general problems of the 2016 Ford Explorer - part 1

While driving the crankcase sensor malfunctioned and caused my vehicle to stall without warning, this is a safety issue because of you are driving at highway speeds this will prevent the vehicle from being controlled properly to get to the side of the road. This sensor does not give any engine codes suggesting that it needs replaced until it goes out completely. The check engine light did not come on until after the component failed. I ordered a new part directly through Ford and even they said "yes that part will go out without any warning at all and will shut the engine down completely". When this sensor went out, it also caused pressure to build up in the engine which in turn has led to several other components that now need to be replaced. I have a had a mechanic look at it, and it now requires a turbo intake hose and a new turbo because the pressure that was built up in the engine due to the crankcase sensor going out burst the turbo intake hose and prevented the turbo from working correctly. It's approximately $4,000 in repairs due to a $150 part going out.

The contact owns a 2016 Ford Explorer. The contact received notifications of NHTSA campaign numbers: 21v316000 (structure), 24v031000 (structure), and 25v347000 (structure). However, the parts to do the recall repairs were not yet available. The contact stated that while the vehicle was parked, the contact became aware that rainwater was leaking inside the vehicle and standing water had accumulated on the carpet. The water was leaking from the front door, the roof near the dome light, and the glove compartment. The contact was unsure of where the water was entering the vehicle. The contact stated that there was a musty odor inside the vehicle. Most recently, while driving at an undisclosed speed, there was an abnormal burnt odor inside the vehicle. No warning lights were illuminated. The vehicle was taken to the dealer; however, the vehicle was not diagnosed or repaired. The contact stated that the check engine warning light was constantly illuminated since the vehicle was purchased. The manufacturer was not made aware of the failure. The failure mileage was unknown.

Coolant intrusion in the cylinder walls.

Torque converter issue causes shuddered, can cause driver to unexpectedly adjust speed rapidly.

The contact owns a 2016 Ford Explorer. The contact stated that while operating the vehicle, the engine overheated, and the temperature gauge had increased to high with the check engine warning light remaining illuminated. The vehicle was taken to the local dealer who diagnosed that the water pump was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer and local dealer were notified of the failure, but no assistance was provided. The failure mileage was 116,000.

The contact owns a 2016 Ford Explorer. The contact stated that upon engaging the parking brake, the parking brake failed to remain engaged. Additionally, the contact stated that upon activating the a/c, the a/c was blowing hot air. The vehicle was taken to a Mazda dealer, where it was diagnosed that there was a blockage in the engine block heater. The dealer informed the contact that no authorization was provided to repair the failure. The vehicle was not repaired. The dealer referred the contact to the NHTSA hotline for assistance. The manufacturer was not notified of the failure. The failure mileage was unknown.

The contact owns a 2016 Ford Explorer. The contact stated that while her husband was driving at an undisclosed speed, the vehicle stalled after coming from a stop. No warning light was illuminated. The vehicle was able to be restarted. The contact stated that the water pump had previously been replaced twice, but the failure persisted. The vehicle was taken to an independent mechanic, who determined that there was coolant intrusion in engine and the water pump needed to be replaced for the third time. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 177,000.

I’ve had it twice be an issue where the engine didn’t run quite right. The first time I took it to the mechanic it was determined the timing chain was bad and they also said this is a well known issue with the ecoboost engines in these Explorers. Only about a year later after replacing that and the water pump I went to start the Explorer and it wouldn’t start. Took it to the mechanic again and they found that the timing chain, again, had failed and this time it also caused damage to a piston rod. They said they were surprised it wasn’t catastrophic damage to the engine because of this. I’ve now had to spend literally thousands of dollars on this vehicle for timing chain related issues alone in just over 3 years of owning it. Searching online finds unending reports of similar issues to this as well as massive issues with the turbos and the cam phasers that also commonly are causing catastrophic engine failures despite routine preventative maintenance being performed. And the a pillar recall issue. I had it inspected December of 2024 and determined it needed them replaced. I was not given a time frame when that would be completed. I got a call over a month ago from the dealer saying to call them to schedule a repair. I did so and then was told that while I was on the list they still are unable to get any parts from Ford to repair this mandated recall and also cannot get a timeline on when said parts would be available. I’m almost six months past them saying it’s been ordered and still no idea when it’ll be repaired. And now a second recall was just announced for the b post coverings and I’m sure this will be just as bad. As many issues as this car is having I think Ford should have to pay for a lot more recalls than they have so far. I also had to have two other recalls fixed that the selling dealer didn’t address before selling to me.

Took the family SUV in for a standard oil change and 100k service to Ford dealership. Upon performing a coolant flush, the water pump began leaking. It was found that the internal water pump was leaking and needed to be replaced along with the primary timing chain and tensioner items. There were no warning lamps or indicators to let us know this was an issue. The dealer service center replaced the internal water pump, refilled system and test drove. It was re inspected and leak has been corrected. However, this cost us $4, 366. 80 for an issue Ford knows is a reoccurring issue in this model of SUV and a huge hazard for families.

The contact owns a 2016 Ford Explorer. The contact stated that the vehicle was idling rough while shifted into drive or reverse. The contact stated that the vehicle operated normally while moving. There was no warning light illuminated. The local dealer was not contacted; however, the vehicle was not diagnosed. The vehicle was not repaired. The contact referenced technical service bulletin: 20-2271; as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 111,000.

The contact owns a 2016 Ford Explorer. The contact stated while driving 68 mph, the vehicle shut off unintendedly. After the failure, the engine warning light illuminated. The contact stated that the failure was related to NHTSA campaign number: 16v925000 (engine and engine cooling); however, the VIN was not included. The vehicle was taken to an independent mechanic where it was determined there was water in the engine oil. The local dealer was contacted and confirmed that there was no recall on the VIN related to the failure. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 164,000.

The contact owns a 2016 Ford Explorer. The contact stated that while his sister was driving 55-60 mph, the engine started to overheat, and there was fluid leaking from the vehicle. The contact stated that there was oil in the coolant overflow tank. There were no warning lights illuminated. The vehicle was taken to an independent mechanic who determined that the engine needed to be replaced. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA hotline. The failure mileage was approximately 120,000.

Water pump.

The contact owns a 2016 Ford Explorer. The contact stated while driving 40 mph, the temperature gauge started to indicate that the engine was overheating, prompting the contact to discontinue driving the vehicle. The engine overheated warning light was illuminated. The vehicle was towed to an independent mechanic, who diagnosed a failure with the water pump. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 125,000.

Good morning, I’m reaching out in regards to my 2016 Ford Explorer. I’ve been trying to get the necessary recall repairs completed, but unfortunately, I’ve been unable to locate the required pillars for the repairs. I recently brought my vehicle back to the dealership, but was told that no work can be done until both parts are available. I was also advised to try sourcing one of the parts from another Ford dealership on my own, which I’ve had no luck with. To be honest, I’m feeling very overwhelmed. I purchased this vehicle used, back in September 2025, and since then, it has been one issue after another. I’ve already invested more into mechanical repairs than what I currently owe on the vehicle. I’m a [xxx], and this vehicle is our only mode of transportation. I’m growing increasingly concerned for our safety, especially knowing that the recall parts are critical and things could start to fall apart — literally — if they’re not addressed soon. With that said, I would greatly appreciate your help in exploring any other options available through Ford or the dealership. Some specific questions I have are: is there any way for the dealership to help source the necessary parts through other Ford networks or escalate this to Ford corporate? can you assist with a temporary vehicle solution while waiting on the parts (loaner or rental)? would there be any way to explore trading in or transitioning into another vehicle, even with the current issues and financial position I’m in? I understand that supply issues happen, but I’m just trying to keep my kids and myself safe, and right now I’m feeling stuck. I would extremely appreciate any help or direction you can offer. Please feel free to call or email me directly. I look forward to hearing from you. Sincerely, [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

The contact owns a 2016 Ford Explorer. The contact received notification of NHTSA campaign number: 24v031000 (structure); however, the part to do the recall repair was not yet available. The contact stated that while the vehicle was at a car wash, the driver's side a-pillar trim detached from the vehicle. The local dealer was contacted and replaced the a-pillar trim. The contact stated that after leaving the dealer after the repair, the driver's side a-pillar became loosened. The a-pillar trim was replaced. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that on a separate occasion, while the vehicle was parked, the contact noticed coolant leaking from the vehicle. There was no warning light illuminated. The vehicle was taken to the dealer and was diagnosed with coolant intrusion into the head gasket. The contact was informed that the water pump and timing chain needed to be replaced. The vehicle was not repaired for the most recent failure due to the cost. The manufacturer was made aware of the failure and referred the contact to the nhsta hotline for assistance. The approximate failure mileage was 120,000. VIN tool confirms parts not available.

The contact owns a 2016 Ford Explorer. The contact stated that the vehicle jerked while shifting into gear. The contact stated that upon shifting to drive(d) on several occasions, the vehicle failed to respond. There was no warning light illuminated. The vehicle was taken to the dealer, where the transmission was replaced. Additionally, the contact stated while driving 25 mph, the vehicle shuddered, overheated, and stalled. There was no warning light illuminated. The contact was able to pull to the side of the road. The vehicle failed to restart and was towed to the residence, where a mobile independent mechanic diagnosed that the head gasket was blown. The vehicle was not repaired. The dealer was notified of the failure, but no assistance was provided. The manufacturer was notified of the failure and referred the contact to the NHTSA hotline for assistance. The failure mileage was approximately 50,000.

2nd time in two years I have to fix the water pump.

The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, the engine overheated. In addition, the check engine warning light illuminated after the failure had occurred. The vehicle was driven to the shoulder of the road. The contact stated that when the vehicle was parked, the engine seized. The contact inspected the vehicle and noticed there was water from the water pump on the ground underneath the vehicle. The contact drove the vehicle to a nearby auto parts store. The contact was informed that the failure might be due to the coolant pump failure. The technician refilled the coolant reservoir with water. The vehicle was driven to the residence. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The dealer was made aware of the failure. The manufacturer was made aware of the failure. The failure mileage was approximately 54,000. The VIN was unavailable.

My vehicles wrench sign would turn on do a little jerk then I would lose power to my car. Showed malfunction to power train. Took it to mechanic said there was a crack in the valve gasket and they fixed that and changed spark plugs. A month later car did the same thing. Has done it a total for 4 times very scary when on a high way and it does it and I have to pull over with traffic coming. Took it to another mechanic and he couldn't figure it out either because there are no codes but said he seem something similar and I needed to change all my coils. So I did that. Thousands of dollars later and no one can still figure out the problem. I don't know if it's some safety issue with the engine or transmission. But 3 certified mechanics can not figure out why my car continues to lose power.

Engine stalls out when accelerating, coolant is leaking into the motor. Got it checked out my mechanic, needs new engine due to improper manufacturing issue.

A engine getting hot light came on in our Explorer and we checked the coolant levels and most of the coolant had leaked out. We filled the coolant but the check engine light was still on. A mechanic did a thorough assessment and found 3 codes were being thrown. He discovered that the coolant was leaking into the combustion chamber. After much research online, we found that there was a class action lawsuit on other ecoboost Ford engines that had the same issue. Out particular model was not included, but it was the same safety issue. The engine could become overheated and start on fire or the engine could fail and seize up while driving. We personally experienced a few times where the engine would hesitate and almost not go forward but we thought it was a spark plug issue. It was a little scary while driving in traffic and could have caused a rear end situation. We called Ford and they offered no solution. Case #cxh-02862684-p9d9b2.

The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, the temperature gauge started indicating that the engine was overheating, and the vehicle then lost motive power. The contact pulled over to the shoulder of the roadway, where the vehicle was able to be restarted. The engine overheating warning light was illuminated. The vehicle was towed to an independent mechanic, who diagnosed a failure with the water pump, resulting in engine damages. The contact was informed that the engine needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA hotline for assistance. The failure mileage was 114,000.

The contact owns a 2016 Ford Explorer. The contact stated that water had entered the vehicle, and the inside of the windshield was freezing. There was an abnormal sound coming from the vehicle. The contact stated that the defrosted was inoperable. Additionally, the tpms warning light was illuminated. The contact received notification of NHTSA campaign number: 24v031000 (structure); however, the part to do the recall repair was not yet available. The local dealer was contacted. The vehicle was towed to the local dealer, who blew out the tubes and replaced the water pump. The vehicle was repaired, but the failure recurred. The contact stated that after a rainstorm, water entered the vehicle from the sunroof. The vehicle was taken back to the dealer, where it was diagnosed that the sunroof track needed to be replaced. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The manufacturer referred the contact to the NHTSA hotline. The approximate failure mileage was 77,000. VIN tool confirms parts not available.

The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, there was steam was coming from under the hood. There was an abnormal odor entering into the cabin of the vehicle. The check temperature warning light was illuminated. The contact attempted to refill the coolant; however, the failure reoccurred, and the vehicle was towed. The local dealer was contacted and advised the contact that the water pump might need to be replaced. The vehicle was not diagnosed or repaired due to the cost. The manufacturer was made aware of the failure. The failure mileage was approximately 100,000.

At around 50,000 miles the turbo on the engine was leaking oil. Dealer replaced the turbo and kept the part. It needed to be replaced to avoid a catastrophic failure of the turbo which in turn could cause severe engine oil loss resulting in engine failure and oil contamination of the catalytic converters O2 sensors and possibly a car fire. There was no warning but was caught during a routine oil change. Unknown if the dealer reported it.

The water pump failed on my way home from work. A light in my vehicle started blinking rapidly and a warning alarm started sounding in the vehicle cabin unexpectedly. My vehicle suddenly overheated in the middle of a busy intersection causing me to stop unexpectedly to assess the situation before proceeding to safety. I (middle aged female) had returned from a long trip with two toddlers 800 miles round trip which extended late into the night on remote stretches of road without assistance available for several miles only a few days earlier. Had this happened a few days earlier, during that trip, I would have been stranded with two toddlers, alone after dark in a remote location. An independent service center made the diagnosis and performed a repair. They stated I was lucky the leak did not enter my oil reservoir based on the location of the water pump, locking up the engine and leaving the car completely inoperable in said intersection. The location of the water pump, and the fact it failed around 100,0000 miles seemed premature for similiar vehicles and the design/placement of the water pump is significantly more difficult to troubleshoot and repair. The cost of the repair was ultimately $3825. 69 plus an additional cost to procure a rental vehicle while for the week my vehicle was being repaired.

The contact owns a 2016 Ford Explorer. The contact stated while attempting to start the vehicle, the vehicle sputtered with the check engine warning light illuminated. The vehicle was taken to an independent mechanic where the vehicle was diagnosed, and it was determined that coolant was leaking into the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The dealer was contacted but the vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the nhsta hotline for assistance. The failure mileage was approximately 137,000.

The water pump failed causing all loss of antifreeze. After doing extensive research, this is a known issue and Ford refuses to fix the issue. To fix the issue a large part of the engine has to be torn down to access the water pump.

The contact owns a 2016 Ford Explorer. The contact stated while driving approximately 65 mph, the temperature gauge indicated that the engine was overheating. The contact pulled off the road and turned off the vehicle to allow the engine temperature to return to normal. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle was not diagnosed or repaired. The contact stated that the vehicle was inspected by a mechanic and was informed that the failure was related to manufacturer recall campaign number: 21n01 for the high-speed cooling fan motor relay (engine and engine cooling). The manufacturer was informed of the failure and the contact was informed that the vehicle was no longer covered under warranty. The failure mileage was approximately 174,000.

The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, the vehicle lost motive power and was not able to exceed 50 mph. The contact stated that the check engine warning light had been illuminated for over 3 years. T uthe vehicle was taken to a dealer to be diagnosed and the contact was informed the engine needed to be replaced due to the rear turbo causing damages to the front turbo and the engine. The vehicle was not repaired. The vehicle was then taken to an independent mechanic where it was determined that the turbos needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure; however; the contact was informed that the vehicle was nonder recall and that the vehicle was out of warranty. The failure mileage was approximately 97,000.

The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, the temperature gauge began to indicate that the vehicle was overheating, prompting the contact to pull to the shoulder of the roadway. After a visual inspection, the contact observed that the vehicle coolant reservoir was empty. The overheating warning light was illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the water pump. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 78,000.

Water pump failure at 60k miles on a 2016 Ford Explorer, this model has the most reported water pump failures on record. This is a 15 hour repair job at the dealer, and the same complaint litters the internet. The failure on my vehicle was confirmed by dealer, $4k to fix. Not to mention the mess in my driveway where the coolant expelled without notice. If I drive it, the engine will be damaged, and there goes my car. In 2020 NY and mi class action lawsuits over this issue were settled & closed with payment to plaintiffs, yet no recall. Why? too expensive for Ford? we see safety recall on clips yet nothing on an admitted engine problem than causes stalling or engine damage while running? there's a class action in canada. Ford is dodging a known defect. Please do something about this.

The water pump failed vehicle only has around 105,225 miles on it. This has been a known issue with the 3. 5l twin turbo ecoboost. The water and coolant continuously coming out happens to be on the alternator which has caused it to short out and no longer be working properly. There has not been any kind of malfunction or warning lights for any of the issues and because of the way Ford designed the water pump to be inside the motor working off the timing chain it turns into what the book lists at 14-15 hours to complete. The motor has to come out taken apart to replace the water pump and with that not just one but both timing chains have to be set again which adds additional hours for the repair and of course more money to take it to a Ford shop to have it fixed the rough estimate which they said did not include the labor for the timing chains being set nor the price of any of the parts needed as I have already purchased them myself so only labor for the water pump (not including timing chains) is about $4,350. 00 + tax of course but they said that would increase because of the labor for the timing chains that you have no option or choice regarding having to work on them or not because of the water pump. Oh and none of that includes rental fees while repaired nor the price to get and replace the alternator and labor for that. So my guess would be somewhere around $6,000 give or take to fix this disaster and Ford does not care about their known failed design and flawed water pump issues and expect someone to be able to fork out that kind of money instead of trying to help fix there issue.

The contact owns a 2019 Ford Explorer. The contact stated that while her husband was driving at an undisclosed speed, the temperature gauge began to indicate the vehicle was overheating, prompting him to pull to the shoulder of the roadway to cool down. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the water pump. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 98,000.