2022 Ford Explorer

On XXX, this 2022 Ford Explorer ST was involved in a low-velocity impact collision (under 20 km/h) into a concrete pillar inside a shopping mall parking structure in [XXX]. The point of impact was isolated to the front passenger quarter panel of the vehicle. Despite the very low speed and localized nature of the collision, a catastrophic deployment occurred where all vehicle airbags unexpectedly deployed simultaneously. My wife was the sole occupant and driver of the vehicle at the time, with no passengers present. As a direct result of the airbag deployment, she sustained significant thermal and friction burns to both of her arms. The incident has been officially registered with the local authorities under Dubai Police Report Reference XXX. Due to the extreme extent of the internal vehicle damage and components deployed from this low-speed impact, the vehicle repair estimate stands at 97,000 AED, and our motor insurers are currently processing the vehicle as an economic total loss (write-off). We are logging this report to highlight an overly sensitive and dangerous deployment parameter that resulted in severe secondary driver injuries during a minor incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Driver side crack at the exit point of the catalytic converter exposes car cabin to emissions exhaust. All 2020-2022 Ford Explorer models. Dealer confirmed that replacement is covered under the 8yr/80K warranty. Ford recognized this problem and manufactured a new and improved/updated the catalytic connection along with new flex pipe configuration. Installing a new catalytic requires new flex pipes aren't covered under warranty and Ford is charging customers $1700 to replace both flex pipes. Ford should cover both under warranty as a result of a known issue and subsequent design change. Dealer message: "The catalytic converter is cracked, and we can warranty out both catalytic converters. Unfortunately, Ford has updated the catalytic and the flex pipe configuration and the only coverage Ford is responsible for would be for the catalytic converters. Customers would also need to replace the flex pipe in order to install the new catalytic converters, which is unfortunately not something that would be covered under any warranty."

I am reporting a potential safety defect involving the panoramic moonroof/sunroof sunshade assembly on my 2022 Ford Explorer King Ranch, which I purchased used. The sunshade track or support mechanism appears to be failing, causing the sunshade material to sag significantly from its intended position. When the panoramic moonroof sunshade is operated, the material hangs downward into the passenger compartment and obstructs my view through the interior rearview mirror and rear window. Even when I attempt to operate only the front sunroof portion, the material continues to sag, creating a visual obstruction. The sunshade no longer functions or remains positioned as intended. My primary concern is that this is not simply a cosmetic issue. The sagging material interferes with my ability to clearly see vehicles and traffic approaching from behind. This creates a potential safety hazard when changing lanes, merging, reversing, or monitoring surrounding traffic. I am concerned that the sunshade assembly may have a defective track, mounting mechanism, or tensioning system that allows the material to detach or sag during normal use. The failure of an original factory-installed component should not compromise a driver’s visibility. I am requesting that NHTSA investigate whether similar failures are occurring in other Ford Explorer vehicles and determine whether this issue represents a widespread manufacturing or design defect requiring a safety recall. This issue directly affects driver visibility and should be evaluated as a potential vehicle safety defect rather than a cosmetic concern.

The contact owns a 2022 Ford Explorer. The contact stated that the front dashboard leather covering had deteriorated and shrunk, and the material covering the passenger’s side air bag had hardened and shrunk. The contact was concerned that during a crash, the air bag would not properly deploy because of a dashboard failure. The vehicle was taken to the local dealer, who informed the contact that the dashboard needed to be replaced. The manufacturer was notified of the failure. The failure mileage was 96,910.

Component Involved: Fuel Tube Support Bracket / Vapor Canister Purge Solenoid Bracket Assembly Part Number: GL3Z-9B325-B Diagnostic Code: P0496 / P1450 Description of Safety Hazard and Defect: I am writing to report a hazardous component defect on my vehicle that presents an immediate safety risk during standard operation. My vehicle triggered an active Check Engine Light with diagnostic trouble code P0496 (EVAP System High Purge Flow). An authorized Ford dealership technician confirmed that the internal mechanism within the purge solenoid bracket assembly (Part GL3Z-9B325-B) failed mechanically by seizing completely in the "stuck-open" position. The failure of this component introduces an uncontrolled, un-metered vacuum leak that continuously pulls raw, highly concentrated fuel vapors out of the charcoal canister directly into the engine's intake manifold. This creates an uncorrectable air-to-fuel ratio imbalance that manifests in severe, dangerous drivability hazards: 1. Engine Stalling in Traffic: The sudden influx of raw vapors disrupts combustion efficiency while idling or driving at low speeds, causing the vehicle to unexpectedly sputter, drop RPM, and stall out in active traffic conditions, creating an immediate crash risk. 2. Severe Hard-Starting/Refusal to Start: Immediately after refueling at a standard gas pump, the action of filling the tank forces massive amounts of vapor through the stuck-open valve. This completely floods the engine cylinders, causing the vehicle to aggressively crank without starting or stumble violently upon catching. This component is failing prematurely well before its intended design life across the EcoBoost engine lineup. Because a sudden engine stall in active intersections or on major highway corridors directly strips the driver of power steering and braking assistance, this systemic mechanical defect constitutes a clear vehicle safety hazard. I request that the NHTSA log this failure data to advance a mandatory safety recall.

I was in a middle school parking lot attempting to park my vehicle. My foot was not on the accelerator, and my foot was light depressed on the brake pedal as I was attempting to park the car prior to school release. The vehicle suddenly accelerated at a high rate, with no indicators on the dashboard that there was a mechanical/electrical issue. I had to swerve to avoid colliding with a parked vehicle and abruptly applied the brake pedal, which depressed into the floor board. This incident would have injured a child or parent at school release had I not arrived prior to end of day release. To summarize: Date/time: October 21, 2026 - 2:55 p.m. Vehicle: 2022 Ford Explorer Platinum Auto Hold: OFF Vehicle was in Drive and moving forward at parking/crawl speed. Accelerator pedal was not depressed and my foot was not near the accelerator. Vehicle suddenly accelerated forward with substantial force, consistent with heavy/full accelerator input. No warning lights or messages appeared before, during or immediately after the event. I had to abruptly steer away to avoid colliding with another vehicle.

Right control arm snapped while reversing into a parking spot

My mom was helping me strap my 3 year old and baby in the car seats of my 2022 ford explorer and said my car smelled like raw gas. I didn’t realize it because I was so used to it. As soon as she said something I did smell it. I had been getting headaches while driving but didn’t think much about it. I took it to the ford dealership and it needed a new purge valve and was causing the fuel in the cab. It could’ve ended up way worse if my mom hadn’t smelled the fuel and was there to help me strap the kids in.