2021 Ford Explorer Engine Problems

I had a very serious safety failure of my 2021 Ford explorer. On Monday, XXX my 2021 Explorer suffered an unprompted, catastrophic failure matching recall 26S48, but Ford is denying coverage based on build dates. After driving roughly 35mph, pressing the brake, and nearing a stop sign, the explorer put itself into park. The engine compartment made noises and the vehicle continued to roll until the I quickly prompted activating the emergency brake before rolling into the intersection with heavy traffic. Even in park, the vehicle continued to roll (until the e-brake was activated). I had my [XXX] child in the vehicle with me, and thankfully nobody was injured. I had no dash warning lights, or any other signs of impending failure. I had it towed to my trusted (certified) mechanic who inspected the vehicle and diagnosed the following: The transmission output shaft is sheered off, right at the parking pawl. He states this would only happen if the vehicle put itself into park, while moving. This catastrophic failure could lead to a tragic accident, and could kill somebody. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11765091

Incident

Sep 14, 2026

I am reporting ongoing safety-related powertrain and drivability concerns involving my 2021 Ford Explorer ST in Fresno, California. The vehicle has experienced recurring transmission and driveline problems, including harsh or delayed shifting, hesitation, abrupt gear engagement, jerking/surging, and inconsistent acceleration. These symptoms are similar to transmission concerns documented by Ford for 2021 Explorers equipped with the 10R60 automatic transmission, including harsh/delayed engagement or shifting and potential issues involving transmission controls, solenoid strategy, and main-control valves. The vehicle has also required CV axle/half-shaft repairs, raising additional concerns regarding driveline reliability. I am also concerned about the known rear differential/rear axle mounting-bolt defect affecting 2021 Explorers. Ford has documented that the rear axle mounting bolt may fracture, allowing the axle housing to move. This can result in severe vibration/noise and possible driveshaft or half-shaft disconnection, potentially causing loss of propulsion. The defect may also contribute to a vehicle rollaway hazard. These combined transmission, CV axle, and rear differential concerns create a significant safety risk. Delayed acceleration or engagement can prevent the vehicle from responding as expected when entering intersections, making left turns, merging onto highways, changing lanes, or avoiding hazards. Abrupt engagement after hesitation can cause unexpected vehicle movement. Failure of a CV axle, half-shaft, or rear axle/differential mounting component could cause sudden loss of propulsion or vehicle control. I am requesting that NHTSA investigate whether these recurring transmission and driveline problems represent a broader safety defect involving the 10R60 transmission, CV axles/half-shafts, rear differential mounting system, or related powertrain components.

NHTSA ID

11761454

Incident

Jan 29, 2026

There was no accident, but very close a few times.when I am stopped at a stop sign or light when I press down on the gas pedal the car hesitates I have to pump the pedal to get the car moving or it would stall in traffic. No check engine light is or has been on. I’ve been to 2 different ford dealerships and after there inspection they claim nothing wrong with my car. It’s already cost me a lot if money. When driving I can feel the car surge likes it’s not getting fuel sufficiently real bad at traveling at or below 50 mph. I’m afraid it will stall and get us t- boned but the mechanics say nothing wrong I disagree there is something wrong. I know another person who had the same problem and he got rid of the car, I can’t afford to do that, please do something to get a recall or something before we’re seriously injured or worse.this started about a year ago and getting worse.

NHTSA ID

11757170

Incident

Jun 18, 2025

The intermediate shaft has gone bad on my 5 year old car. Noticed it on 12/11/25 after owning for 1 year. I’m slowing losing oil which then can cause my engine to go out. I have read many things stating other peoples frustration with this $3.59 part going bad in the 2021 ford explorers but to get it fixed you have to drop the entire engine resulting in it costing $1,800. I think ford should be responsible for this and aware to make a better part.

NHTSA ID

11756607

Incident

Dec 11, 2025

While driving at highway speeds, the vehicle displays a "Drive Train Malfunction" warning message and the traction control warning light illuminates. Shortly after the warning appears, the vehicle loses power and may enter a reduced-power mode or stall, creating a serious safety hazard in traffic. This has occurred while traveling on the highway, forcing sudden deceleration and creating the risk of being struck by other vehicles. The check engine light is illuminated, and diagnostic code P0A1E is present. The problem is intermittent and unpredictable, making it difficult to determine when the next failure will occur. The vehicle has been taken to Ford for diagnosis multiple times, and significant money has been spent attempting to repair the issue. Despite these efforts, the root cause has not been identified and the problem continues to occur. This defect affects the drivetrain system and impacts the safe operation of the vehicle. The sudden loss of power on the highway places the driver, passengers, and surrounding motorists at risk. Based on discussions with other owners, this appears to be a common issue affecting Ford Explorer Police Interceptor Utility vehicles and warrants investigation by NHTSA.

NHTSA ID

11742611

Incident

Mar 18, 2026

2021 Ford Explorer used a work vehicle (house cleaning business) and family vehicle after hours (driving my daughter to soccer practice 4 times a week). Vehicle has been professionally and properly serviced since we first purchased it in 2021( we have been the only owners). Car has worked great not one single problem other then regular things like tires, brakes and battery all purchased and installed by Ford dealership. The day of the incident the car was working perfectly the entire day. As I drove on the freeway taking my daughter to soccer practice in the evening. I noticed the vehicle started to shake and lose all power the vehicle stopped almost completely in a matter of seconds causing cars behind us to almost crash us from behind it was a miracle no one crashed into us as we were traveling at freeway speed 60-65mph. With the little power the car had I cleared 2 lanes and parked on the side of the freeway. A friend of our picked up my daughter as we were both frightened by the incident. The vehicle gave me no alerts that there was something wrong no warnings on the Ford pass app nothing. I had the vehicle towed to Walnut Creek Ford for inspection. Ford did a diagnostic and found that the engine had a hole from the head to the block. They don’t know how this happened and say they have never seen this before. They said the vehicle is in great shape inside and out and even with 160,000 the car is very well maintained (serviced). This needs to be addressed to Ford as lives were in danger and people could have gotten hurt. They want 13,000 to repair engine, but it seems to everyone(ford technicians and second opinion mechanics) it was an engine factory defect. Vehicle suffered catastrophic engine failure while driving on freeway with no warning from the vehicle system, check engine light never came on nothing. It all happened in a matter of seconds. Engine light only came on after the vehicle was no longer drivable.

NHTSA ID

11737187

Incident

May 4, 2026

I own a 2021 Ford Explorer ST (3.0L EcoBoost) with 47,680 miles. The vehicle is exhibiting a severe metallic knocking noise at idle, a flashing Check Engine Light, and a dangerous loss of motive power while driving. A certified Ford dealership technician (Kendall Ford) diagnosed the vehicle with catastrophic engine failure, requiring a full engine replacement estimated at $13,000.My vehicle is exhibiting the exact mechanical failure described in Recall 24S55 (NHTSA Campaign 24V635000) regarding brittle engine intake valves. Although my vehicle shares the same build year, engine type, and failure symptoms as the recalled units, Ford states my specific VIN is not currently included in the 'repair' population.The sudden loss of engine power while operating at highway speeds creates an immediate crash hazard. I request that the NHTSA investigate whether the scope of Recall 24S55 should be expanded to include this production range.Furthermore, Ford offered a 'goodwill' assistance of approximately $3,762, which I believe is an admission of a known manufacturing defect. At the time of this failure, the vehicle was only 17 days past the 5-year warranty period and well under the 60,000-mile limit. Despite this premature failure and the safety risk, Ford refuses to cover the full replacement, leaving me with a $9,000+ bill for a defect already acknowledged in 90,000 other units.

NHTSA ID

11736318

Incident

Apr 29, 2026

The vehicle has an ongoing oil leak originating from the engine/drivetrain area. The affected components include the intermediate shaft and related seals, which are subject to Ford technical service bulletins, and potentially the plastic engine oil pan and its sealing surfaces. The vehicle is currently operable and remains available for inspection upon request. he vehicle is actively leaking engine oil at approximately one drop per day. Oil leakage presents a safety risk due to the potential for oil contacting hot engine or exhaust components, reduced lubrication if the condition worsens, and the possibility of oil dripping onto road surfaces, which could reduce traction for other motorists. The condition has not caused an accident to date, but it presents an ongoing safety concern. Yes. A Ford dealership identified and documented oil leakage during a scheduled service visit in November. In addition, the dealership acknowledged known issues with the affected components and confirmed that the vehicle continues to exhibit oil leakage. The manufacturer has declined repair outside of warranty. The vehicle has been inspected by an authorized Ford dealership on multiple occasions. Ford Motor Company executive customer care reviewed the case and documented a decision to decline repair based on warranty status. The vehicle has not been inspected by police or insurance representatives. No warning lamps or messages were present prior to the discovery of the oil leak. The condition was first identified visually during a scheduled service visit in November when oil leakage was observed. The vehicle currently exhibits ongoing oil leakage without warning lamps or messages. I am also concerned that this model has had several recalls regarding the engin and our falls just outside the range of Ford recall it was build in January of 21 and the recall starts in May of 21. I would like to have that expanded to my vwhicle as well.

NHTSA ID

11716265

Incident

Oct 8, 2025

The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The contact's husband, who was an independent mechanic, used a diagnostic machine to diagnose the vehicle and discovered a failure with the emissions system. The contact stated that the failure was like the failure listed in NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The manufacturer was not made aware of the failure. The failure mileage was approximately 80,000.

NHTSA ID

11715228

Incident

Jan 20, 2026

Mileage

80,000 mi

I was informed by the dealership that the engine issue with my 2021 Ford Explorer is the same issue for which a recall was issued. However, because my vehicle’s VIN was not included in the recall, I was required to pay for the engine replacement. I attempted to work with the dealership to have them coordinate with the manufacturer, but they declined to do so. I then contacted the manufacturer directly to file a complaint and request a review of the issue. I was advised that there was nothing they could do because my VIN is not listed under the recall. I am requesting that the manufacturer investigate this matter further and reimburse me for the repair costs if it is determined that the issue is applicable to my vehicle.

NHTSA ID

11712959

Incident

Jan 8, 2026

Police car started to run rough at low speed. Stalled in middle of road. Scanned codes and code for Catalytic converter showed up along with misfires from numerous cylinders. Brought to dealer and was told needed plugs and a wire. Vehicle was returned and the same issue occurred. Fixed again. Picked up and once again the same issue started. Turned around and brought it back to dealer. The mechanic stated he never checked the catalytic converter as he was never told it had a code for the converter being bad. Two weeks later I am informed that Cylinder 5 is bad. No compression. Two issues. Ford upped the warranty on the catalytic converters because of this common problem. The tech sheet shows that a bad cat will cause misfires, but never checked. Second issue is the recall 24s55 was for fords with a 3.o liter engine, built in Chicago, between the dates of 7/21 and 10/21. My vehicle was built in Chicago on 9/21 and has a 3.0 liter engine. I also received the post card regarding the recall and we had brought it t o the dealer. 24s55 states the valve could cause engine failure. Well now I have a bad engine. Ford says no recall even though prior Chief brought to dealer after receiving postcard for recall.

NHTSA ID

11709769

Incident

Dec 1, 2025

The contact owns a 2021 Ford Explorer. The contact stated that the VIN was included in NHTSA Campaign Number: 24V598000 (Engine). The local dealer was contacted and declined to complete the recall repair. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The contact had not experienced a failure.

NHTSA ID

11705269

Incident

Dec 16, 2025

My explorer is only 4 years old and it suddenly suffered catastrophic engine failure due to low engine oil. The engine started knokcing and clattering BEFORE any warning lights came on the dash. This could also be due to premature bearing failure which is common in the 3.0 ecboost engines.

NHTSA ID

11702559

Incident

Nov 27, 2025

My vehicle is experiencing exhaust fume issue where the exhaust fumes are entering into the cabin for Explorer and Aviator models (Any model with the 3.0L Ecoobost). Upon inspection by 3rd party mechanic, it can be determined that the problematic catalytic converters that are not the one piece cast was installed on my vehicle from the factory. Speaking to other ST and Interceptor owners, the problem seems widespread to every 2021 model that Ford installed the multipiece welded catalytic converters. Apparently the cast part fairs better and is not subject to cracks. The recall originally covered the left side catalytic converter but the flawed design also affects the right side catalytic converter where many owners are experiencing this issue. This has affected all 3.0L Ecoboost engine vehicles. [XXX] I believe the recall should have extended to cover all 2020 and 2021 model year vehicles. There are forum posts where owners outside the recall have experienced the issue in addition to owners having to repeatedly replace the catalytic converters post warrant as Ford continued to reinstall bad catalytic converters as part of the repair process. I have driven this vehicle for several thousand miles with the issue and did not realize exhaust was leaking until notices of headaches and health issues as CO is odorless, causing CO2 levels to reach 3000+ inside the cabin at stop lights and blows in through the vents if A/C is on. I believe NHTSA should investigate this issue further and require Ford to replace both catalytic converters as this issue poses a serious health hazard, especially given the location of the exhaust leak and the commonplace occurrence. I am happy to forward to forums and provide evidence of this occurring. Ford considers lifetime of the vehicle to be ~150K miles and these exhausts do not last close to that, resulting in a massive expense and danger to US consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11699971

Incident

Sep 26, 2025

The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 30 MPH, the check engine warning light illuminated, and there was a burning odor coming from the vehicle. The contact pulled over and parked and allowed the vehicle to cool down before driving back to the residence. The vehicle was towed to the dealer and was diagnosed with coolant intrusion into the engine and the oil main bearings, causing engine failure. The contact was informed that the engine needed to be replaced. The contact received a notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA ID

11694068

Incident

Sep 15, 2025

The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as needed and then lost motive power. The engine made ticking sounds, and the vehicle was running rough. No warning light was illuminated. The contact coasted the vehicle into the driveway. The vehicle was towed to the dealer, who discovered that the timing chain, spark plugs, and intake valves were fractured. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 80,000.

NHTSA ID

11686064

Incident

Aug 28, 2025

Mileage

80,000 mi

The transmission failed. The electrical component also failed

NHTSA ID

11677668

Incident

Jul 1, 2025

Recall Action Soon Issue Since 06-20-2025 Unrequested second-row seat movement For More Information Telematics Generated Issue

NHTSA ID

11674872

Incident

Jun 20, 2025

Recall Action Soon Issue Since 06-20-2025 Unrequested second-row seat movement Unrequested second-row seat movement Recall incomplete Recall service not available right now. We have a remedy but parts are not available right now. We will inform you when the service is available. Or, you can contact your dealer. Contact Dealer Issue Date 2025-06-13 Campaign 25S67/25V393 Description On your vehicle, it is possible that the easy entry seat fold switch on the second-row outboard seats may bind or stick if its surrounding trim bezel was installed incorrectly. If the button is stuck in the down position, the seat may unlatch, fold and or slide unexpectedly, potentially while driving. Safety Risk A seat that unexpectedly folds or slides while driving could increase the risk of injury, particularly in a crash. Remedy Ford Motor Company is working to provide parts for this repair. When the remedy becomes available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge.

NHTSA ID

11674796

Incident

Jun 20, 2025

The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 20-30 MPH, the vehicle stalled, with the check engine warning light illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the VIN was not included. The vehicle was towed to an independent mechanic. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 55,000.

NHTSA ID

11674188

Incident

Jul 11, 2025

Mileage

55,000 mi

I was stoped at a red light with cars in front of me and behind me when with my foot on the break the car accelerated forward like my foot was on the gas pedal but my foot was not on pedal, the car surged forward and came close to hitting the car in front of me I pressed the break and got stopped didn’t happen again but sometimes I can feel the car wanting to keep surging forward when breaking. If there is a problem this could cause me to hit someone in the rear or even worse could hit a pedestrian in the crosswalk please check this out

NHTSA ID

11673262

Incident

Jun 16, 2025

The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: 21E11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.

NHTSA ID

11666641

Incident

May 12, 2025

Mileage

89,000 mi

While our 2021 Ford Explorer with 47,000 miles to work the vehicle warning light came on stating the vehicle was overheated and shut down. We allowed the vehicle to cool for 20 minutes as recommended by the owners manual and then restarted the vehicle which immediately overheated again. We had the vehicle towed to the local dealer who diagnosed the issue as coolant in the oil forcing a replacement of the engine and coolant systems.

NHTSA ID

11666217

Incident

May 21, 2025

The vehicle has intermittent issues with bucking, running poorly, and not shifting properly. It results in several warning lights which will clear at random. The dealer has told us it needed a new alternator. The repair was made but the problem resurfaced again today. This is not a new issue as it has occurred many times before.

NHTSA ID

11660826

Incident

Apr 14, 2025

The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11654149

Incident

Aug 23, 2024