2025 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.

Our first occurrence happened right after we pulled out of a parking space, then proceeded to drive; only to be alerted with numerous warnings, 1. Anti-lock brake fault. 2. Hill start assist warning. 3. Anti-lock brake system fault. 4. Electronic parking brake warning. 5. Pre-collision assist not available. It particularly was a bit scary at first, because we weren't going more than 10mph starting out, and the vehicle abruptly stopped on us, as was the steering became difficult. Luckily, there were not vehicles in front or behind us. The vehicle began to jerk forward and stop hard, if we proceeded, which we could do, limping the SUV, on back streets, only 1/2 mile from dealership. Once at dealership at Ford in Seaside, California, they ran diagnostics, and re-calibrated the faulty module(s), that may have caused this. Fast forward to XXX, while at stop sign in [XXX], we proceeded at slow speed, maybe 10mph or so, and SUV abruptly braked on us and came to complete stop, with warning on instrument display. We pulled over, shutoff vehicle for a minute or so, turned back on and were able to drive again normally. We took a chance, and a few days later, drove vehicle up to the dealership (The Ford Store, Morgan Hill, California) to diagnose. They had it for a few days, and determined the Electronic Brake Booster module needed replaced and whatever they did additionally, like re-calibrations, etc. We're crossing our fingers we don't encounter problem(s). SUV is under warrantly, still, and we did purchase an extended warranty when we purchased it, new, back in XX . We're just praying this doesn't happen if we're driving at a high speed. Never had problems with our three previous Ford Explorers. Of course, these 2025s and newer ones have extensive electronics. Needless to say, my wife is scared this issue might happen again. We can't be the only Ford Explorer or Ford vehicle that might have encountered these issues? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552

NHTSA ID

11776393

Incident

Jul 30, 2026

The contact owns a 2025 Ford Explorer. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 26V451000 (Seats); however, the failure recurred. The contact stated that after slightly brushing against the second-row seat easy access button, the row of seats unlocked and tilted forward. The dealer was contacted. The manufacturer was notified of the failure. The failure mileage was 35,816.

NHTSA ID

11776199

Incident

Oct 16, 2026

Mileage

35,816 mi

I was driving on a highway route on October 24, 2026 with my toddler and mother in the car. I stopped at a red light. While stopped my car lost complete power and could not be restarted (no buttons worked, lock/unlock, start button/ hazard lights etc). The police had to be contacted as even my hazard lights would not activate. The police officer and the tow truck driver attempted to start my car and failed, the car could also not be put in neutral to be towed. The car was then towed the closest ford dealer which kept my car for one full week. I was told the problem could not be duplicated and the car was returned to me with no repairs. Prior to this occurring there had been no warning lights on the dash board or otherwise. I find this unacceptable as this incident could have ended catastrophically and can happen again at any time.

NHTSA ID

11775568

Incident

Oct 24, 2026

While driving yesterday, I heard a loud pop sound on my roof. When I arrived home about 5 min later I checked the roof and saw no issues or visible damage. About an hour later I heard another loud sound coming from my garage. This is when I discovered that the moonroof had spontaneously shattered and cracked. There was no known impact , falling objects or anything that would explain how this happened. The fact that I heard the initial popping noise while driving and that the glass continued to fracture while the vehicle was parked raises serious concerns about a possible defect in the glass or moonroof assembly. I have since found other owner reported complaints involving spontaneous glass failures on other Ford vehicles. I'm glad that no one was in the car when the glass shattered causing serious harm.

NHTSA ID

11775089

Incident

Nov 1, 2026

I own a 2025 Ford Explorer Active, purchased new in April 2025. In approximately early October 2026, I noticed a significant and unexplained brightness difference between the rear taillights. The driver’s-side taillight is noticeably brighter than the passenger-side taillight when the exterior lights are illuminated. On October 19, 2026, I brought the vehicle to Ford Country in Henderson, Nevada, for diagnosis. My service advisor personally observed the difference in brightness. The technicians scanned the vehicle’s electronic systems and reportedly found no diagnostic trouble codes explaining the condition. According to the shop foreman, technicians also installed taillight assemblies from other Ford Explorers for comparison. The driver’s-side taillight remained brighter, suggesting that replacing the lamp assemblies did not correct the condition. The dealership discovered professionally installed aftermarket emergency lighting and two previously disconnected factory liftgate lighting connectors. These modifications were performed in 2025, and the remaining factory taillights appeared to operate normally for more than a year afterward. The shop foreman explained that the dealership would not continue electrical diagnostics because its technicians do not work on modified emergency-vehicle electrical systems. He did not establish that the aftermarket equipment caused the brightness difference. The vehicle is being returned without a confirmed diagnosis or repair. I am concerned that the unexplained difference in rear lighting brightness could affect the visibility or interpretation of the vehicle’s rear lighting by other motorists. The vehicle previously received an inspection under Ford recall 25C42 involving the Body Control Module C, which reportedly passed. I do not know whether that recall is related to the current condition. I am submitting this complaint to document a potential exterior lighting safety issue and request that NHTSA review whether similar

NHTSA ID

11772795

Incident

Oct 14, 2026

On October 19, 2026, I experienced a serious braking malfunction while driving my 2025 Ford Explorer ST at highway speed. While my foot was on the accelerator, the vehicle unexpectedly began braking repeatedly without me pressing the brake pedal. The vehicle jerked and pulsated as though the ABS was activating. When I attempted to brake, the pedal felt unusually loose and did not immediately respond to the pressure I applied. I eventually managed to slow down and pull onto the highway shoulder. This created a dangerous situation that put me and other motorists at risk. Multiple warnings appeared, including Anti-Lock Brake System Fault, Electronic Parking Brake, Pre-Collision Assist Not Available, and Powertrain Malfunction/Reduced Power. The dashboard also displayed “Park Brake Not Applied,” although I had not activated the parking brake. FordPass reported that the ABS control module was sending invalid information to other vehicle modules and that the electronic parking brake had a fault. This was the second nearly identical incident. On September 29, 2026, I experienced similar unexpected braking and difficulty controlling the brakes. The dealership diagnosed a software glitch and charged approximately $690 for a system reboot and update, which they stated was not covered under warranty. Despite that repair, the dangerous braking malfunction returned less than three weeks later. The vehicle was towed back to the Ford dealership on October 19 and is awaiting further diagnosis. I am concerned about this recurring braking malfunction and the risk of a serious collision. I request that NHTSA investigate this potential safety defect.

NHTSA ID

11772449

Incident

Oct 19, 2026

OUR FAMILY SAFETY A RISK BECAUSE THE CAR SEAT WAS BURNING, IT WAS SMOKING AND I GOT BURNED.

NHTSA ID

11772224

Incident

Sep 22, 2026

I was driving at approximately 5mph when my car suddenly slammed on breaks. The pre collision warning popped up. There was no obstical in site. Happened approximately 30 mins ago. Had immediate pain in my shoulder, neck and head.

NHTSA ID

11771498

Incident

Oct 15, 2026

Quality improvemenrs include: -Software update to improve responsiveness of the door control system after the vehicle enters a low-power state

26S21 Recall remedy Infotainment system update to prevent rearview camera image interruptions

Some 2025-2027 Aviator/Explorer/Police Interceptor Utility vehicles may exhibit a "Steering Fault Service Required" message in the instrument panel cluster (IPC) with diagnostic trouble codes (DTC) C1B00, U2016, and/or U3000:96 set in the power steering control module (PSCM) after using the Ford Diagnosis and Repair System (FDRS) scan tool to reprogram the steering column control module (SCCM) and/or the gearshift module (GSM). To correct this condition, perform the following: <br /><br /> - To clear DTCs C1B00 and U2016, disconnect the 12-volt battery for 5 minutes, then reconnect the battery. On hybrid vehicles, the auxiliary battery must also be disconnected.<br /> - To clear DTC U3000:96, download and run the "PSCM - Reset the Power Steering Control Module (PSCM)" application using the latest software version of the FDRS scan tool.<br /> - If U211B is set in the PSCM, download and run the "Trusted Real-Time Operation Network (TRON) Module Authentication" application using the latest software version of the FDRS scan tool. When prompted, select the "TRON Diagnosis and Repair" option.<br /><br />

Some 2025-2027 Aviator/Explorer/Police Interceptor Utility vehicles may exhibit one of the front power windows stuck down or inoperative with a window regulator cable that has come off of the window regulator pulleys. The torque specification is being increased for the 2 upper window regulator nuts from 97 lb-in (11 Nm) to 115 lb-in (13 Nm). Use a torque wrench to apply the updated 115 lb-in (13 Nm) torque specification when installing a new front window regulator. Workshop Manual (WSM), Section 501-11 is in the process of being updated to reflect this change.<br /><br /> Engineering is currently working on a permanent solution for this condition. If the vehicle exhibits this condition, submit a Vehicle Concern Report. To submit a report, click on the "Submit Global Concern Report (GCR)" link at the upper right of the Professional Technician System (PTS) Vehicle ID screen (vehicle identification number ÝVIN¨ required) and fill out the form. Do not use the "Report A Problem" link to submit a report for this condition.

2025-2027 Explorer/Police Interceptor Utility non-hybrid vehicles built on or after 05-Mar-2025 and 2025-2027 Aviator vehicles built on or after 24-Apr-2025 are no longer equipped with the passenger side underbody air deflector. The vehicle is not misbuilt. Do not submit a claim for this condition.

Quality improvements include: -Power Steering Control Module update to prepare for future vehicle enhancements