Ford Explorer

Issue: On certain vehicles, the software update that was installed by a Ford dealer during recall 22S27 (Transport Canada recall number 2022-198) prior to July 2022 may not be effective. As a result, a second repair is required. On certain vehicles, a mounting bolt for the rear axle housing could break. If this happens, the axle housing can move and cause clunking or banging noises and vibrations from the rear of the vehicle. It could also cause the driveshaft and axle shafts to disconnect. This would result in a loss of power to the rear wheels and the vehicle could move when the transmission is in Park, if the parking brake is not used. Note: This recall only affects certain vehicles equipped with a 3.0 L or 3.3 L engine. Safety Risk: A parked vehicle that rolls away could create the risk of an injury or a crash. A loss of power to the wheels could increase the risk of a crash. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a dealership to update the engine control module (PCM) software to set the parking brake when the transmission is in the Park position.

Issue: On certain vehicles, the powertrain control module (PCM) could reset while driving and cause damage to the transmission park system. If this happens, you may not be able to shift the transmission into Park. If you try to exit the vehicle while the transmission is not in Park, and the parking brake is not applied, the vehicle could move unintentionally. Note: This recall only affects vehicles equipped with a 2.3 L engine. Safety Risk: Unexpected movement of the vehicle could increase the risk of a crash. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a dealership to inspect the transmission park system for damage, and repair it as necessary.

Issue: On certain vehicles equipped with a 2.3 L engine, the fuel line connections between the fuel pump and fuel rail may not have been tightened properly. As a result, fuel could leak. Safety Risk: A fuel leak can create the risk of a fire. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a dealership to inspect and, if necessary, replace the fuel line assembly.

Issue: On certain vehicles, a mounting bolt for the rear axle housing could break. If this happens, the axle housing can move and cause clunking or banging noises and vibrations from the rear of the vehicle. It could also cause the driveshaft and axle shafts to disconnect. This would result in a loss of power to the rear wheels and the vehicle could move when the transmission is in Park, if the parking brake is not used. Safety Risk: A parked vehicle that rolls away could create the risk of an injury or a crash. A loss of power to the wheels could increase the risk of a crash. Corrective Actions: Ford will notify owners by mail. For Police Interceptor Utility models, you will be instructed to take your vehicle to a dealership to replace a bushing and the rear axle housing cover. For all other models, you will be instructed to take your vehicle to a dealership to update the engine control module (PCM) software to set the parking brake when the transmission is in the Park position.

Issue: On certain vehicles, the roof rail covers could detach. If this happens while driving, the roof rail cover could separate from the vehicle. Note: This recall only affects vehicles with painted roof rail covers. Safety Risk: A roof rail cover that detaches while driving could create a hazard for other drivers and nearby people, and could increase the risk of a crash. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a dealer to secure the roof rail covers.

Issue: On certain vehicles, the outer ball joint for the rear suspension toe link may seize. If this happens, the toe link could break while driving. This could cause a sudden loss of vehicle stability. Note: This recall only affects vehicles that were originally sold or currently registered in areas of heavy road salt usage (Ontario, Quebec, New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland & Labrador), and that were repaired under any of the following recall campaigns: - 2016-182 (Ford Recall 16S18) - 2017-224 or 2017-577 (Ford Recall 17S11) - 2019-280 (Ford Recall 19S17) Safety Risk: A loss of vehicle stability could cause a loss of control and increase the risk of a crash. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a dealer to inspect the ball joints for the rear suspension toe links. If a ball joint requires replacement, the dealer will replace the rear suspension knuckle.

Issue: On certain vehicles, the protective cover on the engine fuel line may not be long enough. As a result, the fuel line could rub against another fuel line. This could cause damage and result in a fuel leak. Safety Risk: A fuel leak in the engine compartment could result in a fire. Corrective Actions: Ford will notify owners by mail and instruct you to take your vehicle to a Ford or Lincoln dealer to inspect the protective cover on the fuel line. If the fuel line is not fully covered, the dealer will install and secure a new, longer cover.

Issue: On certain vehicles, seats with a manual recliner may not meet the strength requirements of Canadian regulations. A seatback with reduced strength may not properly restrain an occupant in a crash. Safety Risk: A seatback that moves in a crash could increase the risk of injury. Corrective Actions: Ford will notify owners by mail and instruct them to take their vehicle to a Ford or Lincoln dealer for an inspection of the driver and front passenger seat recliners. For 2020 model year Explorer and Aviator, dealers will inspect the rear outboard seats. The seat structures will be replaced as required.

Issue: On certain vehicles, the cover for the manual park release (MPR) lever may not be installed. If the MPR lever is accidentally pushed, the transmission can be shifted out of PARK without a key in the ignition. Canadian regulations require a cover over this lever. Additionally, the vehicle may also be in Factory Mode, which disables warning alerts and chimes, and does not display the transmission gear position (under certain conditions). Safety Risk: A missing MPR cover could create a situation where the transmission can be shifted without a key in the ignition. If the transmission position is not displayed, a user may not know that the vehicle is not in the PARK position. If the parking brake is not applied, either of these situations could create a risk of a vehicle roll-away and increase the risk of a crash. Corrective Actions: The company will notify owners by mail and instruct them to take their vehicle to a dealer to inspect for the MPR cover. If missing, it will be installed. The dealer will also verify that the instrument cluster is not set to Factory Mode.

On certain vehicles, the rear suspension toe link(s) could break. This could cause a sudden loss of vehicle stability. Note: This problem is more likely to occur on vehicles that are driven on rough roads. Safety Risk: A loss of vehicle stability could cause a loss of control and increase the risk of a crash. Corrective Actions: The company will notify owners by mail and instruct them to take their vehicle to a dealer to install improved rear suspension toe links.

On certain vehicles, the front power seat adjuster assembly joint may become loose over time. A loose seat adjuster assembly may increase seat cushion deflection and not properly restrain the seat occupant in the event of a crash, which could increase the risk of injury. Correction: Dealers will inspect for proper torque of the power seat track upper pivot link bolt. If the bolt passes inspection, dealers will remove and clean the bolt, apply new threadlock and reinstall the bolt to the specified torque. If the bolt fails the torque inspection, threadlock will be added to the bolt and will be reinstalled as an interim repair until the final repair is available. The final repair will include replacement of the lift link, including new bushings and fasteners.

On certain vehicles, the steering gear heat shield fasteners may have an incorrect coating that could cause the heat shield to corrode and detach. This could expose the steering gear system to higher temperatures and could cause the steering gear to overheat, which could result in a reduction of steering assist until the gear cools. If the steering gear electrical connectors were to melt, it would result in a sudden loss of steering assist. A loss of power steering assist could unexpectedly increase steering effort, which would increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect the fasteners and replace as required. Note: In the event of a loss of power assist, the message "SERVICE POWER STEERING NOW" would be displayed in the instrument cluster.

Certain vehicles equipped with a manual driver's seat recliner may fail to conform to Canada Motor Vehicle Safety Standard (CMVSS) 202 - Head Restraints and CMVSS 207 - Anchorage of Seats. There may be an inadequate weld between the driver's seat back and the manually operated seat back recliner mechanism, which may fail to meet the requirements of the standards. As a result, the driver's seat back may appear to be loose, twisted or lean to one side, and/or squeak/rattle. If this condition were present, in the event of a vehicle crash, the seat may not adequately restrain an occupant and would increase the risk of injury. Correction: Dealers will inspect and, if necessary, replace the seat back frame.

On certain vehicles equipped with a 2.3 litre GTDI engine and an engine block heater, due to the engine’s orientation, the block heater could be susceptible to overheating. An overheated engine block heater may result in engine coolant leakage, or heat damage to the electrical connector of the block heater. Overheating of the engine block heater may increase the risk of an underhood fire causing injury and/or property damage. Correction: Dealers will replace the engine block heater element with one of a different design, and will inspect the block heater's electrical cord, and replace if required. In the interim, owners are advised to stop using their block heater until the campaign is completed. Note: This risk only exists when the block heater is plugged in and the vehicle is parked.

Certain vehicles fail to comply with the requirements of Canada Motor Vehicle Safety Standard 135 - Brake Systems. During the manufacturing process, the parking brake controller assembly bracket may have been improperly formed. This could result in the pawl to not engage the sector gear during actuation and the parking brake not fully engaging. If the transmission is in Park, there will be no unintended vehicle movement. If the transmission is left in a gear other than Park, and the vehicle is parked on a sufficient slope, a non-functioning parking brake could result in unintended vehicle movement, increasing the risk of a crash causing injury and/or property damage. Correction: Dealers will inspect, and if necessary, replace the parking brake control assembly.

On certain vehicles, a fault in the Electric Power Steering (EPS) system could result in an immediate loss of power steering assist without warning to the driver. This would unexpectedly increase the steering effort force necessary to steer the vehicle at lower vehicle speeds, which could increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will affect repairs as necessary and will reprogram the EPS controller with updated software. In the event that an EPS fault occurs, this updated software would allow for continued EPS function while displaying visual and audible warnings to the driver until the end of the drive cycle.

On certain vehicles, the child safety lock actuation cam may have been manufactured incorrectly. As a result, the child lock may inadvertently disengage, which could allow the rear door to be opened using the inside door handle, possibly resulting in injury. Correction: Dealers will inspect the child safety lock and, if necessary, replace the door latch assembly. In the interim, drivers that have a need to use the child lock feature are advised to check the child lock to ensure it is in the ON position before each use.

On certain vehicles, the fuel tank may have been manufactured incorrectly. As a result, some of the fuel tanks may not provide the expected strength in the event of an impact, and may leak. A fuel leak may also occur even in the absence of an impact. A fuel leak in the presence of an ignition source may result in a fire, increasing the risk of injury and/or damage to property. Correction: Dealers will inspect and, if necessary, replace the fuel tank.

On certain vehicles, the second row 60% seat (with a manual recliner mechanism) may have components that are out of dimensional specifications and thereby may not comply with the seatback strength requirements of the Canada Motor Vehicle Safety Standards 207 - Anchorage of Seats. In the event of a crash, the seatback may not provide the required strength, increasing the risk of injury to the seat occupant. Correction: Dealers will replace the manual recliner mechanism.

On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. Correction: Dealers will install a new switch or fused wiring harness. Note: This is an expansion of recall 2005028 (05S28) for vehicles not previously included in the campaign.

On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The failure mode appears to be different than that of Recall 2005028 (05S28). This time, the concern is with long term durability performance issues causing the switch to fail. Correction: Initially as an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available, owners will be instructed to return to the dealers for installation of a fused wiring harness designed to eliminate the potential risk of fire.

On certain Explorer, Explorer Sport and Explorer Sport Trac vehicles, the upper bolt on the driver's high back seat that attaches the seat recliner mechanism to the seat back frame could fracture. If this happens, the seat back may recline until it makes contact with an object behind the seat, such as the 2nd row seat cushion. The occupant could potentially lose contact with the steering wheel or foot pedals during such an event. Correction: Dealer will replace the driver's seat upper bolt.

On certain 2002 model year vehicles, the ball stud bracket located on the rear liftgate window could rotate out of position on the glass. If this occurs, the window lift strut may detach and become trapped between the glass and the liftgate, possibly causing the window to drop unexpectedly or break. In all of the affected vehicles model year 2002 and 2003, the hinge which attaches the liftgate window to the liftgate body may separate from the liftgate body. If this occurs, the window could drop unexpectedly or break. If the liftgate window drops or breaks, either the person operating the window or a nearby person could be injured. Correction: Dealers will replace the liftgate glass hinge and ball stud bracket (if applicable).

On certain Explorer, Explorer Sport and Explorer Sport Tract vehicles, the speed control cable strand cover could impact the conduit end fitting during speed control engagement. Repeated instance of this may result in flaring the cover end causing a binding condition when speed control is disengaged. Drivers may experience a high idle or a condition where it would appear speed control would not disengage. Braking function would be maintained though stopping distances may be increased. Correction: Dealer will replace the speed control cable.

On certain vehicles, the Powertrain Control Module may allow the vehicle to exceed the design intent top speed. At these extreme speeds. the vehicle may be capable of exceeding the speed rating of the tires. This could lead to tire failure and at these extreme speeds, may result in a crash. Correction: Powertrain Control Module will be reprogrammed with the latest calibration.

Certain vehicles do not comply with the requirements C.M.V.S.S. 209 - Seat Belt Assemblies. The seat belt assemblies may not withstand the force requirements of the standard. In a crash, if the belt buckle fails, there is an increased risk of injury to the occupant. Correction: Belt buckle assemblies will be inspected and replaced if necessary.

On certain vehicles, the generic electronic module (GEM) may experience a condition referred to as "lock-up" in which the GEM controlled functions (front windshield wipers, interior lights, 4X4 system etc.) could not be turned ON or, in some cases if the function in ON, it could not be turned OFF. During this lock-up condition, these functions remain in their last known operating mode and do not respond to driver commands until electrical power is interrupted to the GEM. An inoperative front windshield wiper system could adversely affect driver visibility. Correction: Dealers will install a resistor in the GEM circuit which will prevent the electronic noise on the diagnostic link from affecting the GEM during vehicle operation.