Engine And Engine Cooling Problems of Ford Explorer - part 1

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.

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Vehicle with 42k miles and regular dealer maintenance suddenly stalled out in traffic, creating dangerous situation for driver and children passengers. Towed to dealership from which it was purchased. Told it was a catastrophic engine failure and had coolant and oil mixed. Dealer unwilling to explore exact cause. Vehicle 11 months past 5 year power train warranty but well under mileage.

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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.

Ecoboost. Coolant intrusion into cylinder head causing white smoke to come out of the exhaust. This is the second Ford vehicle I have owned with the same issue.

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At approximately 1,700 miles, my brand-new 2026 Ford Explorer st (3. 0l ecoboost) suffered a sudden, catastrophic engine failure while driving, causing an immediate and dangerous loss of motive power. Prior to the failure, the engine experienced severe misfires. Following manufacturer technical service bulletin (TSB) guidance regarding ecoboost engine misfires, a step-colder spark plug heat range (ngk ltr7ix-11) was utilized to remedy pre-ignition. Ford motor company has denied warranty coverage for this catastrophic powertrain failure, falsely claiming the TSB-compliant heat-range plugs caused the destruction. The sudden loss of engine power poses an immediate safety hazard on public roads. I request an investigation into 2025-2026 Ford 3. 0l ecoboost spark plug issues, pre-ignition failures, and unfair warranty denials leaving dangerous vehicles unresolved. ".

While driving my new Ford Explorer, with 638 miles on it, on the highway I heard a loud pop, and lost power steering. I was barely able to pull the vehicle over to the shoulder to get off the highway. If I would have been on an interstate or a busier highway it could have been very dangerous. I believe that this has put me in danger having to maneuver the vehicle to the side of the highway and sit there while waiting for a tow truck. The vehicle was towed to the dealership where we bought it. The service manager told us that the engine had blown, it was a catastrophic failure. There were holes in the oil pan as well as through the top part of the engine from it exploding. I believe that we are lucky that the engine wasn't hot enough to start a fire, as we were only a few miles from the start of our drive. There were no warning lamps or messages prior to the engine exploding. The vehicle is currently at our dealership in monroe wisconsin, alphorn Ford is the dealership.

My vehicle is experiencing manufacturers defect identical to Ford program 21b35, yet Ford tells me my VIN is not covered under this program. Manufacturer defect includes car converter welds breaking, causing exhaust fumes to enter the cabin. This is a serious safety concern.

My 2017 Ford Explorer suddenly started vibrating intensely whenever I am at a stop or start slowing down. Episodes of hesitation when attempting to take off from a start with significant rpm surges. I am told I need to have my torque converter replaced. My vehicle has 84,697 miles on it, and was bought brand new from a dealer. I already had to have a new engine a month ago. This level of multiple engine and powertrain failures puts consumers and other drivers at risk for harm on the roadway. Not to mention the economic and employment impacts it has on the vehicle owners.

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I am reporting a serious safety concern with my 2017 Ford Explorer. The vehicle currently has approximately 93,752 miles and has become increasingly unreliable and unsafe to operate. On April 9, 2026, while my wife was driving home from work, the vehicle overheated, creating a dangerous situation and risk of sudden breakdown. This is especially concerning as the vehicle is used to transport children. Recently, after taking the vehicle in for an oil change, I was informed of multiple additional problems (three separate issues) affecting the vehicle. In addition, the check engine light remains on continuously, even after attempted repairs, indicating unresolved underlying problems. I have also previously attempted to have a recall repair completed, but was told that the necessary part was unavailable and that I would be contacted when it became available. Months later, I have still not been contacted, and the recall issue remains unresolved. Based on my experience and publicly documented issues, this appears consistent with known defects associated with this model, including reported water pump failures leading to engine overheating, rear suspension issues affecting control, and concerns regarding exhaust fumes entering the cabin. This is not normal wear and tear, but a potential safety-related defect. It is a serious concern that known recalls and defects cannot be repaired due to lack of available parts, leaving the vehicle in an unsafe condition. I am also concerned about the risk of continuing to operate this vehicle and potentially causing an accident that could injure myself, my family, or others on the road. This risk is heightened by the lack of timely communication and resolution regarding known defects and recalls. I am requesting investigation into these issues to prevent harm to drivers and passengers.

At 89k miles, my engine has failed, due to coolant intrusion, according to ken garff Ford dealership in st. George, ut. I started having issues with rough start and timing miss and engine light came on. I immediately took it to dealership and they did two repairs (tune-up) and subsequent gasket change because they said oil was getting into my spark plugs. It did not resolve the issue, took it straight back and now they're telling me I need a new engine. This comes 2 years after I had to pay $7k for a new transmission at only 60k miles. This is wrong and not ok that I am having to deal with this. I don't have $12k laying around for a new engine on a vehicle that shouldn't be having all these issues!.

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The contact owns a 2019 Ford Explorer. The vehicle was taken to the local dealer to be repaired under NHTSA campaign number: 26v101000 (suspension). While retrieving the vehicle, the vehicle failed to start. The contact heard the mechanic revving the engine of the vehicle. The dealer determined that the fuel pump and fuel pump module needed to be replaced, and that the failure was not related to the recall repair. The vehicle was not repaired. The manufacturer was contacted and determined that the failure was not related to the recall. The failure mileage was approximately 50,000.

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Oil is leaking onto my spark plugs and fouling them out. Also took my car into dealership and parts are not available for the recall for the rear toe links.

The 2011 to 2019 Ford Explorers have a huge issue with them. The internal water pump on my 2017 Ford Explorer 3. 5l engine failed. The failure caused coolant to leak into the engine crankcase, where it mixed with the engine oil. This contaminated the oil and led to catastrophic engine failure and seizure. The vehicle has already been brought to a dealership for service and is available for inspection upon request. This failure created a serious safety risk because the engine could have seized suddenly while the vehicle was in motion. If I had not caught the issue early, it could have resulted in a complete engine shutdown without warning, leading to loss of power, reduced steering control, and inability to accelerate in traffic. I have a strong understanding of vehicles and was able to recognize the warning signs, but the average driver would likely not identify these symptoms. Without that knowledge, this type of failure could easily occur without warning and put both the driver and others on the road at significant risk. Yes. The issue has been confirmed by both an independent mechanic and the dealership as a failed internal water pump. Coolant was beginning to leak internally into the engine and oil pan, where it mixed with the engine oil. The symptoms—coolant leaking near the oil pan, loss of coolant, lack of heat, and eventual engine failure—are consistent with this type of failure on this engine. The vehicle has been inspected by both the dealership and my independent mechanic. It is currently at the dealership for service and remains available for further inspection if needed. There were early symptoms, including a coolant leak, bubbling in the coolant reservoir, and loss of heat inside the vehicle. However, there were no clear warning lights or alerts indicating imminent engine failure. The engine did not overheat prior to failure, and the final seizure could have occurred suddenly without adequate warning. These symptoms only appeared about one day prior.

Vehicle experienced white exhaust smoke due to oil entering the exhaust system, caused by turbocharger failure. This led to contamination and failure of all O2 sensors, requiring full replacement, along with replacement of both turbochargers. The radiator also failed and had to be replaced. This appears to be a cascading mechanical failure affecting multiple major systems, including the engine, fuel/propulsion system, and electrical components, rather than normal wear and tear. The failure rendered the vehicle inoperable, leaving me without transportation during a period of financial hardship. The severity and extent of repairs raise concern about a potential broader defect. This also created a safety concern due to excessive exhaust smoke and reduced vehicle reliability while in operation.

The car was up on ramps, to replace a sensor, in park and slipped out of gear rolling backwards with force. Someone could have been under or behind the vehicle. Other vehicles could have been behind, property could have been damaged. The cars door caught the building and pulled it all the way back against the front fender.

Vehicle was brought to an authorized Ford dealership for coolant leak. The dealer confirmed a coolant leak originating from the internal water pump. The water pump on this engine is chain-driven and located inside the engine behind the timing cover, requiring approximately 12 hours of labor to access and replace. This is a known design defect affecting millions of Ford vehicles with the 3. 5l cyclone/duratec engine across multiple model years (2007-2020). The defect allows coolant to leak past the bearing seal, with potential to mix with engine oil and cause catastrophic engine failure. This is a serious safety risk as failure can occur without warning while driving. The problem was confirmed and documented by the Ford dealership. No warning lights appeared prior to the leak being discovered. Repair cost exceeded $4,300. This defect was the subject of a federal class action lawsuit (roe v. Ford motor company, eastern district of michigan) which was settled confidentially in January 2024 without a recall being issued. Ford has not notified owners of this known defect or offered any remedy program to us customers, despite a canadian class action resulting in relief for affected owners there. I am providing the cost invoice but will provide an itemized invoice once repairs are finished.

The contact owns a 2025 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle started shaking violently. The check engine warning light came on, and the vehicle lost motive power and stalled. The contact used a scanner to identify an error code. The contact was able to restart the vehicle and drove to the residence while driving 20 mph with the vehicle shaking abnormally. Upon arriving at the residence, the vehicle lost power. The contact called Ford customer service and spoke with a Ford roadside assistance representative to retrieve the vehicle from the residence. An appointment was scheduled for the dealer to pick up the vehicle at the residence. The vehicle was taken to ciocco Ford, but was not diagnosed or repaired; however, the spark plugs were replaced but the failure persisted. The manufacturer was made aware of the issue. The approximate failure mileage was 9,000.

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On 2/27/26 I heard a knocking sound in my car, no warning lights came on, took it to local car place and was told there was no oil in the tank. I immediately made an appt to take it to river view Ford dealership for service. They looked at it on 3/2 and found the engine to be damaged from the turbos pulling oil out of the oil tank and sucking it into the engine. They informed me nothing was being offered to replace the engine for that year 2020 and my warranty just ended 11/25. This car is worth $70,000 new, just paid it off early, otherwise in great condition. I called the customer service line and was told there is nothing they can do or offer and filed the complaint. My husband called back and spoke to 3 different rude people requesting someone call our dealer and talk with the service people- this didn't happen. Earlier this year this car had a differential leak that cost $3000; it also had the undercarriage of the car that holds the flex pipes up, fall apart and required the entire undercarriage to be replaced. I find it appalling that you google st engine issues and they specifically say 2020 models have issues with and suffer from severe oil-related issues, including high oil consumption, oil starvation, and, in some cases, turbocharger failure or engine knocking. How is this not a recall? no warning signs til its too late.

I am submitting a formal safety complaint regarding a severe design defect in the 3. 5l v6 engine of my 2013 Ford Explorer. The vehicle is equipped with an internal, chain-driven water pump that is currently failing at 100000 miles, as evidenced by coolant actively draining from the factory weep hole. Because this pump is located inside the engine block and driven by the timing chain, a complete seal failure dumps engine coolant directly into the oil pan. This is a critical safety hazard. When the coolant and oil mix, it destroys the engine bearings and causes the engine to completely seize without warning. If this sudden engine seizure occurs while driving at highway speeds, it results in an immediate and total loss of motive power, power steering, and power brakes. This defect creates an extreme crash hazard for the occupants of the vehicle and other drivers on the road. The internal weep hole provides virtually no dashboard warning or indicator to the driver before this catastrophic failure occurs. I am requesting that the NHTSA investigate this known, dangerous design flaw to force a mandatory safety recall before this sudden loss of vehicle control causes severe injuries or fatalities.

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When acceleration hot air blows through dashboard fogging front driver windows. Weather strips in doors are coming apart.

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Upon startup rough idle and check engine light came on. Mechanic confirmed cylinder head thinning causing fluid leak into first cylinder. A mechanical note verifies but Ford won't issue a recall. Apparently Ford has know this for years with ecoboost engines. I don't want to become a victim of vehicle dying in the middle of traffic. Have seen several complaints from Ford owners with no fixes by Ford.

When I'm driving on the freeway. I could be on flatland and it will stall, I could be going down a hill and it stalls, I could be on a regular road, turning a corner, hitting a bump. And it stalls when I'm on the freeway, I have to get over very scary happens all the time when it happens I coast, I put it into park, I turn it off, and it restarts immediately every time. This is constantly happening. Ihave a video and picture but it will not upload on this. But it says hell descending control fail.

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I am writing to formally report a series of catastrophic and life-threatening mechanical and electronic failures in my 2025 Ford Explorer active (VIN: [xxx] ]), purchased in bogotá, colombia. Despite immediately notifying the Ford post-sales support line after the first incident, the technical response was insufficient, leading to a second, more severe event that nearly resulted in a fatal high-speed collision on February 9, 2026. Incidents summary: 1. Total power loss: engine and all electrical systems shut down while in motion (40 km/h), losing steering and braking assistance. 2. Brake system failure: at 70 km/h, the vehicle presented a multi-system failure of sensors, audible alarm and illumination of warning lights (abs, traction control, pre-collision assistant, hill start assist not available, check brake system, brake, esc check, driving modes not available). The vehicle experienced a total loss of brake pedal response followed by a sudden, uncontrolled autonomous "hard braking" event. This happened on a high-traffic highway (autopista norte). Global safety concern: I am formally requesting a global technical investigation into this unit and the 2025 Explorer active series. The failure of the electronic brake booster and the total system shutdown represent a "product liability" risk that could lead to mass-casualty events. I demand: • direct intervention from Ford global to Ford colombia. • a formal safety alert or recall investigation for similar units. Sincerely, [xxx] mail [xxx] bogota colombia phone [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Engine light activation code: p0430 catalyst system efficiency below threshold bank 2.

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The contact owns a 2018 Ford Explorer. The contact stated that after the vehicle was idling at a traffic stop, the vehicle failed to accelerate as intended while depressing the accelerator pedal. The check engine warning light illuminated. The contact pulled over to the side of the road and turned off the vehicle. The vehicle was restarted; however, the vehicle stalled after driving several minutes. The vehicle was towed to an independent mechanic who diagnosed the vehicle with engine failure and determined that the engine needed to be replaced. The vehicle was not repaired due to the cost. The vehicle remained with the independent mechanic unrepaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 162,000.

Unknown.

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.

I own a 2020 Ford Explorer with approximately 85,776 miles. The vehicle has experienced two separate loss-of-propulsion events in traffic. On both occasions, the vehicle suddenly lost power while driving and stalled in the middle of a busy intersection. There was no prior warning of imminent engine failure. After stalling, the vehicle would crank but would not restart. The vehicle was disabled in the intersection for approximately 45 minutes to one hour each time. My family was inside the vehicle during these incidents. The vehicle displayed multiple malfunction warnings including “shift system fault” and messages indicating the vehicle was not in park even when the shifter was in the park position. The dealership, hansel Ford of petaluma, verified the concern and referenced Ford technical service bulletin (TSB) 23-2249 related to internal transmission components, including the valve body and park pawl actuator system. The dealership confirmed that when the vehicle is placed in park, it may actually remain in neutral. This creates an additional safety risk of unintended vehicle movement. This issue presents a serious safety hazard due •sudden loss of propulsion in traffic •vehicle disabled in active intersections •extended inability to restart •potential rollaway risk due to park malfunction the vehicle is currently pending major transmission-related repairs. I am submitting this complaint due to concerns about loss of propulsion and park system malfunction creating a safety risk for occupants and surrounding traffic.

The specific component or system has not fully failed. However, my vehicle is currently experiencing an intermittent check engine light condition, turning off and on, which was diagnosed at a retailer producing code p0018 then at the dealership and produced code p0017. The codes relate to the engine control module (ecm) detects that the camshaft on is out of sync with the crankshaft resulting in misaligned engine timing. I have requested that the dealership further review and escalate the diagnosis to determine whether the issue aligns with any known concerns, technical service bulletins, or manufacturer-supported programs. The vehicle and any related components are available for inspection upon request. At this time, the vehicle experiences reduced engine performance, including stalling, and inability to accelerator as needed, which pose a safety risk while driving, particularly in traffic or at highway speeds. The vehicle has been inspected and confirmed by the dealership. I have also contacted the manufacturer, who advised me to work directly with the dealership to have the issue reviewed and potentially escalated. I have since requested that they further evaluate the condition and determine whether it corresponds to any known issues or manufacturer-supported repair programs. At this time, the vehicle has not been inspected by police, insurance representatives, or other third parties. This check engine light and fluctuating rpm directly impacting the vehicles acceleration was the primary indicator of the issue. The manufacturer previously issued two customer satisfaction program notices to address this issue for other model year vehicles. I have attached both notices to this complaint. This demonstrates a manufacturer defect which is a safety hazard for drivers.

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.

Smoke coming from engine bay area. Vehicle in limp mode. Mechanic says piston broke a hole in engine wall.

Front end axle actuator failing and causing all safety systems to turn off, loss of power and can lead to seized up front end.

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.

Leaking water pump that if isn’t repaired will cause catastrophic engine failure. Very expensive repair, $2800 because of internal placement of the pump. Since the water pump is in line with the crankshaft and located over the main body of the engine, it allows coolant to leak from the water pump into the oil pan. Mixed coolant and oil will lead to engine failure.

- I have experienced a sudden loss of engine power and speed on 5 occasions. Very scary and dangerous to completely lose power on the highway with cars behind you. Had to pull off onto the shoulder(s) in dangerous conditions, with two young kids in the backseat. Hazards, turn off the car, restart the car, etc. - when the power loss happens, the vehicle's dashboard lights turn on, including the engine and wrench icons along with the words "see manual. " - based on my research, I believe it may be due to a defective throttle body and/or software, related to the "terrain management system. " - problem was not reproduced or confirmed by a dealer or independent service center - no inspections by the manufacturer, police, insurance representatives or others - no warning message is provided prior to the failure, which is another issue.