What 1,163 owners told NHTSA about the 2020 Ford Explorer Police Intercept

The fabric on the sunroof fails out when opened and blocks view.

NHTSA ODI 11646397

-2020 Ford Explorer -Panoramic Sunroof Shade. -Sunroof shade sagging, blocking view from rear view mirror while driving. -Problem is reproduced every time I attempt to open/retract the shade. This is a recurrent problem with many 2020 Explorer owners. -Awaiting appointment with dealer for inspection. -No warnings prior to failure of shade retraction mechanism. Problem began 2-3 months ago.

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In May 2023 the passenger side headlight stopped working. For a few months it would intermittently work then go out. Then we had both headlights stop working. Took it to Ford dealership and they said it was just the passenger side headlight. Since it was LED they had to replace the entire assembly for at total with labor of $2,182.54. Now today Feb. 2025 the driver side LED headlight stopped working. Same issues as before with the same symptoms leading up to the light stop working. Took it to my local repair shop and they will need to replace the entire headlight for around $2,400. I am upset because of the safety issues with these headlights and the cost! Also, reading online there seems to be a lot of people with the same problems on these 2020 Ford Explorers.

NHTSA ODI 11644709

Panoramic sunroof shade began sagging over night and now can fall and block view of rear view mirror out of the back of vehicle.

NHTSA ODI 11644445

Sunshade does not retract and sags in the cabin of the vehicle

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Front headlight low beam. Light randomly turn off. Yes No Alert on dashboard to check manual which provides no information. Internet search reveals this is a very pervasive issue with this vehicles and there should be a recall by ford.

NHTSA ODI 11644280

The contact owns a 2020 Ford Explorer. The contact stated that the vehicle was taken to an independent mechanic for a routine oil change. While driving at 35 MPH, the vehicle began to make an abnormal knocking and squealing sound. The vehicle began to jerk. The driver turned off the vehicle. There were no warning lights illuminated. The contact stated that the failure was like the failure listed in NHTSA Campaign Number: 23V597000 (Engine and Engine Cooling). The vehicle was towed to the residence. The mechanic determined that the engine needed to be replaced. The vehicle was towed to the local dealer, where it was diagnosed that the engine, turbo, and battery needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 94,000.

NHTSA ODI 11643736

The contact owns a 2020 Ford Explorer. The contact stated while the vehicle was stationary, another vehicle collided with the passenger side of the vehicle and hit the rim. The wrench, the four-wheel drive, the brake, and the hillside warning lights illuminated after the crash. The vehicle was driven to the dealer. The vehicle was repaired for an axel that needed to be replaced, the module PMI was replaced, a revised part for the four-wheel drive shaft was replaced, and a module switch was replaced. The manufacturer was made aware of the failure and referred to the NHTSA Hotline. The failure mileage was approximately 61,800.

NHTSA ODI 11643744

Electrical shorting caused the transmission to improperly shift stalling the vehicle on a highway

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The contact owns a 2020 Ford Explorer. The contact stated that during cold weather conditions, the front driver’s and passenger’s side door latches failed to unlock to allow the doors to be opened. In addition, the contact was using the rear passenger’s side door to exit the vehicle safely. The vehicle was taken to a local dealer and both door latching cable assemblies were replaced; however, the failure reoccurred. The vehicle was taken back to the same local dealer where it was diagnosed that front door latching cable assemblies needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 67,000.

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Sun/Panoramic roof cloth sags if the clips that hold it in place break as they are very brittle. Happened multiple times already. Rear visibility is blocked due to it and cannot use the rear view mirror.

NHTSA ODI 11641931

The car pulls on the left when driving. And ticking noise

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When my truck is decreasing speed/on the downshift, there is a very hard jerk. I took it to my local Ford dealer and was told there’s an issue with my transmission.

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The contact owns a 2020 Ford Explorer. The contact stated while driving at 65 MPH with the cruise control engaged, the vehicle occasionally exceeded 85 MPH and accelerated independently. No warning light was illuminated. The vehicle was not taken to be diagnosed. The local dealer was contacted; however, the vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 72,000.

NHTSA ODI 11641809

1. Component: AWD system – Front Axle Disconnect Actuator / Intermediate Shaft • Failure Type: AWD system failed, preventing power transfer to front wheels • Availability for Inspection: Yes, diagnosed and confirmed by Zeigler Lincoln Ford 2. On Thursday, [XXX], while driving in a snowstorm with my two children, my 2020 Ford Explorer AWD system failed completely, leaving us stranded on an icy hill with no traction or ability to move. • My vehicle lost all AWD functionality, causing it to become immobilized on an active roadway in hazardous conditions. • We were trapped between two semi-trucks that were also stuck, creating a high-risk situation where a collision or multi-vehicle pileup could have occurred. • With freezing temperatures and no way to move, we were at risk of hypothermia while waiting for a tow truck. This was not an isolated issue. Ford acknowledges this AWD system defect under TSB 23-2174, meaning this failure can happen to any driver under similar conditions, creating a major safety hazard. 3. Yes. The issue was diagnosed and confirmed by Zeigler Lincoln Ford, who determined it was covered under TSB 23-2174. • Ford has officially acknowledged this defect but has not issued a recall. 4. Yes. The vehicle was inspected by Zeigler Lincoln Ford, and the AWD failure was confirmed as a front axle disconnect actuator/intermediate shaft defect. • Ford issued TSB 23-2174 to address the defect, proving that this is a known issue. • However, instead of issuing a recall, Ford is making owners pay for repairs out of pocket, despite the serious safety risk. 5. Yes. Prior to the AWD failure, I received a wrench icon warning (Powertrain Malfunction Indicator) on my dashboard. • Error codes C0631 and C0633 were later retrieved by the dealership, confirming AWD disconnect failure. • I had experienced intermittent AWD traction loss in winter conditions, but the system failed completely during the snowstorm incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11641806

The sunroof fabric fails to retract. When opening the sunroof, the fabric sags and blocks vision in the rearview mirror. I’m overseas active duty military and have not had it inspected. No warning lights are displayed.

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Transmission jerked in and out of low gears, causing very harsh shifting and lack of acceleration. Service shop at dealership found metal shaving in the transmission and replaced the whole thing. Vehicle only had 50k miles on it.

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The contact owns a 2020 Ford Explorer. The contact stated that while operating the vehicle, the interior sunroof shade cloth sagged down causing an obstruction of the rear window for the driver. The contact stated that the failure was due to a failed clip to the sunroof panel roller. The vehicle was not repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 78,000.

NHTSA ODI 11641452

Is making a noise and I have 2 incomplete recalls

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When downshifting from 7th to 6th gear it jerks hard and fluid and everything seems ok

NHTSA ODI 11640218

Check headlamp system see Manuel error message keeps coming up after replacing lighting modules. Led lights are working fine, but error keeps coming up. Dealership wants to keep replacing entire module which is around 2 grand per headlight. Replaced both modules and lights worked fine for about 24 hours before error message returns.

NHTSA ODI 11639803

Passenger low beam light is out. It is dangerous to drive at night. Confirmed by dealer. Component has not been inspected. The message center on the front dashboard said check headlamp system refer to owners manual. Owners manual tells you nothing.

NHTSA ODI 11639944

The tire pressure system for all four tires has completely went out on the monitoring system. It originally started where it was only on one tire then it happened to two then the final monitor keeps going in and out.

NHTSA ODI 11639724

The contact owns a 2020 Ford Explorer. The contact stated that while idling at a stop light or while the vehicle was parked, the vehicle was shaking abnormally. The check engine warning light was illuminated. The failure was intermittent at first but became a constant failure. The vehicle was taken to the dealer who diagnosed that the variable camshaft timing (VCT) system had failed and needed to be replaced. The failure was linked to an unknown Customer Satisfaction Program; however, the vehicle was not included. The vehicle was not repaired. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 60,000.

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I have recently have experienced engine failure with the 2020 Ford Explorer 2.3 ecoboost engine. I was driving on a 4 lane highway, specifically on a bridge, and I experienced loss of power and acceleration. At that time, the engine light came on. I managed to get home, with the vehicle seemed as if in limp mode. I had my vehicle towed to the Ford Dealer ship. The service manager stated that they believe it is complete engine failure. He believes the failure is in the cylinder walls which is due to coolant intrusion in cylinders 2 and 3. His suggestion is to change the "long block" at the costs of $12,284,51. Also, he expressed a concern with the transmission. It might be an issue with the computer, or wire harness. Which would be $1091.81. Plus, a couple sensors, spark plugs. In all The total repair costs are $16,904.16. I owe about $9,500. Prior to this, in 2022 the Turbo went out. It was replaced under the warranty at that time. This was at 90,000 miles. After doing some online research. There has also been a class-action lawsuit involving the 1.5L, 1.6L, and 2.0L EcoBoost engines. Owners of these engines reported issues such as coolant leaks leading to engine overheating and, in some cases, engine failure. The lawsuit claims that Ford was aware of these defects but did not take adequate steps to address them. There are some fantastic videos on youtube that explains and illustrates the reasons for the manufacture defect and engine failure. [XXX] I am a high mileage driver of highways and interstates. I understand that vehicles will have normal wear & tear. I now have 190,000 miles and no longer under warranty. However, based on my investigation, and other similar complaints about the 2020 Explorer with the same or similar issues, I believe there could be a defect with the Cylinder head just like the other ecoboost engines. Other ford explorer owners will likely experience the same as the add miles INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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