2023 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.

As I was driving out of my garage with the car engine forward. Suddenly, as the vehicle was in drive and moving forward, the rear lift gate opened. I did not observe this open, nor was there any warning lights or alarms. bAs my vehicle moved forward the lift gate caught the top of the inside of the open garage door. Causing the rear windshield wiper to break and for the garage door to apparently swing in such a manner as to shatter the rear window. Is my understanding that you cannot open the lift gate, if the vehicle's is in drive mode and your vehicle is moving forward. Normally, if you ever attempted this, an alarm would sound, there was no alarm, I touched nothing other than driving forward pulling out of my garage at a slow speed. I feel this maybe a software glitch that needs investigation. Although I was alone and not severly injured. A similar occurrence could have more troubling ramifications.

NHTSA ID

11774080

Incident

Oct 26, 2026

Panaramic roof shade sagging causing no visbilty issue and common problem with 2020-2026 explorers

NHTSA ID

11773714

Incident

Oct 2, 2026

I am filing this complaint because the federal recall remedy performed on my 2023 Ford Explorer failed, and the Ford dealership that performed it refused to correct the failure. About a year after I purchased my 2023 Ford Explorer (used, from an independent dealer), I received Ford's federal recall notice for the rearview camera software defect (recall 23S02, NHTSA campaign 23V-022). My vehicle had no problems at that time, but I took it to the authorized Ford dealership in [XXX], and had the recall software update installed as instructed. About seven months later, my vehicle developed the exact defect the recall was supposed to prevent: the backup camera stopped functioning and the infotainment screens went completely black, disabling multiple vehicle functions. This created a safety hazard because the vehicle no longer provided any rearview image while backing up. I returned the vehicle to the same dealership and asked them to correct the failed recall repair. Instead, the dealership claimed the problem was not recall-related, diagnosed a failed APIM module, and quoted about $1,600 for replacement plus a $300 diagnostic fee. The dealership then refused to release my vehicle until the $300 fee was paid, holding it for approximately two months. I took the vehicle to an independent repair shop, which confirmed the APIM was fine - the software had simply become corrupted - and repaired it by reinstalling the software. I paid $530.29 for that repair plus $313.79 for a replacement battery (the original died while the car sat at the dealership for two months). Ford was sent a formal demand letter on XXX, with a 10-day deadline, and never responded. NOTE: The incident date entered in this form is my best estimate only; the exact date is approximate. I am asking NHTSA to investigate this dealership's failure to honor a federal recall remedy. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771139

Incident

Jun 1, 2026

I am submitting this complaint involving suspension on 2023 Ford Explorer. Dealership has replaced the right front stunt mount two times. The problem is still not corrected.

NHTSA ID

11767501

Incident

Dec 30, 2025

I was driving on the highway at approximately 70mph in my 2023 Ford Explorer Platinum which has 30,000 miles on it. We heard a loud noise which sounded like a gun went off inside the car. My sunroof exploded outward with no warning or messages and no impact. Edges of the remaining glass were angled upward indicating that the glass burst outward. There were no signs of glass impacting the thin fabric retractable shade. We had been driving for about 3 hours when the incident occurred. I took the vehicle to a Ford dealer, they took pictures and submitted a request for it to be covered under warranty but have not confirmed. We could have been at risk if I had not maintained my composure and moved safely to the shoulder. Vehicles behind us may have been impacted by the flying glass but I did not see any other vehicles pull over. I did get an estimate for repair from a local body shop in case Ford does not agree that it is a manufacturing problem. This should be covered by Ford!!!

NHTSA ID

11765256

Incident

Sep 14, 2026

While driving, vehicle made a grinding sound, and all systems related to cruise, 4wd, decent control all illuminated on dash. Vehicle was taken to dealer, metro ford. Metro ford stated the transfer case has failed internally, and being replaced under powertrain. A week later, I received a callback, and the service writer stated after replacing and a test drive- it is still an issue, and the vehicle has an issue- which they feel is the AWD module, AWD module failed causing clutch in transfer case to lock up when it shouldn’t be resulting in limited power and grinding and depletion of safety systems on vehicle. Dealer states ford is aware of the issue but offered me a discounted repair of 270 dollars vs the 7-800 that it costs to complete the repair. Vehicle is still in shop weeks later with warning lights on.

NHTSA ID

11764616

Incident

Aug 30, 2026

Purchased new June 2023, took delivery October 2023 due to camera recall. Drive to work 5 miles a day, less than 10000 miles on it yet my driver side dash is now Ingles and rolling up. I see this is a common issue. I paid extra for the King Ranch edition. Seems this should be a dealer covered repair. I would like this looked into.

NHTSA ID

11762481

Incident

Aug 26, 2026

The exhaust pipe that connects a catalytic converter to the muffler broke and was dragging on the highway. It was during rish hour and was no safe place for me to pull over and within just a few miles, the other side of it broke off and the whole pipe between the catalytic converter and muffler fell into traffic behind me. Apparently this has been an issue with 2020-2022 model years but It needs to be extended further into atleast the 2023 model year since that is what I have.

NHTSA ID

11760401

Incident

Aug 28, 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

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.

This bulletin supersedes 26-2309. Reason For Update: update the Model section to remove Aviator 10R80, update the Parts list to add 3.3L to W520514-S440, and add L1MZ-7Z490-G valve body separator plate for Aviator. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: * Harsh 3-4, 4-5 upshifts * Harsh 5-3, 4-3 downshifts * Harsh reverse engagements These symptoms may be worse when cold. This may be due to the F clutch friction plates brinelling into the clutch and planetary container cylinder (7B177).

This article supersedes 26-2287. Reason for update: update the labor operation numbers to add MT to operations C, F, G, H, J, K, L and M, and correct the part number LIMZ-4A015-B to L1MZ-4A015-B. 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 (DTC)s 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 axial movement of the CDF clutch cylinder 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 components and flush transmission fluid cooler only as ne