2021 Ford Explorer Complaints

SEATS — Filed 09/25/2026

About 3 months ago, every time I started the vehicle, I heard a whining noise coming from the 2nd row passenger seat that my [XXX] sits in with her car seat that We could not figure it out for awhile. I then took her car seat out of the car 2 weeks ago to clean underneath it and the seat automatically folded up with force. I jammed it back into the lock position and it would hold, sometimes for an hour or so and sometimes for a couple days before it started whining again and folding back up. I switched the car seat to the other seat and put my [XXX] in the seat that kept folding to see if it would fold on her and It folded up on her while I was driving down the interstate causing a big bruise on her arm and causing her to severely stub her toe on the bottom of the seat in front of her due to the seat sliding forward and folding with such force. I pulled over on the interstate and put her in the 3rd row. I reached out to FORD customer relations on September 29th and told them all of this and this was their reply. " There is not a remedy for that until maybe end of October so I would just stop driving the vehicle with your kids in it" We argued back and forth about how that was not possible because this is the vehicle that I bought to haul my kids around and eventually I asked for a supervisor to call me back. He called me back and left a voicemail and this is what he said " We cant fix something that we don't have parts for so call the dealership and get put on a call back list so they will call you when the new parts come in" I will be contacting the dealership on Monday as soon as it opens to get my car in asap or to ask for a loaner until I can get it fixed since it is not safe for my children or any other adult to ride in it. As of now nothing has been inspected . There is no warning lights that have came on the vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

STEERING,POWER TRAIN,ELECTRICAL SYSTEM — Filed 05/24/2026

NHTSA COMPLAINT: VIN [XXX]: Transmission cooler (Part 7869) ruptured, mixing fluid/coolant into corrosive glycol-acid in violation of SSM 52917. Contamination dissolved wiring insulation and delaminated clutch plates, causing systemic short circuits and CAN-bus load-shedding. Boiling fluid released toxic glycol/hydrocarbon vapors through HVAC ducts into the cabin without notice, creating an inhalation hazard. Vehicle available for inspection at South Bay Ford (BAR #XXX; captive 93 days).RISK: On XXX short circuits caused complete power steering assist dropout mid-transit. Steering locked during a turn, causing a crash into gate posts, endangering my minor children inside. Cabin chemical vapor inhalation caused respiratory tract irritation, dizziness, and headaches. Open recall hazards remain for visibility loss (Recall 26S14) and rollaway (Recall 26S48 parts backordered to 2027).CONFIRMATION: Contamination, a -1,212-mile odometer fraud discrepancy, and bricked electrical starting systems confirmed by dealer records XXX. Admitted unauthorized repairs to mask trouble codes and evade SSM 52917 confirmed in writing by Service Director [XXX] XXX, violating CA Bus & Prof Code 9884.9.HISTORY: Tracked under Ford RAV buyback #XXX, Corporate Escalation #[XXX], and CA Bureau of Automotive Repair Investigator [XXX] (Case #XXX). Total statutory loss is $54,628.75.SYMPTOMS: Transmission drops began XXX (42,319 miles). Dealer cleared codes and coerced 500 extra miles. XXX alerts included "Powertrain Malfunction" loops. Telematics registered false "Vehicle is On" loops. On XXX, dealer blocked diagnostics via a manufactured battery charge demand exactly 24 hours before federal Recall 26S48 launched. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

UNKNOWN OR OTHER — Filed 08/01/2026

I previously reported my rear view camera not working despite ford having many recalls for that problem. Now my shade for my sunroof when opened drops into my car & blocks my view from my rear view mirror. So now I have no camera view or physical view of what's behind me. I also have the same peeling metal on my buttons on my driver's door. The same one that was recalled on 2020 model. I cut my arm on it yesterday

UNKNOWN OR OTHER — Filed 04/01/2026

Chrome trim around the window power buttons de-laminate and have a sharp edge. I cut my finger on it.

STRUCTURE,VISIBILITY/WIPER — Filed 04/24/2026

I am reporting a safety incident involving a 2021 Ford Explorer. While driving at normal speed, the hood unexpectedly flew open and struck the windshield, completely obstructing visibility and causing damage. I did not open the hood prior to driving, and there were no prior warnings or indications of failure. The incident suggests a possible hood latch or secondary safety latch malfunction. I am submitting this report due to a serious safety concern involving sudden loss of driver visibility.

ELECTRICAL SYSTEM — Filed 02/28/2022

I am reporting a persistent and escalating electrical safety defect in a 2021 Ford Explorer. On February 28, 2022 (at approximately 10,542 miles), I formally reported a strong burning metal smell and the engine would be loud and idle high, there was abnormal noises and unusual electrical changes to the dealership (West Herr Ford). The dealer service advisor documented no problem found and told me not to worry about it. Over time, this unresolved electrical short and metal smell has resulted in a total system failure. In February 2026, the vehicle suddenly suffered a complete ‘black screen’ (APIM/infortainment failure) and a no-start condition. Most dangerously, the battery suddenly drains within days, which can lead to total loss of vehicle power while in motion, disabling power steering, braking assists and you can’t even put the car in neutral when this happens. I am gravely concerned that this unaddressed metal burning smoking/ electrical short issue poses a significant potential fire risk to myself, my passengers and other drivers. The same dealership has now had this car in there possession for 32 days and admits that what has happened is what happens while they have it and that they cannot find the root cause. Yet the previous service advisor from 2022, and the current service advisors ( gave the car back on 2/21/2026 and 3/6/2026 saying their was no problem) allowed the vehicle to remain on the public roads despite documented fire hazard symptoms.

UNKNOWN OR OTHER,ENGINE — Filed 09/26/2025

My vehicle is experiencing exhaust fume issue where the exhaust fumes are entering into the cabin for Explorer and Aviator models (Any model with the 3.0L Ecoobost). Upon inspection by 3rd party mechanic, it can be determined that the problematic catalytic converters that are not the one piece cast was installed on my vehicle from the factory. Speaking to other ST and Interceptor owners, the problem seems widespread to every 2021 model that Ford installed the multipiece welded catalytic converters. Apparently the cast part fairs better and is not subject to cracks. The recall originally covered the left side catalytic converter but the flawed design also affects the right side catalytic converter where many owners are experiencing this issue. This has affected all 3.0L Ecoboost engine vehicles. [XXX] I believe the recall should have extended to cover all 2020 and 2021 model year vehicles. There are forum posts where owners outside the recall have experienced the issue in addition to owners having to repeatedly replace the catalytic converters post warrant as Ford continued to reinstall bad catalytic converters as part of the repair process. I have driven this vehicle for several thousand miles with the issue and did not realize exhaust was leaking until notices of headaches and health issues as CO is odorless, causing CO2 levels to reach 3000+ inside the cabin at stop lights and blows in through the vents if A/C is on. I believe NHTSA should investigate this issue further and require Ford to replace both catalytic converters as this issue poses a serious health hazard, especially given the location of the exhaust leak and the commonplace occurrence. I am happy to forward to forums and provide evidence of this occurring. Ford considers lifetime of the vehicle to be ~150K miles and these exhausts do not last close to that, resulting in a massive expense and danger to US consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

AIR BAGS — Filed 09/06/2024

The airbag burnt a hole in a cotton shirt and then left 2nd and 3 degree burns on my side.

FIRERELATED — Filed 01/19/2025

The contact owned a 2021 Ford Explorer. The contact stated that the vehicle was parked in the driveway for over three hours before the vehicle caught on fire. The origin of the fire was unknown, however, the contact believes the fire originated from faulty electrical wiring. The vehicle was unoccupied during the fire. The location of the fire was the rear end of the vehicle. The fire department arrived to extinguish the fire. A fire department report was filed. A police report was not filed. The vehicle was destroyed. The local dealer was contacted, and the vehicle was not diagnosed as it was determined to be a complete loss. The manufacturer was notified of the failure. The approximate failure mileage was 75,000.

VISIBILITY,LATCHES/LOCKS/LINKAGES — Filed 10/18/2024

The contact's son owns a 2021 Ford Explorer. The contact stated that while driving at 5 MPH down a hill and making a left turn, the hood was unintentionally released, swung open, and hit the front windshield causing it to shatter. There was an abnormal snapping or popping sound detected. The driver pulled over immediately since their view was obstructed. No warning lights were illuminated before the failure however after the hood shattered the windshield the "hood open sensor" light was displayed. The driver's pregnant fiancé was occupying the front passenger's side seat and sustained injuries and pain to her left side. There was glass in her lap, and medical attention was provided. The vehicle was towed to the local dealer but was not diagnosed or repaired. The manufacturer was notified of the failure and referred to the NHTSA Hotline. The approximate failure mileage was 55,401.

ELECTRICAL SYSTEM,ENGINE — Filed 04/08/2024

[XXX] after driving less than 10 min. warning signs flashed on screen. I immediately pulled off the road where the vehicle completely shut down and realized my 2021 Ford Explorer was on fire. Bystanders attempted to put the fire out with fire extinguishers but were unsuccessful. My passenger and I opened our doors, I exited and attempted to open trunk to remove wheelchair but could not (because door is electrical). My passenger flung himself onto the ground until bystanders came with a rolling office chair to remove him away from the burning vehicle. Had the bystanders not been there I do not know how I would have been able to move my passenger (25 year old, 200 lb male) away from the burning vehicle. Fire Marshall could not determine cause of fire because vehicle was completely melted/too damaged. Ford Motor Company reviewed photos I sent to them but claims they could not determine cause of fire. The vehicle was properly maintained with routine oil changes. There were no issues with the vehicle prior to this incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

SEAT BELTS — Filed 07/17/2024

The contact owned a 2021 Ford Explorer. The contact was stopped at an intersection traffic signal when she was crashed from behind by another vehicle. The contact's seat belt pretensioner failed to lock and was not able to restrain her. The contact's face hit the steering wheel. The contact had suffered a broken nose, and bruises on her arms. The contact was transported by ambulance to a hospital. The vehicle had extensive crush damage to the rear bumper, lift gate. The vehicle was towed to an impound lot and later declared a total loss by her insurance provider. The police were on scene and issued a report. The manufacturer was informed of the failure. The failure mileage was 36,606.

ELECTRICAL SYSTEM,WHEELS,UNKNOWN OR OTHER — Filed 06/27/2024

While driving down the interstate, the tires (rear passenger?) suddenly locked/stuck. This caused vehicle to lose control, 360, and slam into the guardrails. Prior to this incident, when the car was turned on, it stalled a bit like it was about to turn off. This lasted for a few seconds, but returned to normal. So may be a component of electrical and/or directly related to the rear tire. There were no warning messages. Driver was thankful injuries did not occur. Could have flipped, or slammed into other cars, trees, etc. This is a serious issue. While the vehicle was being loaded onto the wrecker, in neutral, the rear passenger tire was visibly stuck. This was observed by owner, husband, police officer and tow company. When offloading from the tow truck, the tire made a loud pop and movement returned to normal. Vehicle is currently at the shop (ford dealership). Will have more information next week from their diagnostic studies. It is available for inspection upon request.

SERVICE BRAKES,ENGINE,FUEL/PROPULSION SYSTEM — Filed 04/09/2024

The recall to replace the rear axle bolt was completed and new boil installed. They left the automatic emergency brake program engager which results in the vehicle lurching forward or backward when shifted into gear and results in collisions with other vehicles as the collision detection system is not working.

SERVICE BRAKES — Filed 07/01/2023

On July 1, 2023, I had the vehicle parked on an incline with a trailer attached to the vehicle. The vehicle was in Park and the Parking Brake was set. As I attempted to unload the trailer, the vehicle started to move and rolled down the incline. I was on the trailer and was moving with the vehicle, I could have been injured but fortunately the vehicle rolled into a pile of topsoil before it could pick up too much speed. However, both the vehicle and trailer were damaged My safety was put at risk as the vehicle was moving without anyone in it. This occurred in my driveway but could have happened on a busy street. I still own the vehicle and it is available for inspection. There were no indications, warning lamps, etc. that would have notified me of the impending failure. I contacted Ford and they have been of little help. It took them 2-1/2 months to get me scheduled to have one of their field service engineers to inspect the vehicle. I was not allowed to talk to the field service engineer and that person did not attempt to duplicate the conditions which caused the failure. The report from Ford to me said they inspected the vehicle on a lift. They said they could not find a problem and said they will take no further action. They have been extremely uncooperative and do not seem the least concerned about the safety of the vehicle. I am concerned that the problem will recur and cause significant damage or injury so I take precautions whenever I park it.

POWER TRAIN,ELECTRICAL SYSTEM,SERVICE BRAKES — Filed 12/07/2022

After receiving a Ford issued recall for a potential rear axle bolt fracture, the dealer reprogrammed the PCM per Ford's reported repair solution. After this PCM update, the vehicle would randomly slam to a complete stop while driving. It happened several times with 3 different drivers (myself, my wife, and my son), each happening at 30-35 mph or less. It was usually preceeded by an audible clicking sound, but not always. We took the vehicle to the dealership several times, but they said they were not able to reproduce the issue, and continually returned the vehicle to us despite our grave concern for high risk of crash and injury. We even contacted Ford's customer service and legal departments several times, who ultimately refused to allow us to continue using a loaner vehicle and demanded that we return the loaner and retake possession of our Explorer because they said they had not received any other similar complaints, and their field engineer could not reproduce the issue and cleared the vehicle as safe, although Ford was never able to supply us with service records proving the repairs they purported despite our repeated inquiries. Ultimately, the issue happened again, and slammed while driving down a hill at about 40-50 mph, but this time the slamming was immediately followed by seemingly disengaging the drivetrain and causing the vehicle to roll downhill with no ability to accelerate, ultimately causing me to roll into a utility pole. Ford has since repurchased the vehicle, but given the severe safety risk associated with this issue and Ford's poor handling of our situation, I wanted others and the NHTSA to be aware in case other similar issues are reported in a effort to protect others from potential injury, especially in light of the increasing number if PCM-related issues and recalls reported against Ford...one of which was a PCM recall pertaining to our reported issue, but was not issued until after our repurchase was complete.

SEATS — Filed 03/21/2023

Front passenger seat overheated and caused 2nd degree burns

POWER TRAIN — Filed 06/04/2022

The contact owns a 2021 Ford Explorer. The contact stated that after his wife set the vehicle to "Park" while the engine was running, as she exited, the vehicle lurched forward and crashed into the garage back wall. There was no damage to the vehicle, however, there was damage to the garage back wall. The contact stated his wife saw no warning lights were illuminated. The contact's wife got back into the vehicle and observed that the gear shift lever was still in "Park" and she shut the vehicle off. The contact had not taken the vehicle to a local dealer, or an independent mechanic. The vehicle had not been diagnosed or repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 10,000.

AIR BAGS,VEHICLE SPEED CONTROL,FORWARD COLLISION AVOIDANCE — Filed 04/29/2022

The contact owns a 2021 Ford Explorer. The contact stated the adaptive cruise control and the collision avoidance systems would malfunction. The vehicle would suddenly deactivate the cruise control and the collision avoidance would detect a non-existing object and stop the vehicle from also turning to avoid the crash. The contact stated that while idled at a stop light when the vehicle suddenly accelerated rear-ending the vehicle in front. The air bags did not deploy however the acceleration did not reach high enough speeds for such a response. A police report was not filed. The vehicle was not towed. There were no injuries or medical attention needed. The contact took the vehicle to the dealer however the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failures. The approximate failure mileage was 10,000.

ELECTRICAL SYSTEM — Filed 12/08/2021

The contact owns a 2021 Ford Explorer. The contact stated that after she had parked her vehicle and retrieved items out of the liftgate compartment; the vehicle began to roll back independently towards her. A witness alerted her that the vehicle was rolling towards her; the contact moved out of the way. She then opened her driver-side door as the vehicle proceeded to roll back; the contact was pinned in between the concrete post and the driver-side door as the vehicle eventually stopped. Witnesses assisted her and aided her away from the vehicle which bruised her left arm. The contact did not seek medical attention for the injury. The contact called the dealer and they offered no assistance. The contact then had the vehicle towed to a different dealer Lithia Ford Idaho Falls(980 W Broadway St, Idaho Falls, ID 83402) where the driver-side door was replaced. The manufacturer was also notified of the failure and she was given a case number. The cement post was damaged as a result of the failure. The police were called after the failure and a report was filed. The vehicle was repaired; however, the cause of the failure had yet to be determined. The failure mileage was approximately 4,500.

ELECTRICAL SYSTEM,ENGINE — Filed 02/23/2022

Got it in the car and pushed the push start button. The cars engine turned over only half way and started to restart and turn over multiple times even though the motor was running halfway. This went on for 15 minutes until i opened up the hood and looked down and after a couple minutes the engine seized and turned off and started smoking, shortly after started on fire from the bottom of the engine. The fire went on for 10 minutes until we turned it off.

FORWARD COLLISION AVOIDANCE — Filed 03/06/2022

The contact leases a 2021 Ford Explorer. The contact stated while his wife was driving at 25 MPH with Co-pilot 360 assist mode and the evasive steering assist engaged, she lost control of the steering wheel. The contact stated that his wife could not feel the connection between the steering wheel and the front tires of the vehicle. The contact stated that the vehicle made a sharp right turn and crashed into a telephone pole. There were no warning lights illuminated. The air bags deployed. The contact 's wife sustained bruises and lesions on the ankle, knee cap, arms and on her left breast but did not seek medical assistance. A police report was filed. The vehicle was towed to a tow lot. The vehicle was then towed to another tow lot where it was totaled. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the contact that they could not assist. The failure mileage was approximately 12,000.

ELECTRICAL SYSTEM — Filed 01/28/2022

The contact owned a 2021 Ford Explorer which was used to haul a 2002 Opus OP. The contact stated that while the vehicle was at the RV dealer for installations to be performed the vehicle caught on fire and was destroyed. The contact was informed after the installation of an electronic brake controller was completed the vehicle was parked and approximately 20 minutes later flames were present coming from the engine compartment. The fire department was called to the scene and extinguished the flames. The vehicle was destroyed. Prior to the incident an electric brake controller was installed in the vehicle and wired DC to DC in order to send a charge to the tow vehicle. The manufacturer was made aware of the failure and a case was opened. The fire department indicated that the fire originated in the engine compartment. A fire report was taken at the scene. The failure mileage was 3,807.

ENGINE — Filed 01/12/2022

A police officer complained of a strong odor of exhaust coming through the hvac vents. Officer complained of a light dizziness feeling. Suv was grounded from service. Complaint was verified. Upon opening of the hood a odor of exhaust gas was smelled on the right side of the motor. No visible leaks could be heard or seen. Suv was driven to our local Ford dealer for repair.

UNKNOWN OR OTHER — Filed 10/20/2021

I took possession of a Ford Explorer approximately October 12, 2021. Two weeks later on October 20, 2021, I took the car to a carwash and after paying with a credit card, the barrier went up and as I was putting my card back into my wallet, and my foot not on the accelerator, the car took off on its' own to approximately 20 to 25 mph, so I applied the brakes and the pedal went to the floor with no braking. I applied the brakes continually, as the car jumped a curb traveled through a meadow went through a fence and crashed into a tree. I had the car towed to the dealer so they could analyze what went wrong and they said they couldn't find anything wrong, but they couldn't say as to why the Explorer spontaneously accelerated without brakes. The carwash had a video surveillance system and the video clearly shows the car accelerating, jumping the curb and eventually going into the forest to hit a tree. It is a blessing that I was in a remote area with no people around as the only control I had for the vehicle was steering and had there been people around someone would have been injured or killed. I contacted the Texas DMV Lemon Law department and they couldn't help because I hadn't tried to get the malfunction repaired more than three times. They did recommend I contact the NHTSA as safety of this vehicle and possibly others of the type represent a major safety hazard. Is there anything the NHTSA can do to look into this case and first see that this malfunction is fixed on future products and second see that I can be treated fairly by the Dealer and Ford Motor Company? The car has been declared a total loss, as it would cost too much to repair. It is in a AAA Insurance lot.