Ford Explorer Recalls

The Ford Explorer has 196 recalls spanning the 1991 through 2026 model years; the most serious recent issue affects 2024–2026 models, where loose trailer hitch assembly bolts can cause loss of vehicle control or trailer detachment while towing.

The 2025 and 2026 model years carry a dense cluster of mechanical and safety concerns. On 2025–2026 vehicles, engine failures tied to connecting rod defects, piston circlip failures, and a separate EGR valve failure can each cause a sudden loss of drive power. The 2025 transmission valve body can cause reverse gear to fail or the vehicle to lurch forward in neutral or reverse, and a powertrain control module reset while driving can damage the park system and allow the vehicle to roll away. Loose front brake caliper bolts on 2025 vehicles can cause brake loss and wheel damage. A loose transmission cross member and a loose front subframe bolt on 2025 vehicles can reduce crash protection. Fuel injectors on 2025 models may leak due to missing O-ring support discs, raising fire risk. On 2025–2026 vehicles, the rearview camera can fail to display while reversing, the Dynamic Bending Light system can aim the passenger headlight in the wrong direction through curves, and windshield glass may contain air bubbles that obscure forward vision. The 2026 model also has a windshield that may not be properly bonded and can separate in a crash, and an HVAC blower motor ground issue that can disable windshield defrosting.

The 2020–2024 generation has the highest concentration of recalls across the full production run. The most repeated structural issue involves the rear axle horizontal mounting bolt, which can fracture and disconnect the driveshaft on 2020–2022 vehicles; prior repair attempts on some of these vehicles were not fully effective, resulting in multiple follow-on campaigns. On 2020–2022 models, a powertrain control module reset can damage the park mechanism and allow the vehicle to roll away, and several follow-on recalls addressed cases where earlier software fixes did not fully resolve this. The 2020–2022 plug-in hybrid (PHEV) high-voltage battery can short internally, causing fire risk or loss of drive power. On 2020–2022 Police Interceptor Utility models, engine failure can release oil vapor near hot exhaust, creating fire risk. The 2020 model year alone carries a large number of individual issues: a driveshaft that can fracture along its weld seam on 3.0L or 3.3L AWD models; loose rear lower control arm bolts that can break and cause loss of steering control; a fuel tank inlet check valve that may not be fully welded on 2.3L models; a wiring harness that can chafe against the air conditioning compressor pulley and short against the battery cable; a fuel line that can rub against another line and leak; and loose motor mount fasteners that can allow the axle to disconnect. Seat belt anchor bolts at multiple positions may be loose on 2020–2021 vehicles, and the second-row seat switch on 2020–2025 vehicles can cause seats to unlatch or fold unexpectedly while driving. The 2024 model year has a hybrid 12-volt battery cable that can chafe against the starter generator and short circuit. Rearview camera failures affecting display, image orientation, or video output appear across 2020–2024 production in multiple separate campaigns.

The fifth-generation 2011–2