2020 Ford Explorer Problems

Transmission downshifts hard, jerks at take off

My 2020 Ford Explorer Limited has a broken transmission matching Recall 26S48. The car cannot be driven. My local dealer wants to help but has zero loaner vehicles available. Ford Corporate is refusing to fund an outside rental car or an emergency interim repair while delaying the official fix until next year. I am completely stranded by a manufacturer safety defect. It is setting at the dealer, and they have said it needs a whole new transmission.

I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain 2020-2021 Explorer AWD vehicles. The bulletin specifically identifies C0631 and/or C00A6 and the front axle disconnect actuator/intermediate shaft and directs replacement with a revised intermediate shaft. I am concerned this is a safety defect because the failure resulted in AWD/drive-mode malfunction while multiple driver-assistance systems became unavailable. I request that NHTSA investigate this known failure and determine whether a safety recall is warranted.

I am writing to formally express serious concerns regarding the safety of a Ford vehicle that continues to carry a 5-star safety rating despite multiple known, safety-critical defects that emerged after relatively low mileage. Two major issues developed between approximately 62,000 and 72,000 miles. Both are documented by Ford Technical Service Bulletins (TSBs), yet neither has been addressed through a formal recall. My vehicle’s warranty expired at 60,000 miles, leaving me responsible for more than $3,000 in out-of-pocket repair costs. Issue 1 – Front axle seal leak (TSB 23-2174) The front axle seal began leaking fluid. According to the TSB, the original affordable seal is no longer available, requiring replacement of the entire axle assemblies at a cost of approximately $2,000. Failure to complete this repair risks axle lock-up and a potential collision. Issue 2 – All-wheel-drive module ground wire omission (TSB 23-2061) Ford failed to install a required ground wire on the AWD module. This caused multiple warning lights to illuminate, including powertrain failure and collision-assist system failure. I refused to allow my wife and children to ride in the vehicle throughout the winter because of these critical warnings. The repair, which required replacement of the AWD module, cost more than $1,000. These are not minor inconveniences. An axle that can lock up, loss of AWD capability in hazardous conditions, and the simultaneous failure of collision-assist systems present clear and foreseeable risks of serious crashes. A vehicle exhibiting these defects does not merit a 5-star safety rating, particularly when the problems are known to the manufacturer and affect used-vehicle buyers who may lack the financial means to perform the repairs. I respectfully urge the NTSB to investigate these issues, determine whether the continued 5-star rating is appropriate, and encourage Ford to issue formal recalls so that owners are not left to bear the cost and risk of repairs.

I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain 2020-2021 Explorer AWD vehicles. The bulletin specifically identifies C0631 and/or C00A6 and the front axle disconnect actuator/intermediate shaft and directs replacement with a revised intermediate shaft. I am concerned this is a safety defect because the failure resulted in AWD/drive-mode malfunction while multiple driver-assistance systems became unavailable. I request that NHTSA investigate this known failure and determine whether a safety recall is warranted.

On August 14, 2026, the power liftgate on my 2020 Forde Explorer unexpectedly began closing while I was loading my dog into a kennel in the rear cargo area. I did not press the liftgate close button and no one else activated a liftgate control. My key fob was inside my purse on the front seat of the vehicle. The liftgate came down while I was underneath it and struck me directly on the head. The impact knocked me to the ground. I saw stars and was confused immediately afterward and sustained a scalp laceration with significant bleeding. I did not lose consciousness and did not require stitches. One person directly witnessed the incident and was also struck by the closing liftgate. Because the liftgate struck my head first, its force was reduced before it contacted the other person, who was not injured. Other people arrived immediately afterward and can confirm my condition following the impact and that the key was in my purse on the front seat. This was not the first time this has happened. It has occurred on multiple occasions while loading without intentionally activating. I have been hit in the head before but not enough to cause bleeding. The incident occurred Friday evening on 8/14/2026. Vehicle has not yet been inspected because the service department is closed for the weekend. I plan to contact Ford once open on Monday. I am reporting this because I am concerned there may be a defect involving unintended activation of the power/hands-free liftgate and/or its safety obstacle-detection system. The unexpected closure has now caused an injury and also struck a second person.

Driving down road when motor started making noise. No lights on dash or anything then it started to buck and wouldn’t accelerate.i pulled over on the highway and shut it off and called a friend for a tow. Got the car checked out and turns out it was almost 5 quarts low on oil and has spun a rod bearing and almost locked up.

Transmission downshifts hard, jerks at take off

The contact owns a 2020 Ford Explorer. The contact stated that the vehicle experienced intermittent starting failures, and upon starting the vehicle and shifting into gear, the vehicle shut off. No warning light illuminated. Additionally, the electronic parking brake was unintendely engaged. The contact replaced the battery; however, the failure persisted. The vehicle was not diagnosed or repaired by a dealer or an independent mechanic. The manufacturer was not notified of the failure. The failure mileage was approximately 100,000.

I experienced catastrophic brake failure on July 14 2026. Total loss of brakes that led me to narrowly miss several vehicles. The Ford Dealership in Manor TX stated it needed the brake booster replaced and program reset. After researching this is a problem with my VIN that was offered free replacement until 2022 this should be a total unexpired recall. I could have lost my life or someone eles! It’s part of the Customer Satisfaction Program 20B51:

The edges of the fabric sunroof cover have come off the tracks, causing the sunroof cover to not roll up properly and block the rear window when open.

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.

Passenger headlight module has blown and seems to be an issue with the 2020 Ford Explorer.

The passenger headlight low beam does not work.This has been identified by an Independent service center. The Check Headlight System message shows on dashboard. Bought the car in 2023 and the headlight has not worked for 2 years. When driving at night I only have one headlight that works this poses a risk to myself and others. The entire headlight assembly must be replaced.

The contact owns a 2020 Ford Explorer. The contact received notifications of NHTSA Campaign Number: 23V675000 (Power Train), 25V093000 (Seat Belts), 26V402000 (Power Train), and 26V451000 (Seats) and would like to be removed from the recall distribution list. The local dealer and manufacturer were contacted.

My Ford explorer has a 3rd row headrest stuck in a down position. So, the passengers head will not be supported in a whiplash situation. I have found many complaints on this issue but cant find what should be a very important safety recall.

First the fuel pump control module went out and now for the 3rd time the electrical to the fuel pump control module has faulted

Cruise in vehicle was set to 58 mph. Vehicle shut off going around a curve and would not restart. At 40mph emergency brake set as car wasn’t running and it was coasting to a stop. I sat on the road barely off the shoulder as car would not restart and would not come out of park to be able to push the rest of the way off the road. Had it towed to a ford dealer where they replaced the fuel pump control module and they had concerns of it possibly not fixing the problem. I made it 10 miles after pickup and it did the exact same thing shuts off no warning like it ran out of gas. Get towed back to the ford dealer and they can’t duplicate the problem and say nothing is wrong and they don’t know why it randomly shuts off and loses fuel. However it still has the same codes as initially in relation to lack of fuel. I don’t feel safe driving the car as now I’ve broke down twice same problem and fear it’ll keep happening and I may not get so lucky as to not get seriously injured as I cannot move it from the road. Asked about getting rid of it and no dealership wants it because of these problems. Now I’m stuck with a $30,000 paperweight that I can’t drive safely and I can’t replace without going into a lot of debt.

On August 14, 2026, the power liftgate on my 2020 Forde Explorer unexpectedly began closing while I was loading my dog into a kennel in the rear cargo area. I did not press the liftgate close button and no one else activated a liftgate control. My key fob was inside my purse on the front seat of the vehicle. The liftgate came down while I was underneath it and struck me directly on the head. The impact knocked me to the ground. I saw stars and was confused immediately afterward and sustained a scalp laceration with significant bleeding. I did not lose consciousness and did not require stitches. One person directly witnessed the incident and was also struck by the closing liftgate. Because the liftgate struck my head first, its force was reduced before it contacted the other person, who was not injured. Other people arrived immediately afterward and can confirm my condition following the impact and that the key was in my purse on the front seat. This was not the first time this has happened. It has occurred on multiple occasions while loading without intentionally activating. I have been hit in the head before but not enough to cause bleeding. The incident occurred Friday evening on 8/14/2026. Vehicle has not yet been inspected because the service department is closed for the weekend. I plan to contact Ford once open on Monday. I am reporting this because I am concerned there may be a defect involving unintended activation of the power/hands-free liftgate and/or its safety obstacle-detection system. The unexpected closure has now caused an injury and also struck a second person.

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

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....

Back in 2026 I bought a vehicle from Wild West Ford in Guymon ok about three weeks after I bought the vehicle there was a safety recall on it for the rear axle bolt. Ever since the recall was done, I noticed a significant change in my vehicle rear and it shook real bad. basically I was eating my tires and so I took about to wild West and they told me to go get alignment done so I went and got an alignment done, and it still was doing it and I had taken it to at least four different Ford dealerships across two different states and they all told me that there is nothing wrong with my vehicle, so I looked it up on the forum in the procedure on how the recall was done and i find out that the bushing was improperly installed. One of The ford dealership is the one who send me a picture of the bushing even starting to rip. Please help my kids ride in this vehicle everyday and Wild West claimed the recall but did it completely wrong and refuses to fix it so I took it to different dealerships and with each dealership, I specifically asked them to re-look into the recall because I feel like it was done wrong and they all said that it was all up to four specs in the end. there was nothing wrong with it, but here’s the proof that it is so how do I get my vehicle fixed?

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.

The contact owns a 2020 Ford Explorer. The contact stated that upon taking the vehicle for regular service, he was made aware that the driver’s side CV axle was leaking. The contact was informed that the driver’s side CV axle needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 54,000.

The contact owns a 2020 Ford Explorer. The contact received notifications of NHTSA Campaign Number: 23V675000 (Power Train), 25V093000 (Seat Belts), 26V402000 (Power Train), and 26V451000 (Seats) and would like to be removed from the recall distribution list. The local dealer and manufacturer were contacted.

The contact owns a 2020 Ford Explorer. The contact stated that while her son was positioned in the third-row seat, the head restraint unexpectedly slammed down on the tip of his left index finger. As a result, he sustained a severe injury that required immediate medical attention. The injury required 6 to 8 stitches, and the child also required surgery. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 110,000.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed on a six-hour trip, the low tire message was displayed, and the tire quickly deflated. The contact slowed down and pulled into a service center and inflated the tire. The vehicle was then driven without failure. While pulling into a parking lot, the driver's side rear wheel detached from the vehicle. The previous tire lug nut had been factored out for installation at a tire center. The towing company became aware that all five bolts had sheared off, and some of the bolts were in the parking lot. The vehicle was inspected by the local dealer, and it was determined that the rear passenger’s side wheel was missing lug nuts as well. The contact stated that three of the five lug nuts had sheared off. The failure recurred. The manufacturer was not contacted. The failure mileage was approximately 57,065.

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....

The contact owns a 2020 Ford Explorer. The contact stated while driving at various speeds the transmission unexpected downshifted from a high gear to a low gear, and the vehicle lurched forward while attempting to decelerate. The TPMS warning light was illuminated. The vehicle was taken to a local dealer, where it was diagnosed that the transmission had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 40,000.

See attached document for complaint

The dash skin covering is deboning and lifting and it’s very concerning that the airbags might be compromised from inflating in an accident.

The dash board has a little split where the air bag is located. The split is in a line of or a crease of the outline of the air bag. I took it to the dealership and they were clueless. They recommended someone to fix it, but since it was closely related to the airbag I can't find anybody to work on it. This happened about a year ago it just appeared and each year I think it's getting larger.

Our explorer has had cascading warnings each time we drive the car for the past 7 days. Sometimes it takes a mile, sometimes it is immediate. The safety warnings include: 4-wheel drive fault, passenger air bag fault, forward Collision avoidance not working, powertrain malfunction, restraint indicator light warning, pre collision assist- . Not all appear each time, and some change ( 4wheel drive fault/ power train malfuntion- restraint warning/ airbag seem to alternate. Power train shows with restraint. 4 wd malfunction shows with airbag). Each time it occurs the airbag warning illuminates. Dealer cannot work on it until July 16th. Sounds like tsb 23-2174, but have been unable to codes when I stopped by a dealer Before July 1 we had no warnings. 48,582 miles. When faults appear- most systems appear to work, have tried 4wd and other modes and they appear to work. But cruise control, seatbelt chimes and others do not work.

I recently had an increasing tire vibration problem on my 2020 ST with 18,500 miles. Took the ST to a Costco tire center to have the tire balance checked for lost weight, damaged rim or whatever. Balancer had massive weight shift so they took tire off the rim. Unknown to me, the original Pirelli P Zero tires have a foam coat inside the tire for noise comfort(????). It had deteriated and was formaing clumps and coming off the rubber.