What 102 owners told NHTSA about the 2023 Ford Explorer Gas

Faint popping and knocking sound coming from front suspension, LOUD clunk coming from rear suspension when going over bumps. Both seem to cause vehicle to be floaty while driving. Also headlights sometime flicker while driving with switch in auto position and sometimes will not shut off after exiting vehicle ( have to turn switch to off position and then back to auto to resolve ) Vehicle has approximately 21k miles on it but off warranty due to time. Will be bringing into local repair shop soon.

NHTSA ODI 11749497

Premature leaking and failure on rear shocks absorbers. Premature failure could lead to handling issues and interference with driver assist handling, action control etc. Some say this is a know issue but not one that has prompted a recall

NHTSA ODI 11744038

The rear subframe bushing is torn, resulting in the rear of the vehicle to sway side to side when traveling down the road at highway speeds, making it difficult to maintain lanes. Bushings are not covered by the 60k power train warranty, and resulting in a 2-3,000 dollar repair due to subframe in rear of vehicle needing dropped and bushing pressed out or entire subframe to be replaced.

NHTSA ODI 11743490

My 2023 Ford Explorer (VIN: [XXX] ) has a persistent front suspension clunk/rattle/knock when driving over small bumps or uneven pavement at low speeds (8–20 mph). The noise is repeatable and has progressively worsened. It matches the condition described in Ford Special Service Message SSM 52405, which identifies a manufacturing defect involving a loose internal pressure tube inside the front strut assembly on 2023 Explorers built between December 1, 2022 and August 31, 2023. My vehicle falls inside this build range. This defect affects vehicle stability, steering control, and suspension performance over bumps and uneven surfaces. The internal looseness in the strut assembly creates unpredictable handling characteristics, which is a safety issue. Multiple owners have reported the same symptoms, and Ford has not issued a recall. I am requesting that NHTSA investigate this defect and Ford’s handling of repairs, as owners are being asked to pay out‑of‑pocket for repairs related to a known manufacturing defect that affects safe vehicle operation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11728983

Struts rattle and shake aggressively while driving

NHTSA ODI 11717140

I noticed a loud squeak when driving over bumps at lower speeds. Almost sounds like a bad shock or spring. I am not sure.

NHTSA ODI 11676040

The contact owns a 2023 Ford Explorer. The contact stated while driving at an undisclosed speed, the steering wheel failed to turn into the intended direction. In addition, the contact stated the vehicle failed to remain in the intended lane while driving. The vehicle was taken to the dealer where it was diagnosed and determined that the shocks and struts needed to be replaced. The vehicle was repaired. In addition, the contact stated the vehicle had been taken to the dealer several times prior to the failure. The vehicle was taken to an alternate dealer where it was diagnosed with strut mount failures. The contact was informed that the strut mounts needed to be replaced. The vehicle was being repaired. The manufacturer was made aware of the failure and a case was filed. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 18,000.

NHTSA ODI 11665773

Around 20,000 miles, I took my vehicle to the dealer due to rattling and knocking in the front right wheel well and it was discovered the stabilizer arm was cracked. Received the vehicle back, and approximately 1000 miles later, there is rattling at the front driver and passenger wheel well and squeaking going down the road. The sounds coming from vehicle are that of a 40-year-old vehicle.

NHTSA ODI 11648886

popping/rattling sound coming from front passenger side and transmission is shifting hard at lower gears. vehicle is in shop waiting on repairs. front struts bad and had to be replaced at 12,555 miles. transmission software had to be upgraded and wiring harness for transmission under vehicle had to be repaired.

NHTSA ODI 11638233

The contact's wife owns a 2023 Ford Explorer. The contact stated while driving at various speeds, there was an abnormal knocking sound coming from the front end of the vehicle. The vehicle was taken to the dealer, where it was determined that the front struts had failed and needed to be replaced. The vehicle was repaired; however, the failure recurred several times. The dealer replaced the front struts three times; however, the failure persisted. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 24V091000(Suspension, Steering); however, the VIN was not included. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 2,000.

NHTSA ODI 11620574

The right front suspension collapsed after crossing railroad tracks at less than 10 mph, causing the vehicle to collapse and deploying all four airbags causing Minor injuries . A higher rate of speed would have caused severe injuries and possible fatalities. Ford has sent field engineers to examine the vehicle and pulled data from the rcm stating starting speed of 4.4 mph and 17.7 mph at time of impact. No collision and nothing in road way. THE Insurance company has the vehicle at a total loss and initially denied my claim, stating manufacturer defect, which I agree with. Ford has since denied my claim returning the liability to the insurance. No warning lights, or symptoms before the incident

NHTSA ODI 11592801

There is a load knocking noise coming from the front suspension. I have taken the vehicle in 3 times to Ford and after I drive off the lot the issue is gone. But after driving for a few days the issue returns. There is a loud clicking noise as well when you back up the vehicle coming from the front suspension.

NHTSA ODI 11581309

The contact owns a 2023 Ford Explorer. The contact stated there was an unknown part loosened at the front of the vehicle. While driving at unknown speeds, there was an abnormal rattling noise detected from the strut that had become louder over time. There were no warning lights illuminated. The vehicle was taken to the local dealer, where the front-end bolts were tightened. The vehicle was repaired, but the failure recurred. The manufacturer was contacted, opened a case, and referred the contact to the NHTSA Hotline. The contact related the failure to NHTSA Campaign Number: 24V091000 (Suspension, Steering). The approximate failure mileage was 3,000.

NHTSA ODI 11575332