2020 Ford Explorer

Above average

Owners filed 1,212 complaints about this vehicle with federal regulators, most often about the power train. It has been recalled 33 times.

When it fails
020k40k60k90k120k200k

408 complaints record an odometer reading. Failures cluster around 010,000 miles; the median is 22,900 miles.

What fails
ComponentReportsCrashesFiresInjuries
Power Train396
601
Unknown or Other150
6213
Electrical System122
331
Engine81
120
Service Brakes72
302
Exterior Lighting45
100
Visibility/Wiper40
100
Back Over Prevention36
200
Structure › Body30
012
Seats28
102

33 safety recalls

Part 573 reports
Seats › Mid/Rear Assembly26V451000
Filed Jul 14, 2026387,911 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2027 Aviator and 2020-2026 Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, tipping, or sliding unexpectedly.

Risk. A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing the risk of injury.

Remedy. Dealers will inspect and replace the bezel around the switch as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters explaining the safety risk were mailed August 19, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Lincoln Aviator owner notification letters were mailed August 21, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S52. This recall expands Recall 25V393. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.

Power Train › Automatic Transmission26V402000
Filed Jun 24, 2026741,195 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2018-2021 Navigator, Expedition, 2020-2021 Explorer, Lincoln Aviator, and 2021 F-150 vehicles. The transmission park pawl may engage while the vehicle is in motion, resulting in park system damage.

Risk. Park system damage may result in a vehicle rollaway, increasing the risk of a crash.

Remedy. Dealers will update the powertrain control module software, and inspect and replace any damaged transmission components as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed July 10, 2026. Additional letters will be sent once the remedy is available, anticipated in April 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S48. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on June 26, 2026.

Seat Belts26V159000
Filed Mar 17, 2026561 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2026 Explorer and Lincoln Aviator vehicles. The seat belt anchor bolts at the second-row outer seating positions may be improperly secured.

Risk. A loose seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.

Remedy. Dealers will inspect the second-row outer seat belt lower anchor bolts and replace or repair them as necessary, free of charge. Owner notification letters were mailed March 30, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C18. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 19, 2026.

Back Over Prevention › Software26V123000
Filed Mar 3, 2026889,950 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2022 Escape, Lincoln Corsair, 2020-2024 Lincoln Aviator, and Explorer vehicles. The image on the center display may flip or invert, resulting in an incorrectly displayed rearview image when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Risk. An incorrectly displayed rearview image can reduce the driver’s view behind the vehicle, increasing the risk of a crash.

Remedy. Dealers will update the accessory protocol interface module (APIM) software, free of charge. Owner notification letters were mailed June 23, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C11. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 5, 2026.

Visibility › Windshield Wiper/Washer › Motor26V117000
Filed Mar 3, 2026604,533 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer, Escape, Lincoln Aviator, and Lincoln Corsair vehicles. The windshield wiper motor may fail and prevent the windshield wipers from operating properly.

Risk. Windshield wipers that fail to operate properly can reduce visibility, increasing the risk of a crash.

Remedy. Dealers will inspect and replace the front wiper motors as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed April 2, 2026. Additional letters will be sent once the final remedy is available, anticipated in October 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S14. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 4, 2026.

Equipment › Electrical › Engine Block Heater25V685000
Filed Oct 10, 202559,006 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.

Risk. An electrical short circuit can increase the risk of a fire.

Remedy. Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.

Back Over Prevention › Software25V442000
Filed Jun 27, 2025200,237 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.

Risk. A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.

Remedy. Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.

Seats › Mid/Rear Assembly25V393000
Filed Jun 13, 2025304,662 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator, and Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, folding, or sliding unexpectedly while driving.

Risk. A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing their risk of injury.

Remedy. Dealers will inspect the second-row seat switch, and replace the bezel around the switch as necessary, free of charge. Owner notification letters were mailed August 7, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S67.

Back Over Prevention › Software25V159000
Filed Mar 14, 202549,399 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles previously repaired incorrectly under recall number 23V-342. The video output may fail, preventing the rearview camera image from displaying.

Risk. Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.

Remedy. Dealers will update the Image Processing Module software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S27.

Power Train › Driveline › Driveshaft25V166000
Filed Mar 14, 20254,247 vehiclesFord Motor Company

Defect. Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles previously repaired incorrectly under recall numbers 23V-199 or 22V-255. The rear axle horizontal mounting bolt may fracture and cause the driveshaft to disconnect.

Risk. A disconnected driveshaft can result in vehicle rollaway when the vehicle is placed in park without the parking brake applied. A disconnected driveshaft can also result in a loss of drive power. Either of these scenarios can increase the risk of a crash.

Remedy. Dealers will update the powertrain control module (PCM) software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S22.

Showing 10 of 33 campaigns, newest first.

What owners reported

Newest filings
Power Train
Filed Sep 17, 2026KS

Vehicle: 2020 Ford Explorer XLT Active Recall: Ford #26S48 The transmission on my 2020 Ford Explorer has completely failed, leaving my vehicle inoperable and my family stranded. The vehicle is currently located at a local Ford dealership, just sitting there waiting for a fix. My vehicle started shifting gears randomly while driving, causing a lot of jerky movements. My wrench light came on the dashboard, and I instantly took my SUV to a local Ford dealership for inspection. After the inspection, the dealership described metal shards floating in my transmission fluid and stated that the only way to fix the issues is to pay for a brand-new transmission to be installed. Having both the dashboard warning light (wrench icon) and shifting issues alongside metal shards strongly points to active internal mechanical damage matching the 26S48 recall pattern associated with my exact VIN. Although my VIN is tied to active safety recall 26S48 for this exact component failure, the dealership refuses to repair it, stating that an official corporate remedy/parts are not available yet. Furthermore, the dealership attempted to quote me roughly $10,000 out of pocket for a transmission replacement for an emergency fix. When I contacted Ford Corporate, they confirmed the lack of a current remedy and refused to provide alternative transportation (such as a loaner or rental vehicle), instead telling me to pay out-of-pocket for a rental or independent repair and "hope" for a future reimbursement. As

Electrical System
Filed Sep 15, 2026NJ

I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain 2020-2021 Explorer AWD vehicles. The bulletin specifically identifies C0631 and/or C00A6 and the front axle disconnect actuator/intermediate shaft and directs replacement with a revised intermediate shaft. I am concerned this is a safety defect because the failure resulted in AWD/drive-mode malfunction while multiple drive

Power Train
Filed Sep 13, 2026CT

I am concerned this is a known and widespread defect. The 10R60 transmission is the subject of multiple Ford Technical Service Bulletins and an active Ford/NHTSA safety recall (26S48 / NHTSA 26V-402) addressing transmission-related park-system and rollaway defects on this same transmission, model, and year. My vehicle was well maintained with routine service, yet the transmission failed internally at approximately 87,000 miles. Given the documented history of failures with this unit, I believe this defect warrants further investigation into transmission reliability and safety on 2020–2021 Ford Explorers equipped with the 10R60, beyond the current recall scope. Repair was quoted by the dealer at approximately $5,000–$8,000. I am filing this complaint so that this failure is documented in NHTSA's database and to support identification of any broader safety defect trend.

Power Train
Filed Sep 13, 2026CT

I am concerned this is a known and widespread defect. The 10R60 transmission is the subject of multiple Ford Technical Service Bulletins and an active Ford/NHTSA safety recall (26S48 / NHTSA 26V-402) addressing transmission-related park-system and rollaway defects on this same transmission, model, and year. My vehicle was well maintained with routine service, yet the transmission failed internally at approximately 87,000 miles. Given the documented history of failures with this unit, I believe this defect warrants further investigation into transmission reliability and safety on 2020–2021 Ford Explorers equipped with the 10R60, beyond the current recall scope. Repair was quoted by the dealer at approximately $5,000–$8,000. I am filing this complaint so that this failure is documented in NHTSA's database and to support identification of any broader safety defect trend.

Unknown or Other
Filed Sep 11, 2026WA

Sunroof headliner sagging. It completely blocks use of rear view mirror when open. Does not retract.

Power Train
Filed Sep 10, 2026TX

I purchased my 2020 Ford Explorer in December 2020. The first incident occurred around June 2021 while I was on a road trip. While driving, the vehicle unexpectedly shifted/downshifted on its own and caused a sudden change in the vehicle's movement. At first, I thought there might be an issue with the rotary gear selector. The problem occurred again, and in 2023 I took the vehicle to a Ford dealership and reported the issue. I was told there was a recall and recall-related work was performed. However, the unexpected shifting continued afterward. I contacted the Ford dealership multiple times about the continuing problem but was told that without an applicable recall I could be charged for diagnosis and that the problem might not be detected unless it occurred during a test drive. I reported the shifting problem again when the vehicle was at a Ford dealership for recall service in 2025. I specifically told the service advisor that the vehicle was still unexpectedly shifting while driving. The advisor told me the vehicle was driven but the problem did not occur during their test drive. The problem has continued. During a recent incident, the vehicle unexpectedly shifted/downshifted while I was driving and I nearly had an accident with my children in the vehicle. I am concerned that the sudden change in the vehicle's movement could cause me to lose control or be struck by another vehicle. I recently contacted the Ford dealership again and was informed that my vehicle has another

Power Train
Filed Sep 9, 2026110,000 milesTX

The contact owns a 2020 Ford Explorer. The contact stated that while driving at various speeds, the transmission shifted erratically. The messages "Service Advancetrac”, "See Owner’s Manual" and an unknown message were displayed. The contact stated that the failure mostly occurred while depressing the brake pedal, and the vehicle lurched forward while depressing the accelerator pedal. The contact stated that the failure progressively worsened, and the vehicle had become undrivable. While researching the failure online, the contact discovered that the VIN was included in NHTSA Campaign Number: 26V402000 (Power Train); however, the recall remedy was unavailable. The failure mileage was approximately 110,000.

Power Train
Filed Sep 8, 202670,000 milesAR

The contact owns a 2020 Ford Explorer. The contact received notification of NHTSA Campaign Number: 26V402000 (Power Train); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. 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 contact stated that while driving at various speeds, the vehicle was shaking and vibrating abnormally. The vehicle was taken to the local dealer, who confirmed that the failure was associated with the recall. The failure mileage was 70,000.

Power Train
Filed Sep 8, 2026PA

The transmission is sporadically shifting causing the vehicle to lose or stop during acceleration and deceleration making it unsafe to pull away from a stop or during deceleration and causing it to stop in the in the rd and then it would shift extremely hard after it would gain power to the transmission again. The vehicle is available for inspection and no codes indicated a transmission issue. Only codes are vacuum leak codes. I've had my snap on scanner attached and have had it at 3 different garages. The vehicle had transmission issues repaired shortly after purchasing at a certified Ford dealer (Fred Beans) of Mechanicsburg. My family and I have been in quite a few near miss accidents stemming from this issue. I've had fluids checked multiple times for the transmission and even had a Ford tech do a complete transmission flush.

Power Train
Filed Sep 3, 2026CA

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

Power Train
Filed Sep 3, 2026TX

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

Unknown or Other
Filed Sep 3, 2026IL

Moon roof is leaking from rain and snow and causing damage to whole interior

Power Train
Filed Aug 28, 2026CA

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

Air Bags
Filed Aug 26, 2026TX

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

Forward Collision Avoidance › Warnings
Filed Aug 26, 2026OH

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

Power Train
Filed Aug 25, 202679,000 milesTX

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

Exterior Lighting
Filed Aug 24, 2026IN

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

Engine
Filed Aug 21, 2026TN

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

Wheels › Lugs/Nuts/Bolts/Studs
Filed Aug 21, 202657,065 milesCA

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

Power Train
Filed Aug 21, 2026AZ

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

20 of 1,212 complaints, reproduced as filed.

Across model years

Worst on record: 2002
YearComplaintsRecallsFiresDeathsAssessment
20270100Routine
2026341400Routine
2025982000Routine
2024201010Routine
20231081520Routine
20222642410Above average
20214232650Above average
2020 — this page1,21233100Above average
2019294600Above average
2018728770Above average
20171,69114110Above average
20162,44915140Above average
20151,782910Above average
20141,676762Fatalities reported
20132,23412111Fatalities reported
2012827760Above average
20111,197840Above average
2010115200Routine
200933100Routine
2008148330Routine
2007208352Fatalities reported
2006630470Above average
2005497361Fatalities reported
20041,3044150High concern
20031,1317102Fatalities reported
20023,29510575Fatalities reported
200137512216Fatalities reported
200095215644Fatalities reported
19991,34815444Fatalities reported
19981,9591410216Fatalities reported
19971,731125334Fatalities reported
19961,450113751Fatalities reported
199584312328Fatalities reported
19941,20778220Fatalities reported
19939399481Fatalities reported
19926337634Fatalities reported
199160911634Fatalities reported
199012010Routine

Compare every Explorer year →

Reading this record

Complaint volume is well above typical for a single model year.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Recall repairs are free for as long as the recall stands. Check whether a specific car still has open work at NHTSA's VIN lookup.

Most recent recall on file: Jul 14, 2026. Source: NHTSA Office of Defects Investigation.