In recent months, the Ford Explorer has been at the center of a sweeping series of recalls affecting hundreds of thousands of vehicles across the United States and beyond. These recalls have been initiated to address a wide array of potential safety defects, ranging from engine fires to gearbox failures, fuel leaks, and electrical short circuits. If you are a current or prospective owner of a Ford Explorer, it is crucial to understand the implications of these recalls, which models are affected, and what steps you need to take to ensure your safety on the road.
This in-depth guide offers a comprehensive overview of the most recent Ford Explorer recalls, detailing the underlying issues, repair solutions, and how they impact you as a vehicle owner.
A Closer Look at the Ford Explorer: A Popular Yet Problematic SUV
The Ford Explorer is one of the most iconic SUVs in North America. Known for its spacious interior, commanding presence, and advanced tech features, it appeals to families, professionals, and off-road enthusiasts alike. However, like many modern vehicles, its increasing complexity has exposed it to several reliability and safety concerns.
Over the last few years, various mechanical and electrical issues have prompted a growing number of recalls. In 2025 alone, Ford has issued multiple recall campaigns for different Explorer model years, including 2020 through 2025. These recalls span various components—from engine management systems to transmissions and battery wiring—each with its own safety risk and technical resolution.
Major Recalls Affecting the Ford Explorer (2020–2025 Models)
🔥 Engine Fire Risk – Recall 24S52
Models Affected:
- 2020, 2021, and 2022 Ford Explorer Police Interceptor Utility (PIU) models
- Engines: 3.3L hybrid and gasoline engines
Issue Summary:
Ford identified a potentially dangerous engine fire risk. The root cause stems from connecting rod bearing failures, which can breach the engine block, releasing oil and fuel vapors into the engine compartment. These vapors can then ignite when exposed to hot surfaces or electrical components.
Reported Incidents:
- 13 reported engine compartment fires linked to the issue, mostly in North America.
Solution:
- Ford dealers will reprogram the Powertrain Control Module (PCM) with updated software and inspect the engine for early signs of rod bearing wear.
- If damage is detected, the long block engine assembly will be replaced at no cost to the owner.
Advisory:
Owners should immediately turn off the engine and call for service if they hear unusual engine noises, experience sudden power loss, or see smoke from the hood.
⚙️ Transmission Gearbox Failure – Recall 24S55
Models Affected:
- 2024–2025 Ford Explorer, Bronco, Ranger, Lincoln Aviator, and F-150
- Transmission: 10-speed automatic (10R)
Issue Summary:
A defect in the gearbox’s main control valve can prevent the transmission from engaging reverse gear. This manufacturing flaw was traced to a production issue at Ford’s Livonia Transmission Plant.
Safety Risk:
Drivers may be unable to back out of parking spaces, driveways, or tight spots, increasing the risk of accidents in traffic or confined spaces.
Solution:
- Ford dealers will replace the faulty valve parts free of charge.
- Notifications to vehicle owners are expected to be completed by May 2025.
🔋 Hybrid Battery Cable Short Circuit – Recall 24S61
Models Affected:
- 2024 Ford Explorer models with 3.3L hybrid engines
Issue Summary:
A 12-volt battery cable may chafe against the Belt-integrated Starter Generator (BiSG). This rubbing can wear through the insulation, causing a short circuit.
Risk:
A short circuit in the engine bay can result in smoke, component damage, or even a fire.
Solution:
- Ford will install a cable tie strap to reposition the wire away from the BiSG. This prevents direct contact and future chafing.
- Notifications were mailed to affected owners in November 2024.
🛢️ Fuel Injector O-Ring Defect – Recall 24S54
Models Affected:
- 2025 Ford Explorer
Issue Summary:
Some fuel injectors may have been installed without their support O-rings. This oversight can cause fuel leakage from the injector rail, especially under pressure.
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Consequences:
A fuel leak in proximity to engine components significantly increases the risk of fire.
Solution:
- Ford will inspect and replace all fuel injector O-rings and install support discs as necessary.
- Notifications to affected owners began in October 2024.
⚠️ Airbag Warning Label Missing – Recall 24C39
Models Affected:
- 2020–2025 Ford Explorer
Issue Summary:
Certain models were shipped without the required airbag warning labels on the dashboard. While seemingly minor, this omission fails to inform passengers of critical airbag deployment risks.
Safety Impact:
Lack of proper warning may result in improper child seat placement or other risky behavior during travel.
Solution:
- Ford mailed adhesive airbag warning labels to affected owners in December 2024, along with clear instructions on where and how to apply them.
What Ford Explorer Owners Should Do
1. Check Your VIN for Recalls
To determine if your Explorer is affected by any of these recalls, visit the National Highway Traffic Safety Administration (NHTSA) recall lookup page and enter your Vehicle Identification Number (VIN). This tool gives you instant access to any open safety recalls.
2. Schedule Service Appointments Promptly
If your vehicle is listed in one or more recall campaigns, contact your nearest authorized Ford dealership immediately. All recall repairs are performed at no cost to the vehicle owner.
3. Follow Manufacturer Advisories
If you’re advised not to drive your vehicle or to monitor for specific symptoms, take these notices seriously. Safety-related recalls are issued only after confirmed risk assessments.
4. Stay Informed
Make sure your vehicle registration is current and your contact information is up-to-date with Ford. This ensures you receive future recall notices and service reminders.
The Bigger Picture: Are Recalls Becoming More Common?
Recalls are an unfortunate but necessary aspect of modern vehicle ownership. As vehicles become more complex—integrating hybrid powertrains, advanced driver-assistance systems, and sophisticated electronics—the potential for manufacturing errors increases. In many cases, recalls reflect manufacturers being proactive rather than negligent.
Ford, like most major automakers, works in conjunction with federal safety regulators like the NHTSA to ensure defects are identified and corrected before they cause widespread harm. In the case of the Ford Explorer, these recalls demonstrate a commitment to transparency and consumer protection, even if they highlight troubling vulnerabilities in quality control.
Conclusion
The Ford Explorer remains a top choice in the midsize SUV segment, but its recent string of recalls raises legitimate questions about long-term reliability. From engine fires to fuel leaks, and from missing labels to gearbox issues, these recalls cover a wide spectrum of potential hazards. Fortunately, Ford is addressing each concern with corrective action and extensive service coverage.
If you own or plan to purchase a Ford Explorer, staying informed and acting swiftly on safety recalls is not just good practice—it’s essential for protecting your passengers, your vehicle, and your peace of mind.
