2022 Ford Explorer

The Office of Defects Investigation (ODI) has received 8 Vehicle Owner Questionnaires (VOQs) and 4 Early Warning Reporting “Death and Injury” reports alleging burn injuries following side airbag deployment in model years 2021-2026 Ford Explorer vehicles. Consumers have described that during a crash involving deployment of the seat-mounted side airbag, they sustained burn injuries. Burn injuries have been reported for both drivers and front passengers and were typically diagnosed as second or third-degree burns requiring medical treatment. Some of the VOQs report injuries to law enforcement officers following side airbag deployments in Ford Explorer Police Interceptors. ODI has opened this PE to evaluate the scope, frequency, and potential safety-related consequences of the alleged defect. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family.  If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On July 17, 2023, the Office of Defect Investigation (ODI) opened this Recall Query (RQ) after receiving 2 consumer complaints alleging loss of vehicle forward power and/or loss of transmission torque of the rear wheels in model year (MY) 2020-2022 Ford Explorer vehicles (subject vehicles). The RQ was opened to focus on the effectiveness of the remedies of Recalls 22V-255 and 23V-199 related to the alleged problem. Recall 22V-255 involved replacing the bushing and axle cover in the following subject vehicles: 3.3L FHEV Police built before October 14, 2020, and 3.3L Gas Police vehicle built before January 31, 2021. For 2.3L RWD, 3.0L PHEV, 3.3LFHEV, and 3.0LST retail (non-police) vehicles, the recall provided an PCM software update to engage the Electronic Park Brake (EPB) when Park is commanded. The recall addressed a breakage of the rear axle bolt that can cause the driveshaft/half shafts to disconnect, resulting in a loss of transmission torque to the rear wheels necessary to hold park. If the parking brake is not applied, the loss of the primary park torque will allow the vehicle to roll in park increasing the risk of crash and injury. Recall 23V-199 addressed 674 of the subject vehicles produced from February 2, 2019 to April 4, 2022, which received an incorrect remedy under Recall 22V-255. The affected vehicles had received a previous Powertrain Control Module (PCM) update which did not include an automatic EPB engagement when vehicle is shifted to park. On October 17, 2023, Ford filed a new safety recall (Recall 23V-675) covering 238,364 MY 2020-2022 Explorer vehicles with the following powertrains: 3.3L FHEV Police, 3.3L Gas Police, 3.0L Gas Police, 2.3L RWD, 3.0L PHEV, 3.3L FHEV, 3.0L RWD and 3.0L AWD, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. Ford stated that the cause of the bolt fracture is due to joint design not robust to peak axle input torques and manufacturing variability. The primary contributor is insufficient bearings for maximum joint loads. This can result in bearing deformation, increasing bending stress on the bolt, which may lead to fatigue failure. On January 19, 2023, Ford amended Recall 23V-675 to add 1,942 MY 2020-2022 Explorer vehicles with the following powertrain: 3.0L RWD Platinum and King Ranch variant, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. In addition to the safety recall, Ford will conduct a customer satisfaction program for the following MY 2020-2022 Explorer vehicles with the following powertrains: 2.3L AWD, 3.3L Gas Retail, 3.0L Gas AWD Platinum and King Ranch, produced from October 22, 2018 to July 6, 2022. Ford stated that the Explorer powerpack variants not covered under Recalled 23V-675 do not present an unreasonable risk to motor vehicle safety due to the combination of lower peak torque levels and torque management strategies to share inputs between front and rear axles, reducing occurrence of higher torque.  According to Ford, this is also evidenced by the lower current and projected failure rates. In view of the recall action being taken by Ford, ODI is closing this RQ. NHTSA will continue to monitor complaints from the customer satisfaction program vehicles and reopen this issue, if necessary. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On XXX, this 2022 Ford Explorer ST was involved in a low-velocity impact collision (under 20 km/h) into a concrete pillar inside a shopping mall parking structure in [XXX]. The point of impact was isolated to the front passenger quarter panel of the vehicle. Despite the very low speed and localized nature of the collision, a catastrophic deployment occurred where all vehicle airbags unexpectedly deployed simultaneously. My wife was the sole occupant and driver of the vehicle at the time, with no passengers present. As a direct result of the airbag deployment, she sustained significant thermal and friction burns to both of her arms. The incident has been officially registered with the local authorities under Dubai Police Report Reference XXX. Due to the extreme extent of the internal vehicle damage and components deployed from this low-speed impact, the vehicle repair estimate stands at 97,000 AED, and our motor insurers are currently processing the vehicle as an economic total loss (write-off). We are logging this report to highlight an overly sensitive and dangerous deployment parameter that resulted in severe secondary driver injuries during a minor incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11776687

Incident

Nov 3, 2026

Driver side crack at the exit point of the catalytic converter exposes car cabin to emissions exhaust. All 2020-2022 Ford Explorer models. Dealer confirmed that replacement is covered under the 8yr/80K warranty. Ford recognized this problem and manufactured a new and improved/updated the catalytic connection along with new flex pipe configuration. Installing a new catalytic requires new flex pipes aren't covered under warranty and Ford is charging customers $1700 to replace both flex pipes. Ford should cover both under warranty as a result of a known issue and subsequent design change. Dealer message: "The catalytic converter is cracked, and we can warranty out both catalytic converters. Unfortunately, Ford has updated the catalytic and the flex pipe configuration and the only coverage Ford is responsible for would be for the catalytic converters. Customers would also need to replace the flex pipe in order to install the new catalytic converters, which is unfortunately not something that would be covered under any warranty."

NHTSA ID

11776254

Incident

Nov 1, 2026

I am reporting a potential safety defect involving the panoramic moonroof/sunroof sunshade assembly on my 2022 Ford Explorer King Ranch, which I purchased used. The sunshade track or support mechanism appears to be failing, causing the sunshade material to sag significantly from its intended position. When the panoramic moonroof sunshade is operated, the material hangs downward into the passenger compartment and obstructs my view through the interior rearview mirror and rear window. Even when I attempt to operate only the front sunroof portion, the material continues to sag, creating a visual obstruction. The sunshade no longer functions or remains positioned as intended. My primary concern is that this is not simply a cosmetic issue. The sagging material interferes with my ability to clearly see vehicles and traffic approaching from behind. This creates a potential safety hazard when changing lanes, merging, reversing, or monitoring surrounding traffic. I am concerned that the sunshade assembly may have a defective track, mounting mechanism, or tensioning system that allows the material to detach or sag during normal use. The failure of an original factory-installed component should not compromise a driver’s visibility. I am requesting that NHTSA investigate whether similar failures are occurring in other Ford Explorer vehicles and determine whether this issue represents a widespread manufacturing or design defect requiring a safety recall. This issue directly affects driver visibility and should be evaluated as a potential vehicle safety defect rather than a cosmetic concern.

NHTSA ID

11775809

Incident

Aug 26, 2026

The contact owns a 2022 Ford Explorer. The contact stated that the front dashboard leather covering had deteriorated and shrunk, and the material covering the passenger’s side air bag had hardened and shrunk. The contact was concerned that during a crash, the air bag would not properly deploy because of a dashboard failure. The vehicle was taken to the local dealer, who informed the contact that the dashboard needed to be replaced. The manufacturer was notified of the failure. The failure mileage was 96,910.

NHTSA ID

11775359

Incident

Jul 3, 2026

Mileage

96,910 mi

Component Involved: Fuel Tube Support Bracket / Vapor Canister Purge Solenoid Bracket Assembly Part Number: GL3Z-9B325-B Diagnostic Code: P0496 / P1450 Description of Safety Hazard and Defect: I am writing to report a hazardous component defect on my vehicle that presents an immediate safety risk during standard operation. My vehicle triggered an active Check Engine Light with diagnostic trouble code P0496 (EVAP System High Purge Flow). An authorized Ford dealership technician confirmed that the internal mechanism within the purge solenoid bracket assembly (Part GL3Z-9B325-B) failed mechanically by seizing completely in the "stuck-open" position. The failure of this component introduces an uncontrolled, un-metered vacuum leak that continuously pulls raw, highly concentrated fuel vapors out of the charcoal canister directly into the engine's intake manifold. This creates an uncorrectable air-to-fuel ratio imbalance that manifests in severe, dangerous drivability hazards: 1. Engine Stalling in Traffic: The sudden influx of raw vapors disrupts combustion efficiency while idling or driving at low speeds, causing the vehicle to unexpectedly sputter, drop RPM, and stall out in active traffic conditions, creating an immediate crash risk. 2. Severe Hard-Starting/Refusal to Start: Immediately after refueling at a standard gas pump, the action of filling the tank forces massive amounts of vapor through the stuck-open valve. This completely floods the engine cylinders, causing the vehicle to aggressively crank without starting or stumble violently upon catching. This component is failing prematurely well before its intended design life across the EcoBoost engine lineup. Because a sudden engine stall in active intersections or on major highway corridors directly strips the driver of power steering and braking assistance, this systemic mechanical defect constitutes a clear vehicle safety hazard. I request that the NHTSA log this failure data to advance a mandatory safety recall.

NHTSA ID

11775155

Incident

Oct 31, 2026

I was in a middle school parking lot attempting to park my vehicle. My foot was not on the accelerator, and my foot was light depressed on the brake pedal as I was attempting to park the car prior to school release. The vehicle suddenly accelerated at a high rate, with no indicators on the dashboard that there was a mechanical/electrical issue. I had to swerve to avoid colliding with a parked vehicle and abruptly applied the brake pedal, which depressed into the floor board. This incident would have injured a child or parent at school release had I not arrived prior to end of day release. To summarize: Date/time: October 21, 2026 - 2:55 p.m. Vehicle: 2022 Ford Explorer Platinum Auto Hold: OFF Vehicle was in Drive and moving forward at parking/crawl speed. Accelerator pedal was not depressed and my foot was not near the accelerator. Vehicle suddenly accelerated forward with substantial force, consistent with heavy/full accelerator input. No warning lights or messages appeared before, during or immediately after the event. I had to abruptly steer away to avoid colliding with another vehicle.

NHTSA ID

11772809

Incident

Oct 21, 2026

Right control arm snapped while reversing into a parking spot

NHTSA ID

11772568

Incident

Oct 20, 2026

My mom was helping me strap my 3 year old and baby in the car seats of my 2022 ford explorer and said my car smelled like raw gas. I didn’t realize it because I was so used to it. As soon as she said something I did smell it. I had been getting headaches while driving but didn’t think much about it. I took it to the ford dealership and it needed a new purge valve and was causing the fuel in the cab. It could’ve ended up way worse if my mom hadn’t smelled the fuel and was there to help me strap the kids in.

NHTSA ID

11770518

Incident

Oct 3, 2026

Special Field Action 26L03 Certain 2013-2024 Model Year California Emissions-Certified Vehicles Transmission Fluid Auxiliary Pump Reimbursement

This bulletin supersedes 26-2309. Reason for update: update the Model section to remove Aviator 10R80, update theParts list to add 3.3L to W520514-S440, and add L1MZ-7Z490-G valve body separator plate for Aviator

This bulletin supersedes 26-2226. Reason for update: update the Service procedure for 2021-2022 F-150 3.5L EcoBoost vehicles with new Ford Diagnosis and Repair System(FDRS) C clutch data anomaly detection test.

This bulletin supersedes 26-2226. Reason For Update: update the Service Procedure for 2021-2022 F-150 3.5L EcoBoost vehicles with the new Ford Diagnosis and Repair System (FDRS) C clutch data anomaly detection diagnostic test. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: * Harsh engagement * Delayed engagement * Harsh shift * Delayed shift * Illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0751, P0752, P0756, P0757, P0761, P0762, P0766, P0767, P0771, P0772, P2700, P2701, P2702, P2703, P2704, P2705, P2707, P2708, P0729, P0731, P0732, P0733, P0734, P0735, P0736, P076F, P07D9, P07F6 and/or P07F7 stored in the powertrain control module (PCM) or transmission control module (TCM). This may be due to PCM software and/or axial movement of the CDF clutch cylinder (7H351) sleeve causing hydraulic circuit leaks. NOTE: If internal transmission service is required to address a concern detected with the CDF clutch cylinder following this article, technicians should carefully inspect and replace other transmission c

Some 2020-2026 Aviator/Explorer/F-150/Bronco/Ranger vehicles equipped with a 2.7L or 3.0L (non-diesel) engine may need the front engine cover removed and reinstalled for various reasons. The Workshop Manual (WSM), Section 303-01 Engine > Removal and Installation > Engine Front Cover service procedure has been updated to include a new essential special service tool (ESST) guide pin alignment tool (303-1790) that is used to align the engine front cover to the engine block, preventing the O-ring seal on the engine oil galley feed tube from getting damaged during installation.

Some 2020-2024 Explorer/Aviator vehicles equipped with 3.0L EcoBoost/hybrid engine may exhibit blue or black exhaust smoke on startup for the first 5 minutes after an overnight cold soak with no illuminated malfunction indicator lamp (MIL) or powertrain diagnostic trouble codes (DTCs) present. This may be due to engine oil breaching the dynamic oil seals separating the bearing core from the turbine housing in the left side turbocharger assembly. There is a new, updated left side turbocharger oil supply tube equipped with an internal check valve to prevent the engine oil from entering turbine housing after the engine is off. Replace the existing left side turbocharger oil supply tube with the updated service part that includes the check valve (service part# L1MZ-9T516-B) or latest level part. Refer to the Workshop Manual (WSM), Section 303-04 Fuel Charging and Controls - Turbocharger > Removal and Installation > Turbocharger Oil Supply Tube LH. For claiming, use causal part 9T516 and labor operation code 9440AL.