What 710 owners told NHTSA about the 2018 Ford Explorer Gas

While driving at highway speed on a 2-lane highway with three children under the age of [XXX] in the vehicle, my 2018 Ford Explorer experienced sudden complete engine failure with no prior warning. No warning lights, no temperature gauge change, no unusual sounds. The vehicle went from operating normally to catastrophic failure instantaneously, forcing me to sharply cross active traffic to exit the roadway. The vehicle came to rest near a train track. The root cause was internal water pump failure. Ford's design places the water pump inside the engine, causing coolant to leak internally with no external indicators and no dashboard warning until catastrophic damage has already occurred. Ford did not install a coolant level sensor in the reservoir, and the only coolant warning available is an overheating alert, which never triggered. I had taken every reasonable precaution. Two thousand miles prior, an oil change showed no coolant contamination. One week prior, I physically checked the coolant level and it was within safe range. Ford's design gave me zero opportunity to detect or prevent this failure. This is a known recurring issue. Over 86 engine complaints have been filed with NHTSA for this model year alone and Ford has been aware of this defect since at least 2007. Despite class action litigation in both Canada and the United States, Ford has not issued a U.S. recall. Repair costs exceed $9,000. I am requesting NHTSA open a formal investigation and compel Ford to issue a U.S. recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11749510

The High-Speed Cooling Fan Motor Relay (Recall 21N01) and the Exterior A-Pillar Apical Molding (Recall 24V031) failed on my vehicle. The cooling fan caused the engine to overheat repeatedly, and the vehicle became undrivable. Unfortunately, I no longer have the vehicle, as it was surrendered to my bank and later sold at auction. However, service records, diagnostic reports, and recall information are available upon request. The overheating engine presented a significant safety risk while driving, as it could have caused the vehicle to stall or catch fire. A AAA roadside technician confirmed that the vehicle was unsafe to drive due to the overheating issue. This defect left me stranded, requiring alternative transportation and creating a hazard for others on the road had I continued driving the vehicle. Yes, the problem was confirmed by a AAA roadside technician, who performed a diagnostic scan and identified that the engine overheating was due to a defective cooling fan relay. The issue aligns with Recall 21N01. The molding defect (Recall 24V031) was not specifically inspected, but it was noted as part of the recall documentation. No, the vehicle was not inspected by Ford or any other representatives after the issues arose. I checked Ford’s website in February 2024 and learned about the recalls, but I was never notified by Ford about these safety defects while I owned the vehicle. AAA provided the only diagnostic assessment before I surrendered the vehicle to my bank. Yes, there were symptoms prior to the failure. The vehicle’s engine temperature warning light came on repeatedly, and the battery required constant recharging. The overheating symptoms first appeared in February 2024, and the vehicle became completely undrivable the next day.

NHTSA ODI 11640982

My 2018 Ford Explorer rolled backwards down a hill while in park and engine off.

NHTSA ODI 11640308

Vehicle had a major mechanical issue that ignited a fire in the engine compartment. The fire quickly spread to the passenger compartment of the vehicle and totally engulfed the unit causing major damage to the entire vehicle. The vehicle is an obvious total loss.

NHTSA ODI 11473554

WE TOOK OUR 2018 FORD EXPLORER INTO THE SHOP LAST WINTER COMPLAINING OF A BAD SMELL. THE SHOP KEPT OUR CAR FOR ABOUT 5 DAYS AND SAID THERE WAS NOTHING WRONG. 2 WEEKS AGO MY WIFE WENT TO THE ER AND WAS DIAGNOSED WITH CARBON MONOXIDE POISONING. WE BEGAN WORKING WITH FOR TO HELP GET THIS FIXED, 5 DAYS LATER SHE PASSED OUT AT THE WHEEL AND WRECKED INTO A TELEPHONE POLL. WHILE AT THE ER THERE WAS CARBON MONOXIDE IN HER BLOOD AGAIN. THANK GOODNESS SHE DIDN'T HIT A FAMILY OR SOMETHING WORSE. SINCE THEN FORD HAS REFUSED TO WORK WITH US SINCE THE CAR IS WRECKED. THIS IS A PROBLEM AND NEEDS TO BE LOOKED INTO!*DT*JB*DT *TR

NHTSA ODI 11385749

TL* THE CONTACT LEASED A 2018 FORD EXPLORER. THE CONTACT DETECTED AN ABNORMAL FUEL ODOR INSIDE THE VEHICLE THAT WAS SO STRONG, SHE COULD TASTE FUEL. TOWNE AUTO GROUP (3535 SOUTHWESTERN BLVD, ORCHARD PARK, NY 14127, (716) 662-6500) WAS NOTIFIED OF THE FAILURE, BUT WAS UNABLE TO REPLICATE, DIAGNOSE, AND PROVIDE A REMEDY AFTER SEVERAL VISITS. THE DEALER LATER REPLACED THE DOOR SEALS, BUT THE FAILURE CONTINUED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 18V807000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT A PASSENGER INSIDE THE VEHICLE EXPERIENCED NAUSEA AND HEADACHES WHILE THE VEHICLE WAS IN OPERATION. MEDICAL ATTENTION WAS NOT RECEIVED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA ACTION NUMBER: EA17002 (STRUCTURE, ENGINE AND ENGINE COOLING). IN ADDITION, THE CONTACT WAS UNABLE TO USE THE AIR CONDITIONER AND HEATING, AND HAD TO CLOSE THE VENTS DUE TO AN ASTHMA CONDITION. THE APPROXIMATE FAILURE MILEAGE WAS 4,278.

NHTSA ODI 11166470

EXHAUST FUMES ENTERING THE VEHICLE. FORD ENGINEER INSPECTED AND FOUND 3PPM ENTERING CABIN IN LESS THAN AN HOUR. FORD STATES THIS IS NORMAL. OVER 3 HOURS IN THE CAR CAUSES PHYSICAL ILLNESS, FORD DENYING ANY RESPONSIBILITY. VEHICLE IN MOTION ON HIGHWAY OVER 40MPH. FORD ENGINEERING REPORT WILL BE AVAILABLE TO ME WITHIN THE NEXT 48 HOURS. CAUSED PHYSICAL ILLNESS, DIZZINESS AND VOMITING.

NHTSA ODI 11142733

EXHAUST FUMES ARE ENTERING THE CABIN DURING ACCELERATION AND WHEN THE AC IS ON. SEVERAL FAMILY MEMBERS HAVE COMPLAINED ABOUT THE SMELL WITHIN THE CABIN. I PERSONALLY HAVE EXPERIENCED HEADACHES AND BURNING EYES BECAUSE OF THE ISSUE. IT SMELLS LIKE BURNT HAIR. THIS IS A FAMILY VEHICLE USED TO TRANSPORT MY ENTIRE FAMILY INCLUDING MY 5 MONTH OLD BABY. THIS SMELL IS MAKING EVERYONE NAUSEOUS.

NHTSA ODI 11111383