What 2,423 owners told NHTSA about the 2016 Ford Explorer

Transmission died with no warning at under 80k miles. The car lost its ability to accelerate while merging on the highway. Got off highway and to friends home. Car would not reverse and could not accelerate over 15mph. Had it towed to AAA repair shop. According to AAA repair shop a new Transmission is needed. This is unacceptable with only 80k miles, never received warning lights, and regular maintenance. 2016 Ford Explorer has know Transmission issues.

NHTSA ODI 11490505

The contact owns a 2016 Ford Explorer. The contact stated while stopped in traffic, the vehicle was shuddering and appeared to be going into idle mode. The contact depressed the accelerator pedal and the vehicle responded as needed. The vehicle was taken to an independent mechanic where it was diagnosed that the torque converter needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and informed the contact that the vehicle was previously repaired under Customer Satisfaction Program Number: 20N07, which had expired. The failure mileage was 130,000.

NHTSA ODI 11489017

I felt a thumping when turning the steering wheel and took it to the dealership who kept it for two days to attempt to replicate the same noise but they were unable to reproduce or replicate. Two or maybe three months later, the thumping noise turned into a clicking noise. Again, I immediately took it to the Ford dealership and fortunately a mechanic was still on duty. They test drove the vehicle and heard the same noise. They ask if I could leave the vehicle for more testing with their suspension specialist and they will contact me the next day. The next day they contacted me and I was told 'this is a common problem and Ford is aware of issue but has not issued a recall'. Concerned about the comment I took it to a second Ford dealership. The second dealership kept it for a day and of course they could not replicate the thumping or clicking sound. They even inspected the steering/wheel components but found nothing. Worried, I did some additional research and found this website with other people complaining about the same issue https://www.carcomplaints.com/Ford/Explorer/2016/steering/steering-rack_and_pinion.shtml I even found a few YouTube videos addressing the same problem. October is here and winter is about to set in and my vehicle is still thumping and clicking. I am driving the vehicle but concerned I am putting my safety and the safety of others at risk. Based on the information I found, it is clear that I am not the only one with this issue.

NHTSA ODI 11488083

You can smell a sickly metal burning smell in the cabin when accelerating to get onto a freeway.

NHTSA ODI 11481679

The contact owns a 2016 Ford Explorer. The contact stated while driving at various speeds, the vehicle was shuddering significantly and was emitting abnormal rumbling sounds. There were no warning lights illuminated. The vehicle was taken to the dealer who informed the contact that they could not duplicate the failure. The vehicle was taken to a second dealer Big Valley Ford, Inc. (M-28, Ewen, MI 49925), where it was diagnosed that the driveshaft needed to be replaced. However, the parts were on national backorder. The vehicle was taken to an independent mechanic where it was diagnosed that the driveshaft needed to be replaced. The driveshaft was replaced. However, the failure persisted. The vehicle was taken back to the independent mechanic where it was diagnosed that the transfer case needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance as the vehicle was out of warranty. The failure mileage was approximately 47,075.

NHTSA ODI 11479391

Check engine light came on low engine oil pressure light come on made loud knocking noise regular maintenance 147k miles vehicle is at mechanic shop estimate total $1500-$2500 to fix do not have money for repairs

NHTSA ODI 11478473

The engine shut off when driving on the highway at 65 and the wrench light came on ... I could not navigate the vehicle...took it to the Legacy Ford dealership and was informed that the Electronic Throttle Body needed to be replaced...I believe ford had that on a recall back in 2017 but not for my VIN....The dealership said that my VIN does not qualify for the recall to my surprise

NHTSA ODI 11477805

The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle stalled. There were no warning lights illuminated. The vehicle was taken to the local dealer where it was diagnosed and determined that the transmission needed to be replaced. The manufacturer was contacted and referred the contact to the NHTSA for assistance. The contact related the failure to NHTSA Campaign Number: 20V692000 (Power Train). The failure mileage was approximately 180.000.

NHTSA ODI 11476854

My vehicle build date is May 10, 2015 @ Chicago plant. NHTSA put out a recall on my vehicle but it wasn't attached to my VIN # and my vehicle is currently having said recall problems. The recall was NHTSA-20-V-692. Is there a way to get it added to my VIN please

NHTSA ODI 11476524

The contact owns a 2016 Ford Explorer. The contact stated while driving 50 MPH, the vehicle was vibrating abnormally. Additionally, while attempting to accelerate the vehicle failed to respond. The check engine warning light was illuminated. The vehicle was taken to the local dealer and diagnosed with failure with the torque converter. The vehicle was not repaired. The manufacturer was notified of the failure. The contact related the failure to Manufacturer Communication Number: 20N07-S2. The approximate failure mileage was 60,000.

NHTSA ODI 11475885

The contact owns a 2016 Ford Explorer. The contact stated while driving 65 MPH, the vehicle unintentionally downshifted without warning. The contact called the manufacturer and was informed that his vehicle was included in a customer satisfaction program; the contact scheduled an appointment at a local dealer for service. The contact took the vehicle to the dealer where she was informed that the transmission was defective and that the recall did not apply to the vehicle. The vehicle had yet to be repaired and remained in the possession of the dealer. The failure mileage was 72,000.

NHTSA ODI 11474457

The contact owns a 2016 Ford Explorer. The vehicle had previously been serviced by an independent mechanic who replaced the engine and two engine cylinders. The contact stated that while driving at an undisclosed speed, the gear shifter was unable to shift to the intended gear. Additionally, the vehicle jerked and hesitated during acceleration. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 71,600. The consumer stated this is the 2nd engine and still having problems with the engine stalling.

NHTSA ODI 11472796

The contact owns a 2016 Ford Explorer. The contact stated while driving 40 MPH, the accelerator pedal was depressed and the vehicle started jerking and sputtering. There was no warning light illuminated. The vehicle was towed to an independent mechanic where it was diagnosed that the transmission had failed. The vehicle was towed to the transmission specialist where it was diagnosed that the transmission needed to be rebuilt. The vehicle was repaired; however, the failure reoccurred a year later. The vehicle was taken back to the transmission specialist where the torque converter was replaced; however, the failure persisted. The contact stated the vehicle was shifting hard while driving and was jerking upon acceleration. The vehicle was taken to an independent mechanic where the engine mounts were replaced twice. The vehicle was repaired; however, the failure persisted. The contact became aware of Ford Technical Service Bulletin Number: 20-2271, which he associated with the torque converter failure. The independent mechanic informed the contact that the vibration caused by the torque converter failure was damaging the engine mounts, causing the engine mounts to be repaired often. The dealer was notified of the failure and referred the contact to the manufacturer. The manufacturer was notified of the failure but did not provide any assistance. The failure mileage was approximately 45,000.

NHTSA ODI 11471431

Water pump failure no warning car over heats and water pump cost over $2000 to repair no option but to take to a dealer

NHTSA ODI 11470738

The contact owns a 2016 Ford Explorer. The contact stated while driving approximately 35 MPH, the vehicle was vibrating while the brake pedal was depressed. The contact stated that on several occasions while driving the vehicle stalled without warning. The vehicle was taken to the local dealer to be diagnosed. The contact was informed that the water pump was leaking causing a mixture of the engine oil and coolant. The contact was also notified of a front axle failure. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 109,000.

NHTSA ODI 11467300

The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, the transmission became inoperable. The check engine warning light was illuminated. The vehicle was taken to the local dealer where it was diagnosed that the torque convertor needed to be replaced. The vehicle was repaired however, the failure recurred. The manufacturer was contacted and referred the contact to NHTSA. The approximate failure mileage was 75,000.

NHTSA ODI 11464394

Vehicle started overheating, when inspected I notice a coolant leak. Had it diagnosed, outcome was water pump leaking. Vehicle only has about 58685 miles. Warranty expired and extended warranty also expired. Not sure why the water pump started to leak at such low milage. Vehicle is currently at the Ford Dealer for repairs.

NHTSA ODI 11463287

The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, there was a clicking sound coming from the vehicle and then there was an explosion. There was smoke coming from under the hood of the vehicle. The vehicle was towed to an independent mechanic who diagnosed that the PTU, transfer case and differential had exploded. The mechanic informed the contact that the PTU, transfer case and differential needed to be replaced. The vehicle was not repaired and remained at the independent mechanic. The manufacturer was made aware of the failure and advised the contact to file a complaint with NHTSA. The manufacturer informed the contact that the warranty had expired and to research the lemon law. The failure mileage was approximately 85,000.

NHTSA ODI 11462282

While driving would shudder when getting to approx. 60-65mph. No check engine light. Dealer stated could not diagnose if no check engine light on. This went on for 1.5 years. I kept taking back but still no light. March 2022 it started running really rough while sitting at a stop light, no power at take off. Took to the dealer who said it was covered , diagnosed it as Torque Converter, and pump waited 4 weeks to get parts after being told twice covered 100% but then found out not covered as when it was there previously they did not do the Customer Satisfaction Program 20N07 where PCM reflash was required. Now Ford corp and dealer say they are not covering this. Why did the dealer not advise of this while there before this program expired.

NHTSA ODI 11460836

The contact owns a 2016 Ford Explorer. The contact stated while driving approximately 65 MPH, the vehicle began to shake and shudder when the accelerator pedal was depressed. The contact stated that to control the shudder she slowed the vehicle to the point that the motion stopped and then slowly accelerated back to highway speeds. The contact stated that the shuddering occurred any time the contact attempted to accelerate. The contact stated no warning light was illuminated. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the power train control module needed to be updated and the transmission torque converter needed to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 103,000.

NHTSA ODI 11460064

I was driving along in town and heard a real loud pop sound and the car jerked. The front started smoking heavily. I get off to the nearest parking lot and fluids had spewed underneath and there was a small fire from this that went out. I had two children both in child restraints that had to be removed from the vehicle, thankfully my husband was with me. It was towed to two repair shops whom both stated the PTU had exploded and broke the transmission as well. I tried to get assistance through Ford and have hit a dead end. It is at the local dealership where they claim the ptu exploded, broke transmission and cracked the engine block resulting in close to $14,000 dollars needed in repairs. This vehicle was running completely fine, no lights had been displaying on the dash. Consumer stated dealer is blaming the defects on a tread pattern on 1 tire(not size).

NHTSA ODI 11459428

The contact owns a 2016 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle was shaking. The vehicle was taken to the dealer where it was diagnosed that the transmission and engine mounts were damaged and needed to be replaced. The dealer replaced the transmission and engine mounts; however, the failure recurred. The dealer was made aware of the failure but informed the contact that a recall for the transmission had expired. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 77,235.

NHTSA ODI 11456944

Water pump has failed. Causing the engine to shutter and stop running normally. This happened on the highway with kids on board. Water pump is internally and cost of repairs are more expensive than what is fair for a consumer. No one should pay for that, it’s misleading at least. If they were to warn that a regular wear an tear part would causes thousands. No one would buy Ford. The responsibility should be Ford and not the consumer

NHTSA ODI 11456533

The contact owns a 2016 Ford Explorer. The contact stated that while driving at 65 MPH, there was a loud snap sound and smoke came from the air vents. The contact rolled down the windows and pulled over while smoke was billowing from the vehicle. The vehicle was towed to an independent mechanic and diagnosed with engine and transfer case housing failure, where the transfer case housing was fractured in half. The vehicle was repaired with an engine and transfer case housing replacement. The dealer and Napleton Ford in Libertyville (1010 S Milwaukee Ave, Libertyville, IL 60048) were made aware of the failure but informed the contact that the vehicle was out of warranty and the parts for the repair were not available. The manufacturer was made aware of the failure and referred the contact to file a complaint with NHTSA. The failure mileage was approximately 88,000.

NHTSA ODI 11446338

The Power transfer unit is leaking fluid onto the exhaust and it caught on fire as I pulled into my driveway. I was able to extinguish the fire before any damage was done. There is also a nauseous odor in the cabin of the vehicle that makes me sick, burns my eyes every time I drive my vehicle. I was told by a mechanic that this was the fluid from the PTU burning Did some research and discovered this is a common problem with these PTU's leaking fluid. Very concerned now that it will catch on fire again and cause damage or even a wreak if it locks up. I fear that this could harm me or someone else if this problem is not fixed ASAP. I have no other vehicle and not sure how to even get it fixed. The dealership said it would cost around $2000 to have it fixed. I would like someone to look at this issue, Ford advised that is not there problem and its not covered by any recalls. There is no way of knowing if it catches on fire going down the road until its actually on fire.

NHTSA ODI 11446083