2021 FORD EXPLORER Complaints

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)

The contact owns a 2021 Ford Explorer. The contact stated that while driving at approximately 25 MPH, the liner of the panoramic sunroof was opened and was sagging, which obstructed the view of the rearview mirror. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 38,800.

We received notification from Ford that there is a "rear axle bolt fracture" possible on our 2021 Ford Explorer and noted we were to contact our dealer to address. However when I reached out to the dealership (and then subsequently to Ford Customer Service) I was told that the issue was being treated on an "extended warranty" basis. We would recognize the issue when we noticed severe vibration and lost of mobility in the vehicle and that putting it in Park would not keep the vehicle from rolling. Based on those calls, my wife could be left on the side of the road, involved in a fatal accident (to her or others) etc., instead of addressing the issue as a preventive measure. In addition, nothing in our coversations or in their notice involved the cost to us for additional damage to the vehicle, towing or a rental car (as the dealership said they wouldn't even be able to order the bolts until the fracture occurred and they had the vehicle in their shop. The service code for this defect is 24N01. As of this date we have not experianced this issue but am trying to avoid it occurring since it is a known defect by Ford.

Roof window cover/headliner has come loose and is impeding full vision to the rear of the car while the headliner is retracted.

The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was not yet available. The contact stated that after purchasing the vehicle, while driving at an undisclosed speed, the vehicle failed to accelerate as intended while depressing the accelerator pedal. No warning light was illuminated. The local dealer was not contacted. 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 failure mileage was approximately 60,000.

The shade that covers the moonroof has fallen off the tracks (or something) and it's sagging down from the headliner. There wasn't a snapping or breaking sound, I just went to open it and it sagged instead of sliding back under the headliner like it should. The car is only 4 years old, we bought it new, and we hardly ever use this feature, so it hasn't received a lot of use. With the shade sagging down (it won't go back into place) it blocks the view of the rear window, which makes it a safety hazard. Apparently it's not covered by my warranty, and will be around $1,800 to fix. My car is at the dealership right now and they just told me it's not covered. This is very dangerous because it also blocks the view of my children in the back seat, and most of the rear window. I just googled how to fix it, and it seems like this is a known issue that many others are having. There was no warning lights or messages about this failure. It first happened on October 11, 2025. Note: It's still at the dealership, and I need to pick it up after work, so I don't have a photo to include. I apologize.

When operating the sunshade a plastic clip sprung from the assembly mechanism that retracts the shade towards my face. Now the shade is obstructing my vision of the road and I am concerned that I am going to run over someone and/or something.

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.

I bought the car brand new in 2021. It handled great, no issues, not even on extremely icy roads. The temporary fix for Recall 22S27 was done in July 2023 which was just a computer flash to set the park brake each time the car was put into park. Each time I put it in gear the car would make a loud noise as the park brake released. I immediately felt a difference when driving, it felt like the front end was "floating" and the car wasn't holding to the road. On dry roads it would be unstable if the road wasn't perfectly smooth. Driving in the winter on icy roads was scary, no control, it would fish back and forth. They performed the actual fix recall 23S55 in May 2024. They did not remove the temporary fix that sets the park brake. In January 2025 I was in a flat parking lot, icy and raining, I had NO control. There were 5 mornings with those road conditions that I couldn't make it 1/8 of a mile. Absolutely no control, it pushed me all over the road and when I braked, it continued to push me all over the road. It never showed warning lights on my dash. My local dealership pulled codes, told me it was a park brake module code but they couldn't do anything until they could duplicate it. I have spent the last 9 months arguing with the dealership and winter is almost here with no help, they treat me like I'm crazy and told me that I'm the only person in the world with this problem. I just traded it off yesterday, lost a bunch of money, but I couldn't go through another winter with it. It's way too dangerous!

LED LIGHT ISSUE. PASSENGER SIDE LOW BEAM. LIFETIME OF LED SHOULD BE 45,000 HOURS OR 12-15 YEARS. IT IS NOT WORKING. FORD NEEDS TO GENERATE A REPAIR ALSO CURRENT WARRANTEE WORK NEEDS TO BE COMPLETED INCLUDING THE REAR CAMERA.