Summary
The Ford Explorer has 161 recalls spanning the 1991 through 2026 model years, with the most serious recent issue being a transmission valve body defect on 2025 models where the vehicle can lurch forward or roll when reverse or neutral is selected, creating an immediate crash risk.
The 2025 model year carries several other significant issues. Connecting rod and bearing defects can lead to engine failure and a stall while driving. The powertrain control module can reset in motion, damaging the park system and allowing the vehicle to roll away when parked without the parking brake. Loose front brake caliper bolts can result in a loss of front braking. An EGR valve failure can cut drive power without warning. Loose transmission cross member bolts can also cause sudden loss of drive power. On 2025 models equipped with the dynamic bending headlight system, the passenger-side headlamp can sweep in the wrong direction through curves, creating glare for oncoming drivers — a problem that carries into 2026 as well. The 2024 model year has a 12-volt battery cable that can chafe against the starter generator and short circuit, raising fire risk, and 2024 through 2026 vehicles have trailer hitch assembly bolts that may be loose enough to cause the trailer to detach while towing. The 2026 model year also has a windshield bonding defect that can allow the glass to separate in a crash, and a cylinder head defect shared with some 2025 models where failed ball plugs cause an oil leak near hot exhaust components, raising fire risk.
The 2020 through 2023 generation has a dense recall history. A rear axle horizontal mounting bolt on 2020 through 2022 models can fracture and disconnect the driveshaft, causing loss of drive power or rollaway — prior repair attempts did not fully resolve this issue across several successive campaigns. Also on 2020 through 2022 vehicles, a powertrain control module reset while driving can damage the park system and result in rollaway. On 2020 through 2022 Police Interceptor Utility models specifically, an engine failure can release oil and fuel vapor near hot exhaust components and start an engine fire. The 2020 model year alone saw fuel line chafing that can leak fuel near ignition sources, a fuel tank inlet check valve with an incomplete weld that can fail and leak substantially in a crash, loose motor mount fasteners that can disconnect the axle from the transmission, and wiring harness contact with the air conditioning compressor pulley that can short the battery wire and cause a fire. Second-row seat easy-entry switches on 2020 through 2025 models can bind and cause the seat to unlatch or slide unexpectedly while driving. Side airbag attachment problems affect 2020 and 2021 models, where the bags may not deploy properly in a crash. The 2022 and 2023 model years have separate fuel system concerns: a loose fuel line connection on 2022 vehicles can leak fuel, a detached fuel filler tube on 2022 models creates a fire risk in a crash, and a turbocharger oil supply line on 2023 models with the 2.3L engine can leak oil onto hot engine components. A loose or missing strut-to-knuckle fastener on 2023 models can pull the front suspension out of alignment and affect steering. Rearview camera failures appear across 2020 through 2024 vehicles in multiple forms — blank images, distorted images, and software-related display failures — with some prior
