtered and died leaving me stranded on the side of the road. The vehicle would not start. I took the vehicle to a local repair shop and had to replace the Fuel Pump for the vehicle. That was very low mileage to have an issue with a major part like a fuel pump.

NHTSA ID

11473252

Incident

Jun 3, 2022

NOTICED SEVERE EXHAUST SMELL WHEN DEFROST IS ON WHILE DRIVING, AND MORE MODERATELY WHEN THE RECIRCULATED AIR IS ON. LOOKED UP THE ISSUE ONLINE AND FOUND THAT OUR 2019 FORD EXPLORER IS EXPERIENCING THE SAME ISSUES THAT CAUSED A SOFT RECALL FROM FORD FOR THEIR 2011-2017 MODELS. TOOK IT TO LOCAL FORD SERVICE CENTER, BUT THEY COULD NOT REPLICATE THE ISSUE. HOWEVER, THE TECH AT FORD SERVICE CALLED THEIR HOTLINE, WHO STATED "REAR AIR VENTS WERE LOOSE CAUSING THIS CONCERN". FOLLOWING THIS CALL, FORD SERVICE CENTER DID THE FOLLOWING (ALL QUOTES ARE FROM SERVICE INVOICE): "REMOVED REAR BUMPER COVER AND INSPECT[ED] AIR EXTRACTORS. INSPECTION FOUND BOTH EXTRACTORS WERE NOT CONNECTED ON THE LEFT REAR CORNER OF BOTH SIDES, LIKE THEY ARE BROKEN WILL NOT PROPERLY SEAT. INSPECTION ALSO FOUND LIFTGATE DRAIN VALVE WAS MISSING AND LR TAILLAMP GROMET WAS NOT SEATED TO THE BODY. REPLACED BOTH EXTRACTORS AND DRAIN VALVE, RESEATED LR TAILLAMP BODY PLUG, REINSTALLED REAR BUMPER AND TEST DROVE." WE HAVE NOT NOTICED THE EXHAUST SMELL SINCE THE FIX ONE WEEK AGO. I AM REPORTING THIS SO THAT NHTSA AND ANYONE READING THIS KNOWS THAT THE FORD EXHAUST ISSUES THAT CAUSED SO MANY PROBLEMS ARE STILL ONGOING THROUGH THE 2019 MODEL, AND ALSO SO THAT CONSUMERS WHO HAVE THIS MODEL KNOW EXACTLY WHAT TO TELL THEIR LOCAL FORD SERVICE CENTERS TO DO TO FIX IT.

NHTSA ID

11306220

Incident

Jan 24, 2020

Mileage

10,000 mi

BURNING SMELL (PRESUMABLY EXHAUST FUMES) ARE LEAKING INTO CABIN WHILE DRIVING. HAPPENS MORE OFTEN UPON HARD ACCELERATION AND WITH AIR CONDITIONING ON IN AIR RECYCLE MODE.

NHTSA ID

11240611

Incident

Jul 30, 2019

Mileage

700 mi

ON MARCH 2ND 2019 FORD EXPLORER SPORT WITH 1,800 MILES WAS TOWED TO THOMASSEN FORD IN CHARLES TOWN WV LEAVING OWNER STRANDED. COMPLAINED OF STRONG FUEL/GASOLINE ODOR INSIDE THE VEHICLE. FUEL/GASOLINE WAS LEAKING BADLY OUT OF THE VEHICLE ONTO THE EXHAUST PIPE. ON MARCH 4TH NOTIFICATION WAS PROVIDED FROM SERVICE WRITER THAT NONE OF THE FUEL LINES OR CLAMPS WERE ATTACHED PROPERLY FROM THE FACTORY. VEHICLE SAT AT THOMASSEN FORD UNTIL MARCH 27TH WHEN REPAIRS WERE COMPLETE. APRIL 9TH 2019 SOME FORM OF FLUID LEAKED OUT OF THE PARKED VEHICLE FOR 8 HOURS AFTER A 7 MINUTE DRIVE. VEHICLE WAS TAKEN TO JERRY'S FORD IN LEESBURG VA "UNABLE TO DUPLICATE" THEREFORE NO ACTION WAS TAKEN. THERE ARE PHOTOS OF THIS ISSUE. APRIL 18TH 2019 A STRANGE NOISE COMING FROM THE STEERING COLUMN WHEN DRIVING. VEHICLE WAS TAKEN BACK TO JERRY'S FORD IN LEESBURG VA "UNABLE TO DUPLICATE" THEREFORE AGAIN NO ACTION WAS TAKEN. TO THIS DAY THE VEHICLE STILL MAKES THE NOISE WHICH HAS GOTTEN PROGRESSIVELY WORSE. THERE IS VIDEO OF THIS ISSUE

NHTSA ID

11208940

Incident

Mar 2, 2019

Mileage

1,800 mi

TL* THE CONTACT OWNS A 2019 FORD EXPLORER. WHILE DRIVING THE VEHICLE, THE CONTACT SMELLED EXHAUST FUMES AND FUEL INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO ADVANTAGE FORD (4000 SE FEDERAL HWY, STUART, FL 34997, (772) 287-0955) TO BE DIAGNOSED, BUT THE TEST WAS NOT YET COMPLETED. THE MANUFACTURER WAS NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 4,500.

NHTSA ID

11193405

Incident

Mar 2, 2019

Mileage

4,500 mi