What 398 owners told NHTSA about the 2021 Ford Explorer Gas

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.

NHTSA ODI 11728030

[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)

NHTSA ODI 11610148

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.

NHTSA ODI 11597713

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.

NHTSA ODI 11517162

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.

NHTSA ODI 11465778

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.

NHTSA ODI 11459057

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.

NHTSA ODI 11449762