2021 Ford Explorer
Problems, recalls and owner-reported issues
Power train is the leading concern among 429 owner complaints filed for this model year. This is the 17th highest complaint count among 26 Explorer model years with reports.
Of the 2021 reports, 14 involved a crash and 5 involved a fire. 16 people were injured.
What owners report most often
Recalls and investigations
Seats, mid/rear assemblyJul 14, 2026
Ford Motor Company (Ford) is recalling certain 2020-2027 Aviator and 2020-2026 Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, tipping, or sliding unexpectedly.
A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing the risk of injury.
Dealers will inspect and replace the bezel around the switch as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters explaining the safety risk were mailed August 19, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Lincoln Aviator owner notification letters were mailed August 21, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S52. This recall expands Recall 25V393. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.
Campaign 26V451000 on NHTSA.gov
Power train, automatic transmissionJun 24, 2026
Ford Motor Company (Ford) is recalling certain 2018-2021 Navigator, Expedition, 2020-2021 Explorer, Lincoln Aviator, and 2021 F-150 vehicles. The transmission park pawl may engage while the vehicle is in motion, resulting in park system damage.
Park system damage may result in a vehicle rollaway, increasing the risk of a crash.
Dealers will update the powertrain control module software, and inspect and replace any damaged transmission components as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed July 10, 2026. Additional letters will be sent once the remedy is available, anticipated in April 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S48. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on June 26, 2026.
Campaign 26V402000 on NHTSA.gov
Seat beltsMar 17, 2026
Ford Motor Company (Ford) is recalling certain 2020-2026 Explorer and Lincoln Aviator vehicles. The seat belt anchor bolts at the second-row outer seating positions may be improperly secured.
A loose seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.
Dealers will inspect the second-row outer seat belt lower anchor bolts and replace or repair them as necessary, free of charge. Owner notification letters were mailed March 30, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C18. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 19, 2026.
Campaign 26V159000 on NHTSA.gov
Back over prevention, softwareMar 3, 2026
Ford Motor Company (Ford) is recalling certain 2020-2022 Escape, Lincoln Corsair, 2020-2024 Lincoln Aviator, and Explorer vehicles. The image on the center display may flip or invert, resulting in an incorrectly displayed rearview image when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
An incorrectly displayed rearview image can reduce the driver’s view behind the vehicle, increasing the risk of a crash.
Dealers will update the accessory protocol interface module (APIM) software, free of charge. Owner notification letters were mailed June 23, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C11. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 5, 2026.
Campaign 26V123000 on NHTSA.gov
Visibility, windshield wiper/washer, motorMar 3, 2026
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer, Escape, Lincoln Aviator, and Lincoln Corsair vehicles. The windshield wiper motor may fail and prevent the windshield wipers from operating properly.
Windshield wipers that fail to operate properly can reduce visibility, increasing the risk of a crash.
Dealers will inspect and replace the front wiper motors as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed April 2, 2026. Additional letters will be sent once the final remedy is available, anticipated in October 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S14. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 4, 2026.
Campaign 26V117000 on NHTSA.gov
Equipment, electrical, engine block heaterOct 10, 2025
Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
An electrical short circuit can increase the risk of a fire.
Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.
Campaign 25V685000 on NHTSA.gov
Fuel system, gasoline, delivery, fuel pumpJul 7, 2025
Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
An engine stall increases the risk of a crash.
Dealers will replace the low pressure fuel pump on super duty vehicles and update the powertrain control module (PCM) software on all other affected vehicles, free of charge. Owner notification letters were mailed July 27, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S75.
Campaign 25V455000 on NHTSA.gov
Back over prevention, softwareJun 27, 2025
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.
Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
Campaign 25V442000 on NHTSA.gov
Seats, mid/rear assemblyJun 13, 2025
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator, and Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, folding, or sliding unexpectedly while driving.
A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing their risk of injury.
Dealers will inspect the second-row seat switch, and replace the bezel around the switch as necessary, free of charge. Owner notification letters were mailed August 7, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S67.
Campaign 25V393000 on NHTSA.gov
Power train, driveline, driveshaftMar 14, 2025
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles previously repaired incorrectly under recall numbers 23V-199 or 22V-255. The rear axle horizontal mounting bolt may fracture and cause the driveshaft to disconnect.
A disconnected driveshaft can result in vehicle rollaway when the vehicle is placed in park without the parking brake applied. A disconnected driveshaft can also result in a loss of drive power. Either of these scenarios can increase the risk of a crash.
Dealers will update the powertrain control module (PCM) software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S22.
Campaign 25V166000 on NHTSA.gov
Back over prevention, softwareMar 14, 2025
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles previously repaired incorrectly under recall number 23V-342. The video output may fail, preventing the rearview camera image from displaying.
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Dealers will update the Image Processing Module software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S27.
Campaign 25V159000 on NHTSA.gov
Seat beltsFeb 14, 2025
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer and Aviator vehicles. The seat belt buckle anchor bolts at one or more seating positions may be improperly secured. Additionally, vehicles may have an improperly secured seat belt retractor anchor bolt and/or seat belt anchor bolt at the second-row center seating position, if equipped.
A loose seat belt or seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.
Dealers will inspect seat belt buckle anchor bolts in all seating positions. Additionally, dealers will inspect the seat belt retractor anchor bolt and seat belt anchor bolt at the second-row center seating position, if equipped. If loose anchor bolts are found, the affected seat components will be replaced. Repairs will be performed free of charge. Owner notification letters were mailed on June 5, 2025. Owners may contact Ford customer service at 866-436-7332. Ford's number for this recall is 25S09.
Campaign 25V093000 on NHTSA.gov
Equipment, other, labelsNov 8, 2024
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Without a label that shows the proper restraint usage guidelines, the occupants may have an increased risk of injury in the event of a crash.
Ford will mail owners the warning labels, free of charge. Owner notification letters were mailed December 19, 2024. Owners may call Ford customer service at 1-866-436-7332. Ford's number for this recall is 24C39.
Campaign 24V852000 on NHTSA.gov
Engine and engine cooling, engine, hard parts internal/mechanicalAug 23, 2024
Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.
A loss of drive power increases the risk of a crash.
Dealers will perform an engine cycle test and replace the engine as necessary, free of charge. Owner notification letters were mailed July 3, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S55.
Campaign 24V635000 on NHTSA.gov
EngineAug 10, 2024
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles equipped with the Police Interceptor Utility Package. In the event of an engine failure, engine oil and fuel vapor may be released into the engine compartment and accumulate near ignition sources such as hot engine or exhaust components, possibly resulting in an engine compartment fire.
An engine compartment fire increases the risk of injury.
Owners are advised to park and shut off the engine as promptly as possible upon hearing unexpected engine noises, or after experiencing an unexpected engine power reduction, or seeing smoke from the engine compartment. Dealers will update the Powertrain Control Module (PCM) software. In addition, dealers will inspect for connecting rod bearing failure and if necessary, replace the engine long block. All inspections and repairs will be performed free of charge. Owner notification letters were mailed August 15, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S52.
Campaign 24V598000 on NHTSA.gov
Power train, driveline, driveshaftOct 6, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles. The rear axle horizontal mounting bolt may fracture and cause the driveshaft to disconnect.
A disconnected driveshaft can result in a loss of drive power or a vehicle rollaway if the parking brake is not applied. Either of these scenarios can increase the risk of a crash.
Dealers will replace the subframe bushing and rear axle bolt. They will also inspect the rear axle cover for damage near the bolt hole location and replace with a new cover if any damage is found. Repairs will be performed free of charge. Owner notification letters were mailed January 19, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S55.
Campaign 23V675000 on NHTSA.gov
Electrical system, propulsion system, traction batterySep 8, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Lincoln Aviator and Ford Explorer vehicles equipped with 3.0L PHEV engines. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.
Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
Dealers will perform a Battery Energy Control Module (BECM) diagnostic test and replace the high voltage battery pack, as necessary, free of charge. Owner notification letters were mailed on April 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford Motor Company's number for this recall is 23S53.
Campaign 23V626000 on NHTSA.gov
Back over prevention, sensing system, cameraMay 12, 2023
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Dealers will replace the 360-degree camera, free of charge. Owner notification letters were mailed November 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S23. This recall expands and replaces NHTSA recall number 23V-022. Vehicles previously repaired under 23V-022 will need to have the new remedy performed.
Campaign 23V342000 on NHTSA.gov
Back over prevention, display functionApr 28, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer Police Interceptor Utility vehicles equipped with a 12.1-inch Integrated Computer Screen (ICS). When the Display On/Off Button is used to turn the display to "Off" prior to placing the vehicle in reverse, the backup camera rearview image will not appear on the display. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
A rearview camera that does not display an image can reduce the driver's rear view, increasing the risk of a crash or injury.
Dealers will update the ICS software, free of charge. Owner notification letters were mailed July 27, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C14.
Campaign 23V305000 on NHTSA.gov
Power train, automatic transmission, control module (tcm/pcm/tecm)Mar 24, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles equipped with a 2.3L RWD, 3.3L GAS, 3.3L FHEV, or 3.0L ST powertrain. The previous powertrain control module (PCM) update completed under recall 22V-255 did not include the automatic electronic parking brake feature when the vehicle is shifted to park, as intended. In addition, the rear axle horizontal mounting bolt may fracture and cause the driveshaft to disconnect.
Without the electronic parking brake applied, the vehicle could rollaway if the driveshaft disconnects. A disconnected driveshaft can also result in a loss of drive power. Either of these scenarios can increase the risk of a crash.
Dealers will update the PCM software, free of charge. Owner notification letters were mailed on May 31, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S16.
Campaign 23V199000 on NHTSA.gov
Power train, automatic transmission, control module (tcm/pcm/tecm)Feb 10, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles equipped with a 2.3L engine and 10R60 automatic transmission. An unintentional powertrain control module (PCM) reset may occur while the vehicle is in motion and result in park system damage.
A park system that is damaged may not shift into "PARK," resulting in a vehicle rollaway and increasing the risk of injury or crash.
Dealers will inspect the park system for damage and repair as necessary, free of charge. Owner notification letters were mailed March 28, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S05.
Campaign 23V069000 on NHTSA.gov
Back over prevention, sensing system, cameraJan 23, 2023
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Dealers will update the image processing module (IPMB) software, free of charge. Interim owner notification letters informing owners of the safety risk were mailed April 25, 2023. Owner notification letters were mailed February 13, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S02. This recall expands and replaces NHTSA recall number 21V-735. Vehicles previously repaired under 21V-735 will need to have the new remedy performed.
Campaign 23V022000 on NHTSA.gov
Suspension, rearNov 10, 2021
Ford Motor Company (Ford) is recalling certain 2021 Explorer and Lincoln Aviator vehicles. Incorrect rear suspension module components may have been installed due to a labeling error.
A rear suspension module with incorrect components may affect vehicle handling, ride height, and braking characteristics, increasing the risk of a crash.
Dealers will inspect the rear suspension module, and replace any incorrect parts, as necessary, free of charge. Owner notification letters were mailed December 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S47.
Campaign 21V870000 on NHTSA.gov
Back over prevention, softwareSep 22, 2021
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer, Lincoln Corsair, and Lincoln Aviator vehicles equipped with 360-degree cameras. The video output may fail, preventing the rearview camera image from displaying.
A rearview camera that does not display an image reduces the driver's rear view, increasing the risk of a crash.
Dealers will update the Image Processing Module (IPMB) software, free of charge. Owner notification letters were mailed November 16, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S44.
Campaign 21V735000 on NHTSA.gov
Air bags, side/window, curtainAug 23, 2021
Ford Motor Company (Ford) is recalling certain 2021 Explorer and Lincoln Aviator vehicles. The side air bag attachment weld studs could detach during the deployment of the side air bag, resulting in an improper deployment. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard 214, "Side Impact Protection".
Improper deployment of a side air bag increases the risk of injury during a crash.
Dealers will replace the side air bag assemblies, free of charge. Owner notification letters were mailed September 10, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C19.
Campaign 21V652000 on NHTSA.gov
EngineDec 17, 2020
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer and Lincoln Aviator vehicles. The right hand motor mount fasteners may have been incorrectly tightened, and may loosen over time.
With a loose motor mount, motor vibration may cause the axle to disconnect from the engine and could result in loss of power, increasing the risk of a crash.
Ford will notify owners, and dealers will remove and replace the right hand motor mount fasteners, free of charge. The recall began February 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S72.
Campaign 20V788000 on NHTSA.gov
Representative owner complaints: engine
57 reports, newest first. Show all
Engine, Sep 17, 2026
I had a very serious safety failure of my 2021 Ford explorer. On Monday, XXX my 2021 Explorer suffered an unprompted, catastrophic failure matching recall 26S48, but Ford is denying coverage based on build dates. After driving roughly 35mph, pressing the brake, and nearing a stop sign, the explorer put itself into park. The engine compartment made noises and the vehicle continued to roll until the I quickly prompted activating the emergency brake before rolling into the intersection with heavy traffic. Even in park, the vehicle continued to roll (until the e-brake was activated). I had my [XXX] child in the vehicle with me, and thankfully nobody was injured. I had no dash warning lights, or any other signs of impending failure. I had it towed to my trusted (certified) mechanic who inspected the vehicle and diagnosed the following: The transmission output shaft is sheered off, right at the parking pawl. He states this would only happen if the vehicle put itself into park, while moving. This catastrophic failure could lead to a tragic accident, and could kill somebody. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Power train, Vehicle speed control, Engine, Sep 1, 2026
I am reporting ongoing safety-related powertrain and drivability concerns involving my 2021 Ford Explorer ST in Fresno, California. The vehicle has experienced recurring transmission and driveline problems, including harsh or delayed shifting, hesitation, abrupt gear engagement, jerking/surging, and inconsistent acceleration. These symptoms are similar to transmission concerns documented by Ford for 2021 Explorers equipped with the 10R60 automatic transmission, including harsh/delayed engagement or shifting and potential issues involving transmission controls, solenoid strategy, and main-control valves. The vehicle has also required CV axle/half-shaft repairs, raising additional concerns regarding driveline reliability. I am also concerned about the known rear differential/rear axle mounting-bolt defect affecting 2021 Explorers. Ford has documented that the rear axle mounting bolt may fracture, allowing the axle housing to move. This can result in severe vibration/noise and possible driveshaft or half-shaft disconnection, potentially causing loss of propulsion. The defect may also contribute to a vehicle rollaway hazard. These combined transmission, CV axle, and rear differential concerns create a significant safety risk. Delayed acceleration or engagement can prevent the vehicle from responding as expected when entering intersections, making left turns, merging onto highways, changing lanes, or avoiding hazards. Abrupt engagement after hesitation can cause unexpected vehicle movement. Failure of a CV axle, half-shaft, or rear axle/differential mounting component could cause sudden loss of propulsion or vehicle control. I am requesting that NHTSA investigate whether these recurring transmission and driveline problems represent a broader safety defect involving the 10R60 transmission, CV axles/half-shafts, rear differential mounting system, or related powertrain components.
Engine, Fuel/propulsion system, Aug 15, 2026
There was no accident, but very close a few times.when I am stopped at a stop sign or light when I press down on the gas pedal the car hesitates I have to pump the pedal to get the car moving or it would stall in traffic. No check engine light is or has been on. I’ve been to 2 different ford dealerships and after there inspection they claim nothing wrong with my car. It’s already cost me a lot if money. When driving I can feel the car surge likes it’s not getting fuel sufficiently real bad at traveling at or below 50 mph. I’m afraid it will stall and get us t- boned but the mechanics say nothing wrong I disagree there is something wrong. I know another person who had the same problem and he got rid of the car, I can’t afford to do that, please do something to get a recall or something before we’re seriously injured or worse.this started about a year ago and getting worse.
Engine, Aug 12, 2026
The intermediate shaft has gone bad on my 5 year old car. Noticed it on 12/11/25 after owning for 1 year. I’m slowing losing oil which then can cause my engine to go out. I have read many things stating other peoples frustration with this $3.59 part going bad in the 2021 ford explorers but to get it fixed you have to drop the entire engine resulting in it costing $1,800. I think ford should be responsible for this and aware to make a better part.
Power train, Vehicle speed control, Engine, Jun 7, 2026
While driving at highway speeds, the vehicle displays a "Drive Train Malfunction" warning message and the traction control warning light illuminates. Shortly after the warning appears, the vehicle loses power and may enter a reduced-power mode or stall, creating a serious safety hazard in traffic. This has occurred while traveling on the highway, forcing sudden deceleration and creating the risk of being struck by other vehicles. The check engine light is illuminated, and diagnostic code P0A1E is present. The problem is intermittent and unpredictable, making it difficult to determine when the next failure will occur. The vehicle has been taken to Ford for diagnosis multiple times, and significant money has been spent attempting to repair the issue. Despite these efforts, the root cause has not been identified and the problem continues to occur. This defect affects the drivetrain system and impacts the safe operation of the vehicle. The sudden loss of power on the highway places the driver, passengers, and surrounding motorists at risk. Based on discussions with other owners, this appears to be a common issue affecting Ford Explorer Police Interceptor Utility vehicles and warrants investigation by NHTSA.
Engine, May 11, 2026
2021 Ford Explorer used a work vehicle (house cleaning business) and family vehicle after hours (driving my daughter to soccer practice 4 times a week). Vehicle has been professionally and properly serviced since we first purchased it in 2021( we have been the only owners). Car has worked great not one single problem other then regular things like tires, brakes and battery all purchased and installed by Ford dealership. The day of the incident the car was working perfectly the entire day. As I drove on the freeway taking my daughter to soccer practice in the evening. I noticed the vehicle started to shake and lose all power the vehicle stopped almost completely in a matter of seconds causing cars behind us to almost crash us from behind it was a miracle no one crashed into us as we were traveling at freeway speed 60-65mph. With the little power the car had I cleared 2 lanes and parked on the side of the freeway. A friend of our picked up my daughter as we were both frightened by the incident. The vehicle gave me no alerts that there was something wrong no warnings on the Ford pass app nothing. I had the vehicle towed to Walnut Creek Ford for inspection. Ford did a diagnostic and found that the engine had a hole from the head to the block. They don’t know how this happened and say they have never seen this before. They said the vehicle is in great shape inside and out and even with 160,000 the car is very well maintained (serviced). This needs to be addressed to Ford as lives were in danger and people could have gotten hurt. They want 13,000 to repair engine, but it seems to everyone(ford technicians and second opinion mechanics) it was an engine factory defect. Vehicle suffered catastrophic engine failure while driving on freeway with no warning from the vehicle system, check engine light never came on nothing. It all happened in a matter of seconds. Engine light only came on after the vehicle was no longer drivable.
Engine, May 7, 2026
I own a 2021 Ford Explorer ST (3.0L EcoBoost) with 47,680 miles. The vehicle is exhibiting a severe metallic knocking noise at idle, a flashing Check Engine Light, and a dangerous loss of motive power while driving. A certified Ford dealership technician (Kendall Ford) diagnosed the vehicle with catastrophic engine failure, requiring a full engine replacement estimated at $13,000.My vehicle is exhibiting the exact mechanical failure described in Recall 24S55 (NHTSA Campaign 24V635000) regarding brittle engine intake valves. Although my vehicle shares the same build year, engine type, and failure symptoms as the recalled units, Ford states my specific VIN is not currently included in the 'repair' population.The sudden loss of engine power while operating at highway speeds creates an immediate crash hazard. I request that the NHTSA investigate whether the scope of Recall 24S55 should be expanded to include this production range.Furthermore, Ford offered a 'goodwill' assistance of approximately $3,762, which I believe is an admission of a known manufacturing defect. At the time of this failure, the vehicle was only 17 days past the 5-year warranty period and well under the 60,000-mile limit. Despite this premature failure and the safety risk, Ford refuses to cover the full replacement, leaving me with a $9,000+ bill for a defect already acknowledged in 90,000 other units.
Engine, Feb 6, 2026
The vehicle has an ongoing oil leak originating from the engine/drivetrain area. The affected components include the intermediate shaft and related seals, which are subject to Ford technical service bulletins, and potentially the plastic engine oil pan and its sealing surfaces. The vehicle is currently operable and remains available for inspection upon request. he vehicle is actively leaking engine oil at approximately one drop per day. Oil leakage presents a safety risk due to the potential for oil contacting hot engine or exhaust components, reduced lubrication if the condition worsens, and the possibility of oil dripping onto road surfaces, which could reduce traction for other motorists. The condition has not caused an accident to date, but it presents an ongoing safety concern. Yes. A Ford dealership identified and documented oil leakage during a scheduled service visit in November. In addition, the dealership acknowledged known issues with the affected components and confirmed that the vehicle continues to exhibit oil leakage. The manufacturer has declined repair outside of warranty. The vehicle has been inspected by an authorized Ford dealership on multiple occasions. Ford Motor Company executive customer care reviewed the case and documented a decision to decline repair based on warranty status. The vehicle has not been inspected by police or insurance representatives. No warning lamps or messages were present prior to the discovery of the oil leak. The condition was first identified visually during a scheduled service visit in November when oil leakage was observed. The vehicle currently exhibits ongoing oil leakage without warning lamps or messages. I am also concerned that this model has had several recalls regarding the engin and our falls just outside the range of Ford recall it was build in January of 21 and the recall starts in May of 21. I would like to have that expanded to my vwhicle as well.
Fuel system, Gasoline, Engine, Feb 3, 2026
The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The contact's husband, who was an independent mechanic, used a diagnostic machine to diagnose the vehicle and discovered a failure with the emissions system. The contact stated that the failure was like the failure listed in NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The manufacturer was not made aware of the failure. The failure mileage was approximately 80,000.
Engine, Jan 23, 2026
I was informed by the dealership that the engine issue with my 2021 Ford Explorer is the same issue for which a recall was issued. However, because my vehicle’s VIN was not included in the recall, I was required to pay for the engine replacement. I attempted to work with the dealership to have them coordinate with the manufacturer, but they declined to do so. I then contacted the manufacturer directly to file a complaint and request a review of the issue. I was advised that there was nothing they could do because my VIN is not listed under the recall. I am requesting that the manufacturer investigate this matter further and reimburse me for the repair costs if it is determined that the issue is applicable to my vehicle.
Engine, Jan 8, 2026
Police car started to run rough at low speed. Stalled in middle of road. Scanned codes and code for Catalytic converter showed up along with misfires from numerous cylinders. Brought to dealer and was told needed plugs and a wire. Vehicle was returned and the same issue occurred. Fixed again. Picked up and once again the same issue started. Turned around and brought it back to dealer. The mechanic stated he never checked the catalytic converter as he was never told it had a code for the converter being bad. Two weeks later I am informed that Cylinder 5 is bad. No compression. Two issues. Ford upped the warranty on the catalytic converters because of this common problem. The tech sheet shows that a bad cat will cause misfires, but never checked. Second issue is the recall 24s55 was for fords with a 3.o liter engine, built in Chicago, between the dates of 7/21 and 10/21. My vehicle was built in Chicago on 9/21 and has a 3.0 liter engine. I also received the post card regarding the recall and we had brought it t o the dealer. 24s55 states the valve could cause engine failure. Well now I have a bad engine. Ford says no recall even though prior Chief brought to dealer after receiving postcard for recall.
Engine, Dec 16, 2025
The contact owns a 2021 Ford Explorer. The contact stated that the VIN was included in NHTSA Campaign Number: 24V598000 (Engine). The local dealer was contacted and declined to complete the recall repair. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The contact had not experienced a failure.
Engine, Dec 2, 2025
My explorer is only 4 years old and it suddenly suffered catastrophic engine failure due to low engine oil. The engine started knokcing and clattering BEFORE any warning lights came on the dash. This could also be due to premature bearing failure which is common in the 3.0 ecboost engines.
Other or unspecified, Engine, Nov 17, 2025
My vehicle is experiencing exhaust fume issue where the exhaust fumes are entering into the cabin for Explorer and Aviator models (Any model with the 3.0L Ecoobost). Upon inspection by 3rd party mechanic, it can be determined that the problematic catalytic converters that are not the one piece cast was installed on my vehicle from the factory. Speaking to other ST and Interceptor owners, the problem seems widespread to every 2021 model that Ford installed the multipiece welded catalytic converters. Apparently the cast part fairs better and is not subject to cracks. The recall originally covered the left side catalytic converter but the flawed design also affects the right side catalytic converter where many owners are experiencing this issue. This has affected all 3.0L Ecoboost engine vehicles. [XXX] I believe the recall should have extended to cover all 2020 and 2021 model year vehicles. There are forum posts where owners outside the recall have experienced the issue in addition to owners having to repeatedly replace the catalytic converters post warrant as Ford continued to reinstall bad catalytic converters as part of the repair process. I have driven this vehicle for several thousand miles with the issue and did not realize exhaust was leaking until notices of headaches and health issues as CO is odorless, causing CO2 levels to reach 3000+ inside the cabin at stop lights and blows in through the vents if A/C is on. I believe NHTSA should investigate this issue further and require Ford to replace both catalytic converters as this issue poses a serious health hazard, especially given the location of the exhaust leak and the commonplace occurrence. I am happy to forward to forums and provide evidence of this occurring. Ford considers lifetime of the vehicle to be ~150K miles and these exhausts do not last close to that, resulting in a massive expense and danger to US consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Engine and engine cooling, Oct 17, 2025
The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 30 MPH, the check engine warning light illuminated, and there was a burning odor coming from the vehicle. The contact pulled over and parked and allowed the vehicle to cool down before driving back to the residence. The vehicle was towed to the dealer and was diagnosed with coolant intrusion into the engine and the oil main bearings, causing engine failure. The contact was informed that the engine needed to be replaced. The contact received a notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.
Engine, Sep 9, 2025
The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as needed and then lost motive power. The engine made ticking sounds, and the vehicle was running rough. No warning light was illuminated. The contact coasted the vehicle into the driveway. The vehicle was towed to the dealer, who discovered that the timing chain, spark plugs, and intake valves were fractured. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 80,000.
Power train, Electrical system, Engine, Jul 31, 2025
The transmission failed. The electrical component also failed
Electrical system, Seat belts, Engine, Jul 20, 2025
Recall Action Soon Issue Since 06-20-2025 Unrequested second-row seat movement For More Information Telematics Generated Issue
Engine, Fuel/propulsion system, Forward collision avoidance, Jul 19, 2025
Recall Action Soon Issue Since 06-20-2025 Unrequested second-row seat movement Unrequested second-row seat movement Recall incomplete Recall service not available right now. We have a remedy but parts are not available right now. We will inform you when the service is available. Or, you can contact your dealer. Contact Dealer Issue Date 2025-06-13 Campaign 25S67/25V393 Description On your vehicle, it is possible that the easy entry seat fold switch on the second-row outboard seats may bind or stick if its surrounding trim bezel was installed incorrectly. If the button is stuck in the down position, the seat may unlatch, fold and or slide unexpectedly, potentially while driving. Safety Risk A seat that unexpectedly folds or slides while driving could increase the risk of injury, particularly in a crash. Remedy Ford Motor Company is working to provide parts for this repair. When the remedy becomes available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge.
Fuel system, Gasoline, Engine, Jul 17, 2025
The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 20-30 MPH, the vehicle stalled, with the check engine warning light illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the VIN was not included. The vehicle was towed to an independent mechanic. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 55,000.
Other or unspecified, Service brakes, Engine, Jul 14, 2025
I was stoped at a red light with cars in front of me and behind me when with my foot on the break the car accelerated forward like my foot was on the gas pedal but my foot was not on pedal, the car surged forward and came close to hitting the car in front of me I pressed the break and got stopped didn’t happen again but sometimes I can feel the car wanting to keep surging forward when breaking. If there is a problem this could cause me to hit someone in the rear or even worse could hit a pedestrian in the crosswalk please check this out
Engine and engine cooling, Jun 12, 2025
The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: 21E11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.
Power train, Engine, Jun 11, 2025
While our 2021 Ford Explorer with 47,000 miles to work the vehicle warning light came on stating the vehicle was overheated and shut down. We allowed the vehicle to cool for 20 minutes as recommended by the owners manual and then restarted the vehicle which immediately overheated again. We had the vehicle towed to the local dealer who diagnosed the issue as coolant in the oil forcing a replacement of the engine and coolant systems.
Power train, Engine, May 14, 2025
The vehicle has intermittent issues with bucking, running poorly, and not shifting properly. It results in several warning lights which will clear at random. The dealer has told us it needed a new alternator. The repair was made but the problem resurfaced again today. This is not a new issue as it has occurred many times before.
Engine and engine cooling, Apr 11, 2025
The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.