Gas Recirculation Valve (egr Valve) Problems of Ford Explorer

My brand new 2020 Ford Explorer platinum top of line model (VIN [xxx]) broke down on christmas eve 2019 after a complete engine seizure with less than 2000 miles and left us stranded with my family for hours in the middle of the road. The vehicle lost all power and control and had this happened on an interstate highway doing 80 miles per hour the result could have been catastrophic and potentially fatal. It has been at the dealership since and I am being told it needs a new engine but Ford cannot provide a date when the engine will be available. Remember. . . . This vehicle was only a month old! a 2020 vehicle broke down in 2019!!! the dealership is being fantastic and trying to swap the vehicle out for me but Ford has denied their request. I finally spoke with a Ford customer service rep ([xxx]) and she told me that the engines for this model (yes engines plural!) are being shipped at the end of the month. I asked her directly if I was the only one experiencing this issue and she flat out said "no, you're not". I regret having purchased a new model year vehicle of this Explorer and now fully think this is a dangerous vehicle. I hope Ford sees this. I think they have a serious issue and soon it will come out that there are serious problems with the 2020 Explorer. Just wait. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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The contact owns a 2013 Ford Explorer. The contact stated while driving 75 mph, the contact started to smell an abnormal gasoline and exhaust odor inside the vehicle. The contact started to feel a burning sensation in her eyes and chest. Additionally, the contact developed a headache and rolled down the windows, turned off the air conditioner to eliminate the odor inside the vehicle. The contact decided to drive back to the residence because of the fumes. The contact took the vehicle to the local dealer to be diagnosed. The contact was informed that the vacuum pump needed to be replaced. The vehicle was repaired however, the failure persisted. The local dealer was contacted to have the vehicle diagnosed a second time however, the contact was informed that there was an out of pocket cost for the inspection. The contact declined the inspection due to the cost. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 88,500.

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Carbon monoxide in the passenger compartment of a 2018 Ford interceptor utility (a honeywell bwc2r-m carbon monoxide alarm had been installed in the vehicle due to the history of carbon monoxide issues with these vehicles). On October 21, 2019 two officers were patrolling in the 2018 Ford interceptor utility. The officer were accelerating quickly as they entered the highway when the carbon monoxide alarm activated. The officer stopped accelerating and rolled down the windows. The carbon monoxide alarm reset and no further activations have been reported. (this report came a month after another of the city's Ford interceptor utility vehicles went to the dealership twice for carbon monoxide in the passenger cabin. The first incident was accompanied by a foul odor and the egr purge valve was replaced. The vehicle was placed back in service and within a week the carbon monoxide alarm activated again. Ford was unable to duplicate the carbon monoxide in the passenger cabin so no repairs were done. ).

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The police interceptor utility was being driven with windows down in a parking lot when a foul odor was smelled by the officer, followed by the carbon monoxide alarm activating. The reading on the CO alarm was 127 ppm. The vehicle was taken to hilltop Ford and a repair was made to the egr purge valve. The vehicle was returned to service and within a couple of days the CO alarm activated again, however no smell accompanied the alarm. The vehicle was being driven during the activation. The CO alarm is a honeywell bwc2r-m. The vehicle was taken back to hilltop Ford and after remaining with them for a month, a field service engineer tested the vehicle with specialized equipment and was unable to duplicate the complaint. No repair was made. All prior recall work had been performed on this vehicle.

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Tl the contact owns a 2016 Ford Explorer. The contact took the vehicle to star Dodge Chrysler Jeep ram (5101 s 1st st, abilene, TX 79605, (325) 698-2222) to have the vla emission computer update completed. After a few days, the vehicle began to exhibit a delayed response when the accelerator pedal was depressed. In addition, the vehicle downshifted on its own suddenly, especially while driving uphill. The vehicle was taken back to the dealer where it was diagnosed that the vehicle was affected by the vla emission update. After the update, the vehicle tended to overheat and the fuel gauge did not accurately display the correct reading. The vehicle was taken to star Dodge a third time where it was diagnosed that the egr was throwing coolant into the turbo. The contact reached out to the manufacturer and was proivdecase number: 407224. The dealer stated that the case would be closed because they could not remedy the failure. Prior to updating the vla, the contact was informed by the eco system hotline that the vehicle would not be affected. The failure mileage was 51,000.

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Vehicle surge on first acceleration after starting the engine. Surge - the vehicle experiences an accelerating lunge forward and then stops for about two or three cycles (stop/start, stop/start etc. ) it is unexpected and uncontrollable until it subsides within 20 to 30 feet. The degree of the unexpected acceleration is excessive when compared to the slight application of the gas pedal conditions - happens only after the first startup of the engine, in warmer weather when the "choke" is not required. Example: start engine, back out of garage, place in first gear, accelerate slowly for the first time. This is when the surge is experience. It does not happen with every stop/start cycle during normal driving, like stopping at a traffic light. It happens only after starting the engine, and going forward for the first time. The primary problem is the degree of the uncontrolled, oscillating acceleration relative to the slight amount that the gas pedal is applied. It is not about an overly sensitive accelerator pedal. It about the engine surging, then dying off, then surging again.

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There is a smell of exhaust inside the cabin of our Explorer at times when driving on the freeway and when our air conditioning is on, recycling the air inside the vehicle. This smell gives our teenage daughter headaches, and we are concerned that it could cause other health issues over time. Living in arizona, we cannot just turn off the ac when it is 110-117 degrees outside. We have taken it into our local Ford dealer three times and they said that they have done three repairs, including removing the back bumper and sealing some gaps, replacing the ceiling air vents and adjusting the software in the vehicle. None of these have fixed the issue, however, and the dealer's service department says that they have done all the repairs that they know how to do, per the instructions from Ford corporate. They recommended that we call Ford corporate customer service, but after two weeks of waiting for a "good faith review," the regional customer service manager informed us today that we do not meet the requirements for a buy-back, and we should just take it to another Ford dealer for a second opinion on the repairs, or buy a new vehicle and trade ours in. We are very concerned about this issue, but don't want to lose a lot of money trading it in, as the value has depreciated severely in the year since we purchased the vehicle.

On January 27th, 2017, my wife and I leased a new 2017 Ford Explorer. Every time we operate the vehicle, we get extremely sick (some symptoms we experience are sore throat, running nose, headaches, and nausea that last hours after exiting the vehicle). This occurs about 10-15 minutes while driving/operating the vehicle. The heating system was set to 75 degrees fahrenheit and the windows were closed. After we felt sick we did shut off the heating system and open the windows but there was a slight odor in the cabin and we still feel several aliments. Doctor appointments have been made for myself and my 6-month-old daughter that was in the vehicle (this being my most significant concern). Ford motor corp installed a new exhaust system, removed the rear bumper and resealed any leaks, checked cabin pressure and tried to reseal any cracks that may allow exhaust to renter the cabin. Ford stated that the vehicle was fixed, after being brought to them for the third time (they said they found more leaks and resealed them), but refused to give me any documentation stating that the vehicle is safe for my family and myself to be in. The vehicle has been in and out of service several times, a Ford service technician located at sayville Ford test drove the vehicle with me and confirmed the same ailments. The vehicle was picked up from service after Ford stated it was fixed for a 3rd time and we were still getting sick when we drove the vehicle. We contacted Ford again and we advised them of the situation for a 4th time and their response was �by its very nature, new car smell is due to plastics and adhesives in the vehicle. It could be an irritant to some. Unfortunately, you may have to consider other options that may be available to you. �.

Check engine light came on and the code was p0106 and p0401. I discovered plastic tubing failed by breaking (disintegrating really), all in the vicinity of a part that I suspect controls those functions. The part is a harness with 4 of these plastic tubes that connect to various places. The fact that they are disintegrating indicates the wrong materials are used. Ford motor company should have this issue addressed as a recall for defective materials. I have samples of the tubing that survived.

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Carbon monoxide leaking into the car cabin: the car was being driven at 75mph on a highway, climate in the car 71 degrees, and recirculating air was on. Car was driven for about 2-3 minutes before carbon monoxide detector started sensing carbon monoxide. Digital carbon monoxide detector alarm sounded when it hit 35ppm, then the levels climbed all the way to 49 ppm. No smell was present at the time of the test. No cars surrounding the vehicle. At this time, when levels hit 49ppm the windows were rolled down for fresh air to gain safety for the driver. We were able to document video and images of this event. Ford field service engineer states to his knowledge the 2016 Explorer has been redesigned and the concern had only been documented on the earlier models.

Car has auxiliary a/c system and cabin will fill with exhaust smell after merging into traffic. This is to say after heavy acceleration and then backing off to traffic speed you can smell exhaust in the car and when I do I open a back window to get rid of the odor. Have personally gotten headaches after longer drives and now suspect exhaust. A/c settings are in recirculation with the auxiliary system on also. Dealership had a tech ride with me and we went for a drive in the car, he did not smell the exhaust to the same degree as I did but said there was a TSB to seal the rear area of the car and the rear valance would have to be taken off. (rather long job) dealership told me it would cost about $669 and is not covered by my extended warranty or by a safety recall. This is something I think the manufacture should take care of since it is a safety issue.

Exhaust gas fumes come into the inside cabin while driving, mostly from the rear of the vehicle. The air conditioning or heater is on and the recirculation fan can be either on or off. Failure mode can be on flat surface but mostly occurs going up and down hills. Not sure if the decelleration of the vehicle is part of the cause. Problem is intermittent, may not occur for weeks and then might occur 3-4 times in a day one specific example is on November 30, 2015, at 2:30 pm hvac system is set to heat, set to 73 degrees heat in dual temp control is on, recirculation is on, elevation is 3100 feet, going uphill on catron blvd towards highway 16 in rapid city, sd,(outskirts of town), decelerated from 50 to 40 mph at 40mph speed limit sign, several vehicles around us, odometer reading was 5482. 5 miles, and smelled exhaust fumes in the cabin that appeared to come from the rear of the cabin, had to open both front windows for about a minute to get the smell out.

Driving home up a hill with a newly purchased 2015 Ford Explorer my wife and I noticed a bad smell like exhaust fumes; we put this down to the new engine/exhaust burning off any factory grease etc. Subsequent trips with all of my family in the SUV we all experienced a foul exhaust and sulfur smell when going up a hill or accelerating above 3k rpm; there were no other vehicles in front of us to blame for the odor. We have taken the SUV to the dealer 4 times now and they in conjuction with Ford technical support cannot find the root cause. They have replaced/ installed: egr valve cover (tech bulletin), both exhaust down pipes, front transfer case. The dealer has no test equipment to find the problem or confirm we are smelling engine exhaust containing toxic gases including CO.

I bought my first Ford Explorer almost 8 years ago. I had absolutely no problems with this vehicle and felt very safe driving my newborn son. I had a second son and decided to buy a new Ford Explorer because it was such a dependable car. Now I am regretting that decision. I bought a 2006 Ford exploer at round 60,000 miles. It now has 70,000 and I have already had to get another transmission and it still has not fixed the problem. It jolts, lunges, and sometimes the transmission doesn't engage. I feel extremely unsafe trying to pull out at an intersection because the car starts to jolt and I have to slam on the gas in order for the car to go. It is horrible and I feel very unsafe driving; especially with my children in the car. Even if I am driving on the interstate I have to put the car into overdrive to stop the majority of the jolting, and that does not even guarantee it will stop. My husband is in the military and gone a great deal. He should not have to worry about the safety of his children or wife when he is deployed overseas or when he is training away from home. He is currently away from home for training, getting ready for deployment. He is calling every chance he gets to make sure the car has not broken down or we have not been in and accident due to this very horrible vehicle. If I had enough money I would buy another vehicle and tell everyone not to ever buy a Ford again. I think I am more upset with the fact that my husband is possible being sent overseas in October, and he cannot even go to war with the knowledge his family is safe. I really wish someone would understand that this is a huge problem and major safety problem. Please help all of the families with this defect.

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I purchased a 2004 Ford Explorer in July 0f 2011, and traded in my 2001 Oldsmobile of 5 years. I also purchased the 12 month 12,000 mile warranty. Before driving it off the lot I had the dealer fix the abs system because the light was on. There is a crack going down the back of the trunk but nothing else was wrong at the time so I left the crack alone. In April of 2012 I took it to the dealership for a belt, check trans, shocks, ball joints, and a ticking in the heater when knob was turned to heat (not cool). I told him to just fix what was on the warranty and also give it a oil change. He informed me that the trans was fine. After getting the car back my heat went out and I was told by a mechanic buddy that my brakes, rotters, emergency brake pads and the back tires were shot. So I had him replaced them because this was also not covered on warranty. Just last week my rpm started jumping with miles over 65. (no lights were on at the time)so I took it to 6 different places getting estimates on what could be wrong. All shops said the same thing. "start with fuel filter, oil filters and oil change". The day after I paid for all this the service engine light came on. (egr valve code) the man at auto zone told me to take it off and clean it with spray and let it dry before replacing. I took it to a shop and had them do this. The same day I picked up the car my service engine light came on again, o/d light and the car was driving like I was hauling a bus and jumping. I took it back the next day and he replaced the egr valve new since the same code was showing up. Later that day after getting it back the car started doing the same thing after driving for 5 miles this was Friday 9/21/12.

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I discovered a leak in the radiator after noticing that the temperature gauge needle was bouncing around at an idle. After about a minute, the vehicle overheated and started steaming. We ended up having to have the radiator replaced at a cost of $600. (it was also over 90 degrees that day and I was stranded with two small children, the youngest was 4 months old. ) then about a month ago, in may 2012, I was at a grocery store and when I went to enter the vehicle I noted a large puddle of antifreeze on the ground and it was dripping from the radiator. We had to have the radiator replaced, again at a cost of $600. The same mechanic repaired it both times and said it was the same issue as the first one. Now we are having transmission fluid leaking from the cooling line that leads from the transmission to the radiator. These incidents have caused us serious hardships financially and could have caused physical injury due to the fact that it was extremely hot out on both occasions and I had small children with me miles from home. I have already contacted Ford motor company and they have declined to do anything about this issue. I am requesting, as are many others, that a recall be issued. And I also suggest that you research this problem on the internet as it is a major one. It is strange that Ford changed the radiator in the 2007 model year Explorer.

My 2002 Ford Explorer had a failed tube mounted "differential pressue feedback from egr" (dpfe) sensor after 30k miles. Ford created a technical service bulletin (TSB) regarding this know issue affecting several 2000-2003 Ford models including the 2002 Explorer (see Ford TSB 04-11-1 may 25, 2004 ). However, when Ford turned this issue of the faulty dpfe sensor into a recall, or "field service action" (fsa) as they call it, they did not include the 2002 Ford Explorer in the dpfe recall. All vehicles included in fsa 02m01 were given an extended 2yr/24k mile warranty on the dpfe sensor. The 2002 Explorer was not included in this extended warranty despite the fact that the 2002 Explorer was included in the original TSB on this issue and the fact that the 2002 Explorer was know to use the same tube mounted differential pressure sensor as all the vehicles included in the recall. See fsa 02m01.

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There is Ford TSB 02m01 and ntsb 10007207 for replacement of the egr sensor on 2002 Ford Explorers. The Explorer needed that sensor replaced, but the warranty claim was denied although my vehicle fell within age and mileage guidlines. I would like Ford to compensate me for the cost of the repair.

The contact owns a 1999 Ford Explorer. The contact called about the current NHTSA investigation dp05005 concerning the engine and engine cooling/the spark plug. A spark plug wire burned and it messed up the egr sensor. This occurred on September 16, 2005 while going out of town ,and they noticed the spark plug wire burned out and burned a hose to the vacuum hose as well as other wires. The vacuum hose and the spark plug were replaced . This still did not solve the problem. The contact took the vehicle to a repair shop and mechanic determined that the egr sensor was bad according to the diagnostic test, and that it had to be replaced . Also, it showed a vacuum leak and on the upper intake platinum. They found a bunch of cracks in it. The upper intake platinum had to be replaced.

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At a complete stop vehicle surges (accelerates). Have to place in neutral at standing stops to prevent an accident. Driver's side power window switch failed, had replaced, also the window whines when rolling up. Passenger's side power window regulator(cable) snapped?? when rear windows are down at a speed of 20 mph+ it sounds like a helicopter is in the back seat(actually physically hurts your ears!!!) <<<<no fix or repair?? anyone else have this problem? 55-65 mph steering wheel shakes. Repair attempt balanced and rotated tires and suspension was inspected. Still shakes. Rear spare tire accessories cover handle broke. <<not abused. How do you change a flat with no jack or no tools?? (spare tire came down alright though). Egr valve failure @ 40,000 miles. 4x4 intemittent shifting issues from low>auto and auto>high. Can not pin point problem. That about wraps up my lovely experience with this vehicle. I am a married father of two and the only one working on a limited income. I bought this truck with very low miles thinking it would be dependable not unaffordable.

About 3 months ago, my Explorer began occasionally experienced dramatic, random engine acceleration. While driving, the rpms would shoot up for no apparent reason. 2 months ago, it was taken to the Ford dealership in millington, TN. They found no problems and hinted it was "driver error". A week later, I made an 800 mile drive to visit my newly hospitilized father. The sudden, drastic increase in rpm' started out happening 1 - 2 times in the first 30 minutes. The frequency rapidly increased, and 4 hours into the trip, the sudden acceleration was occurring at least 1 time every 5 minutes or so. After arriving in pittsburgh, the Explorer was again taken to a Ford dealership. They informed me that the co2 detector had gone bad. This was covered under warranty, but since I was driving with a bad detector, the egr sensor was caused to malfunction. I was informed that this was not covered under the warranty since it was a result of my continuing to drive it with a bad co2 detector. The egr sensor cost me $300 to get replaced. A week after this "repair" was made, I began the trip back to TN. 2 hours into the trip, the sudden, drastic accleration started again, and soon was occuring several times every 30 minutes. On reaching TN. , I once again took the Explorer to the Ford dealership in millington. They were unable to find any problem. So, not only did I pay for a repair that 1) was caused by the dealership's inability to find a problem, it 2) should have been covered under the warranty. Then it became apparent that the "repair" did not even fix the problem. To this day, the random acceleration is a problem.

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Vehicle began stalling when it was around 30 degrees or lower in the winter and would have to restart the vehicle 3 or 4 times to get it to stay started, now vehicle does this every morning and even when its warm out. Took vehicle to dealer, dealer put seal on intake platton. Vehicle does it every time you start it now.

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First evidence of noise reported to dealer on 7/22/98. They said there was no problem. Noise became unbearable and engine began lossing power. Took it to dealer on1/2/01 and found out the front cam tensioner disintegrated causing severe metalic noises from the engine compartment. Bankston Ford supposidly did the well known recall. My paperwork shows they replaced the tensioner cassette and changed the oil. I obtained their own proceedures for this issue because many engines have had to be replace due to the pieces of the broken tensioner clogging oil passages and destroying the engines. The instructions they should have followed included inspecting the heads for clogged passages and other things. I believe they should have replaced the engine then, but they made me take it. As soon as I left dealer, the noise was back. Called them and they said to give it a week and see if it goes away. It got worse and I brought it back in to the dealer. This time they said it was the rear tensioner (the one not coverered by their recall since it requires removing the engine. Same part- same defect, but not covered due to cost). Since Ford was losing too much money on their defect replacing engines, they stopped helping their customers. The dealer offered a $500 and 75,000 mile warrantee dealer concession, but I expected it to be taken care of like everyone else. The defective part ruined the engine and it should be replaced, or at least repaired properly. Have been at a stand-still for almost 2 years now with a non-funcioning vehicle. Ford customer service will not do anything and the dealer now wants $5000 for a new engine.

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Egr valve failed at cost of over $250. This is part of the emissions system and is covered by an extended warranty. I requested warranty status for this part from Ford motor CO. Customer relations center in letter of 7/17/03 with 76,172 miles on vehicle. Initial "check engine light" for this failure was at about 66,000 on 8/30/02. Ford did not answer my inquiry, instead referring me to their customer service reps in india, against my wishes.

Egr sensor/control failed causing check engine light to come on. Mjs.

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Exhaust gas recirculation valve tube failed.

Egr valve failed.

Repeated failed attemps to correct ping/tick when engine is below 30 degrees f.

Recall 97v074000. The dealer has no parts.