2020 Ford Explorer Other / unspecified Problems

I keep feeling a clunk or thump towards the back of the car at random times, towards the back axle. Sometimes it's when i stop and drive forward, other times it happens while I am just driving normally, usually at slow speeds around 5-45mph. I have an extended warranty and the ford dealer has said they can;t replicate it and want to give my car back until it gets worse, and then try fix it. I am highly concerned about this process....

NHTSA ID

11753585

Incident

Jul 29, 2026

The contact owns a 2020 Ford Explorer. The contact received notifications of NHTSA Campaign Numbers: 25V685000 (Equipment), 26V117000 (Visibility), and 26V402000 (Power Train); however, the parts to do the recall repairs were not yet available. The contact was concerned that the incomplete recalls presented significant safety risks, specifically because the contact resided in Alaska, where it rained constantly with low temperatures. The dealer was contacted and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11752205

Incident

Jul 22, 2026

My driver window won’t stay up once it gets to the top it goes back down. The underbody is starting to detach. It is shifting hard and makes a loud noise. Worse at low speeds and applying brakes . The tire pressure sensors all went out at one time

NHTSA ID

11747989

Incident

Dec 31, 2025

When putting the car in reverse and moving backwards start to feel the vehicle look drive power and knock sounds. Sounds likes and feels like gear teeth or not aligned. When putting the car into drive the vehicle jumps a little and you hear a lout pop noise.

NHTSA ID

11738967

Incident

May 19, 2026

Wheels / Tire Pressure Monitoring System The tire pressure monitoring system (TPMS) on my 2020 Ford Explorer intermittently fails to detect the tire pressure in one or more tires. The system will show missing pressure readings or fail to display a reading for a tire. The vehicle may operate without accurate tire pressure information being displayed to the driver. This creates a potential safety risk because the driver may not be alerted to a low tire pressure condition. The vehicle had approximately 56,000 miles when this began, and the issue appeared without prior warning. The vehicle is scheduled for inspection by a Ford dealership.

NHTSA ID

11722436

Incident

Dec 10, 2025

Tire pressure sensor fault. A rear tire pressure sensor has defaulted more than once. As this is built into the wheel assembly, I believe this is a safety issue

NHTSA ID

11683209

Incident

Aug 3, 2025

The tire pressure monitoring system has failed. Per the dealership, each tire needs a new battery, which run around $150/each. The first sensor went out approx 1 month ago, with the other 3 going out shortly after. While this does not pose an immediate risk for the driver, it does appear that numerous other 2020 explorers are having the same issue. If the batteries provided are faulty, a recall should be issued.

NHTSA ID

11673288

Incident

Jun 2, 2025

I am filing a complaint regarding a safety issue with my 2020 Ford Explorer that was not properly addressed during a recall repair, leading to a dangerous situation. Vehicle Details Make: Ford Model: Explorer Year: 2020 Recall Repair Details In January 2024, I took my vehicle to Coconut Point Ford in Estero, FL, for a recall repair related to the rear axle horizontal mounting bolt, which was at risk of fracturing. The recall required the replacement of the subframe bushing and rear axle bolt to prevent driveshaft disconnection. Incident Description Recently, while driving under normal conditions, the bolt fractured, causing the differential to nearly detach from the vehicle. This failure could have resulted in a catastrophic accident. I am now facing a $6,000 repair bill for an issue that should have been resolved under the recall. Safety Risk The failure of the bolt and the near detachment of the differential posed a severe safety risk, as it could have led to a loss of control of the vehicle, especially at highway speeds. Dealership Response When I brought this to the attention of Coconut Point Ford, they stated that "bolts are not covered under the extended warranty." However, since this is a recall-related issue, I believe Ford is obligated to cover the repair costs. The service writer, Steve, has been helpful, but the resolution has been delayed. Additional Context I am aware of class action lawsuits against Ford regarding this defect, which allege that the recall fix does not fully address the issue and that the design is inherently flawed. Request I request that the NHTSA investigate this matter to ensure that Ford is held accountable for properly addressing this safety recall and to prevent similar incidents from occurring to other vehicle owners. Thank you for your attention to this serious safety concern.

NHTSA ID

11667955

Incident

Jun 14, 2025

1. Component: AWD system – Front Axle Disconnect Actuator / Intermediate Shaft • Failure Type: AWD system failed, preventing power transfer to front wheels • Availability for Inspection: Yes, diagnosed and confirmed by Zeigler Lincoln Ford 2. On Thursday, [XXX], while driving in a snowstorm with my two children, my 2020 Ford Explorer AWD system failed completely, leaving us stranded on an icy hill with no traction or ability to move. • My vehicle lost all AWD functionality, causing it to become immobilized on an active roadway in hazardous conditions. • We were trapped between two semi-trucks that were also stuck, creating a high-risk situation where a collision or multi-vehicle pileup could have occurred. • With freezing temperatures and no way to move, we were at risk of hypothermia while waiting for a tow truck. This was not an isolated issue. Ford acknowledges this AWD system defect under TSB 23-2174, meaning this failure can happen to any driver under similar conditions, creating a major safety hazard. 3. Yes. The issue was diagnosed and confirmed by Zeigler Lincoln Ford, who determined it was covered under TSB 23-2174. • Ford has officially acknowledged this defect but has not issued a recall. 4. Yes. The vehicle was inspected by Zeigler Lincoln Ford, and the AWD failure was confirmed as a front axle disconnect actuator/intermediate shaft defect. • Ford issued TSB 23-2174 to address the defect, proving that this is a known issue. • However, instead of issuing a recall, Ford is making owners pay for repairs out of pocket, despite the serious safety risk. 5. Yes. Prior to the AWD failure, I received a wrench icon warning (Powertrain Malfunction Indicator) on my dashboard. • Error codes C0631 and C0633 were later retrieved by the dealership, confirming AWD disconnect failure. • I had experienced intermittent AWD traction loss in winter conditions, but the system failed completely during the snowstorm incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11641806

Incident

Dec 5, 2024

The tire pressure system for all four tires has completely went out on the monitoring system. It originally started where it was only on one tire then it happened to two then the final monitor keeps going in and out.

NHTSA ID

11639724

Incident

Dec 7, 2024

it is well know fack that rear bolts for axle and all part tend break ford replace them once with what ? bolts that still break so probems was never fix, now as ford did this as was no recall they refuseing replace bolts a 2ed time to fix there error, wich lead to many cars being damage so bad ford has refuse to fix them leaveing the people holding the bag more so when car wreckes, probem is ford and may others are hiding cars throw use of modle number vr ack year that car was made under, 2020 ford expoler made 2019 throw not one 2019 recall was place on this car, ? and why vin is base on modle number not year was made, and your department dose not force these busness to investgate part number in reclall list, parts should not been used in newer cars but was this goneing on more then not, now again i get message replace rear axle bolts only after they brake ONLY AFTER THEY BREAK now they know what will happen if they brake going 70 mpr, this probem was never fix right first time and now again this time ford saying we not going replace bolts , it is time you all step up and find out why this keeps going on why wasent it fix and get fix right, this is huge saft probem, that one can lose a hole tire if more one bolts breaks this has happen, ford and others do not look at part numbers as part there recall process throw part number in the system so if other cars has this probem people has fix it, think change must be made to not only look at vin but part numbers in all recalls regardless of vin or what car if that part is in it should be replace, now i cant explane why ford refuse to not replace such a critcal part this is not just something as lose pice of molding these bolts hold rear end in place and all the bolts prone to breaking, i ask that u look in to why they replace first time and why they must be replace again and force ford to replace these bolts befor some one dies

NHTSA ID

11619064

Incident

Oct 8, 2024

The contact owns a 2020 Ford Explorer. The contact stated while driving 75 MPH, the vehicle was shaking abnormally. The contact drove the vehicle to the side of the road and performed an inspection of the vehicle. The contact noticed that 3 of the 4 lug nuts were fractured on the driver's side rear tire. The vehicle was towed to the dealer where it was diagnosed with detached lug nuts. The contact was informed that the lug nuts needed to be replaced. The vehicle was not repaired. The contact stated that the failure had occurred four times within the year. The manufacturer was not made aware of the failure. The failure mileage was approximately 90,000.

NHTSA ID

11612904

Incident

Aug 31, 2024

Mileage

90,000 mi

August 22, 2024 Ford Motor Company Customer Relationship Center P.O. Box 6248 Dearborn, MI 48126 Regarding: Customer Satisfaction Program 24N01 I want to let you know how dissatisfied I am with your customer service claim to have happy satisfied customers, that is so proudly proclaimed in the introduction to this notice. We travel long distances in very remote areas of the Southwest. The last thing I want is to be stranded in the hot desert with an axle bolt beginning to or actually failing. Your policy to notify us of a potential problem, but not repair until the bolt fails gives me no confidence in my vehicle. In fact I am reluctant to make this trip again in this vehicle that has a known parts failure issue. It would have been better to have not notified me of this concern, in which Ford has no intention of repairing until it fails. If the issue was only non critical, such as the chrome around the window operation buttons this process would be acceptable. However this issue has the potential for severe mechanical failure, resulting in dropping the driveline. The approach presented in this letter for this issue demonstrates a lack of customer service. At this point I am ready to sell this vehicle and purchase a different vehicle from a different manufacturer before taking another long distance trip in it.

NHTSA ID

11610251

Incident

Jul 1, 2024

The rear left brake caliper locked up and caused damage to the wheel, tire, rotors and most of the brake assembly. Ford service thought that maybe a bolt fell out. The vehicle has ~36000 miles. I purchased what was called a bumper to bumper warranty from the dealership but was told it did not cover the problem. The damage is $3200. I looked at online forums and found numerous entries about the brake caliper issues. A parts employee at a dealership told me the part (L1MZ2B511C) was on national backorder due to a "Quality" problem. Ford customer service said they would not cover the repair because there is no recall.

NHTSA ID

11564689

Incident

Dec 31, 2023

The contact owns a 2020 Ford Explorer. The contact stated that while the transmission was shifting gear, there was an abnormally loud grinding sound coming from the front-end of the vehicle. There was transmission fluid leaking underneath the vehicle while the vehicle was idling. There were no warning lights illuminated. The vehicle was taken to the dealer who diagnosed that the transmission cooler had fractured and needed to be replaced. The contact related the failure to Customer Satisfaction Program NHTSA ID Number: 10185994 (Power Train, Equipment) however, the VIN was not included. The vehicle had not been repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not included in the Customer Satisfaction Program. The repair was not covered under warranty. The approximate failure mileage was 31,000.

NHTSA ID

11555199

Incident

Oct 15, 2023

Mileage

31,000 mi

The contact owns a 2020 Ford Explorer. The contact stated that while driving at various speeds and whenever attempting to accelerate the vehicle would display a jerking sensation. It would jump as if it wanted to fail and or stall. power train malfunctioning, hill start pre-collision assist, front camera low visibility, as well as others, all had illuminated on the dashboard. The vehicle had been taken to the dealer who diagnosed that the all wheel drive module had failed and needed to be replaced. The vehicle was in the process of being repaired. The manufacturer was made aware of the failure and referred them to NHTSA. The approximate failure mileage was 34,412.

NHTSA ID

11553352

Incident

Oct 31, 2023

Mileage

34,412 mi

On November 16, 2022, my 2020 Ford Explorer XLT AW, VIN # 1FMSK8DH2LBC95627, was being driven when it experienced a horrific incident of spontaneously bursting into flames. There were flames coming from under the hood and smoke inside the car. The vehicle was in traffic and had to maneuver over to the breakdown lane while the vehicle was filling with smoke in order for the occupants to escape. The Explorer’s mileage was 10,744 miles and had just recently been at the Ford dealer for regular maintenance. The vehicle had been driven that particular day approximately 100 miles without incident before it caught on fire. 1. Damage beyond repair Vehicle was totaled by insurance company 2. A spontaneous fire put everyone in the traffic area at risk 3. No reproduction of the event 4. Fire started with no warning

NHTSA ID

11507142

Incident

Nov 15, 2022

MY 2020 FORD EXPLORER WHICH I PURCHASED A WEEK AGO AND IS EQUIPPED WITH HANKOOK KINERGY GT TIRES HAS ME ALL OVER THE ROAD WHEN TRAVELING ON THE FREEWAY AT SPEEDS ABOVE 55 MILES PER HOUR ON STRAIGHT AWAYS ALONG WITH CURVES. IT IS DANGEROUS BECAUSE WITH SHORT NOTICE THE VEHICLE WILL DRIFT TO THE LEFT OR RIGHT BECAUSE OF THE QUALITY OF THE TIRES, UPON FURTHER INVESTIGATION IT APPEARS THAT MANY OTHERS THAT HAVE VEHICLE'S WITH THESE TIRES EXPERIENCE BLOW-OUTS, UNEVEN WEARING, AND COMPLAINTS ABOUT RIDE QUALITY. *TR

NHTSA ID

11325688

Incident

May 21, 2020

Mileage

267 mi