2020 FORD EXPLORER Complaints

My 2020 Ford Explorer experienced a catastrophic mechanical failure directly tied to active Safety Recall 26S48 / NHTSA Campaign 26V402000. While operating the vehicle, the transmission's internal parking pawl failed/shattered, completely locking the rear wheels mechanism. The vehicle is entirely immobilized and cannot move even an inch, even when the gear selector is manually turned to Neutral or when the Manual Park Release (MPR) tether is fully engaged. [1, 2] The vehicle had to be flatbed-towed using specialized wheel dollies to prevent severe structural and drivetrain destruction because the wheels are locked solid. When attempting to have the vehicle received at an authorized Ford dealership, the dealership refused to accept the vehicle or open a formal repair ticket, claiming that because the final recall remedy parts are delayed until 2027, they "cannot take the vehicle." [1] Ford Motor Company is failing to provide a timely safety remedy or manage its dealership network to accommodate a vehicle that has already suffered a total mechanical failure due to this exact recalled defect. The vehicle is a severe rollaway and structural hazard, completely undriveable, and Ford is denying responsibility or alternative transportation assistance because the parts do not yet exist. I am requesting immediate federal intervention to compel Ford to ground this vehicle, provide a safe loaner, and initiate a manufacturer buyback.

Ford Corporate office has responded with the following: “You are not responsible for paying the actually recall remedy out of pocket. The recall remedy has not yet been released. At this time, the costs being discussed are specific transmission repairs related to damages the recall may cause. The dealership is offering to complete those repairs at your expense, and we recommend keeping all receipts for potential reimbursement once the official recall remedy becomes available. Again, I want to clarify the reason for the costs of the needed repairs, those are being done under normal diagnosis and because the vehicle is outside of NVWL, it is coming up as a customer pay repair. The advanced notice recall also does not authorize for a rental vehicle to be provided” We are requesting additional review of this case and are rejecting the proposal to complete repairs at my own expense or through partial "financial assistance”, which is not the case since we are being asked to pay $4,400 for an interim repair. I explicitly request that you do not close this case file. The physical damage to my vehicle's transmission pump, valve, and park pawl is not a "normal diagnosis" issue. The servicing dealership and corporate office have explicitly confirmed that this mechanical failure is the exact manifestation of the safety risk detailed under Ford Safety Recall 26S48 / NHTSA 26V402. Under federal regulation 49 CFR § 573.13 (i)(1)(ii), a manufacturer's recall program cannot exclude or deny coverage simply because an interim or pre-notification.

While driving my car, the transmission suffered a mechanical failure. The vehicle is shuddering when decelerating, causing sudden jolting and knocking sounds with no warning or error messages. Because of this defect, the vehicle poses an immediate hazard and cannot be safely driven. The vehicle was dropped off on Monday August 24 with the Ford dealership and the service team has made contact to confirm the transmission valve body, pump and park pawl are damaged and confirmed that this is a result of NHTSA Recall 26V402 (Ford Recall 26S48). The Ford service team have advised that they are able to complete a temporary repair to get the car working again only if I agree to pay them $4,400 despite the recall. Ford’s interim remedy involves replacing failed components with identical, un-remediated parts that possess the exact same engineering flaw, which fails to permanently resolve the safety crisis. Furthermore, I am facing severe difficulties obtaining immediate vehicle recovery, interim repairs, and alternative transportation (such as a loaner or rental vehicle) from authorized Ford dealerships while the vehicle remains grounded due to this manufacturer safety defect. Ford’s corporate office was also contacted on Tuesday to discuss after we were advised that we would need to pay to get the car drivable and the dealership refused a temporary vehicle or rental during repairs. A Ford corporate employee replied that they would make contact within 24 hours. When we did not hear back, we contacted the corporate office again on Thursday and spoke to a rep who stated they would escalate and we would hear back Friday (today). Ford has failed to make contact with any resolution. I am filing this complaint to document a premature, complete component failure under this recall, and to request that NHTSA review the manufacturer’s remedy timeline, as leaving safety-compromised vehicles un-remediated on the road or stranded presents an unreasonable risk to public safety.

I am writing to formally express serious concerns regarding the safety of a Ford vehicle that continues to carry a 5-star safety rating despite multiple known, safety-critical defects that emerged after relatively low mileage. Two major issues developed between approximately 62,000 and 72,000 miles. Both are documented by Ford Technical Service Bulletins (TSBs), yet neither has been addressed through a formal recall. My vehicle’s warranty expired at 60,000 miles, leaving me responsible for more than $3,000 in out-of-pocket repair costs. Issue 1 – Front axle seal leak (TSB 23-2174) The front axle seal began leaking fluid. According to the TSB, the original affordable seal is no longer available, requiring replacement of the entire axle assemblies at a cost of approximately $2,000. Failure to complete this repair risks axle lock-up and a potential collision. Issue 2 – All-wheel-drive module ground wire omission (TSB 23-2061) Ford failed to install a required ground wire on the AWD module. This caused multiple warning lights to illuminate, including powertrain failure and collision-assist system failure. I refused to allow my wife and children to ride in the vehicle throughout the winter because of these critical warnings. The repair, which required replacement of the AWD module, cost more than $1,000. These are not minor inconveniences. An axle that can lock up, loss of AWD capability in hazardous conditions, and the simultaneous failure of collision-assist systems present clear and foreseeable risks of serious crashes. A vehicle exhibiting these defects does not merit a 5-star safety rating, particularly when the problems are known to the manufacturer and affect used-vehicle buyers who may lack the financial means to perform the repairs. I respectfully urge the NTSB to investigate these issues, determine whether the continued 5-star rating is appropriate, and encourage Ford to issue formal recalls so that owners are not left to bear the cost and risk of repairs.

The dash skin covering is deboning and lifting and it’s very concerning that the airbags might be compromised from inflating in an accident.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that whenever the transmission shifted into sixth gear, the vehicle failed to accelerate as intended, and the vehicle was shaking erratically. No warning lights were illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed with a transmission parking system failure. The contact was informed that the failure was associated with an unrepaired recall. The vehicle was not repaired. The dealer was made aware of the failure. The contact was informed that the parts were unavailable. The contact received notification of NHTSA Campaign Number: 26V402000 (Power Train); however, the part to do the recall repair was unavailable. The manufacturer was not made aware of the failure. The failure mileage was approximately 79,000.

The passenger headlight low beam does not work.This has been identified by an Independent service center. The Check Headlight System message shows on dashboard. Bought the car in 2023 and the headlight has not worked for 2 years. When driving at night I only have one headlight that works this poses a risk to myself and others. The entire headlight assembly must be replaced.

Illuminated powertrain malfunction (wrench) indicator with DTCs C00A6 and C0631, caused by failure of the front axle disconnect actuator/intermediate shaft on an AWD 2020 Explorer at 46,821 miles. The vehicle displayed the wrench light along with "Service AdvanceTrac," "4WD Fault," "Hill Start Assist Not Available," and "Pre-Collision Assist Not Available." Multiple driver-assistance and stability systems disabled themselves simultaneously, including AdvanceTrac stability control and pre-collision braking. Loss of stability control and automatic emergency braking without warning is a safety concern, particularly at highway speed. The fault was intermittent at first. The dealer had the vehicle five days and could not duplicate it. Within a week of getting it back the condition became nearly constant. The repair is Ford TSB 25-2568, which replaces the front axle disconnect actuator/intermediate shaft with a revised, non-disconnecting design and a new halfshaft. Ford has published this bulletin repeatedly since spring 2023 — 23-2114, then 23-2174 (July 2023), then 25-2373, then 25-2568 (January 2026) — for 2020-2021 Explorer and Aviator AWD vehicles built on or before 30-Aug-2021. Ford has redesigned the part and eliminated the disconnect feature entirely, but has issued no recall or customer satisfaction program. Because this vehicle is out of factory warranty by age at 46,821 miles, the roughly $2,500 repair fell to me. I request that NHTSA review whether a known design defect that disables stability control and pre-collision braking warrants a safety recall rather than a service bulletin.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed on a six-hour trip, the low tire message was displayed, and the tire quickly deflated. The contact slowed down and pulled into a service center and inflated the tire. The vehicle was then driven without failure. While pulling into a parking lot, the driver's side rear wheel detached from the vehicle. The previous tire lug nut had been factored out for installation at a tire center. The towing company became aware that all five bolts had sheared off, and some of the bolts were in the parking lot. The vehicle was inspected by the local dealer, and it was determined that the rear passenger’s side wheel was missing lug nuts as well. The contact stated that three of the five lug nuts had sheared off. The failure recurred. The manufacturer was not contacted. The failure mileage was approximately 57,065.

While driving down a main road, the speed limit changed from 40 to 55 mph. When the gas pedal was pushed, the car violently jerked, did not speed up, and proceeded to have a grinding sound emitting from the engine. No warning lights appeared. The grinding noise continued until the vehicle was placed in neutral and back in drive. We began looking into it and found a recall for the transmission. We contacted a local dealership and were told that they would not be able to inspect or address the issue until Ford issues a remedy (projected to be 8-11 months from now). Since then, the car has experienced harsh upshifting, hesitation with acceleration, jerking, and grinding along with significant rolling when put in park and let off the brake. We contacted Ford directly with no avail. No one has had any advice to “help” with the issue until Ford decides to issue the remedy. We have essentially been told to either park it and continue to make payments on something that is of no use, or to keep driving it and go until it stops. The concern is we have two small children and can not risk engine/transmission failure while driving down the road. The safety of our children comes before anything else, and this vehicle no longer provides safety for them.