NHTSA Defect Investigations for the 2014 Ford Explorer

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2014 Ford Explorer, both ongoing and closed, are listed below:

  1. INVESTIGATION: Ford Explorer Exhaust Odor

    NHTSA Preliminary Evaluation #PE16008

    • Status:
    • Date Opened: July 01, 2016
    • Date Closed: September 12, 2017
    • Recall: No recall issued

    Component(s): Engine And Engine Cooling:Exhaust System

    Summary: During the National Highway Traffic Safety Administration-s (NHTSA-s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 VOQs for Model Year 2011-2017 Ford Explorers pertaining to exhaust odor claims.ODI has identified three crashes and 41 injuries potentially linked this issue.The reported injuries range from unspecified to loss of consciousness, with the majority being nausea, headaches, or dizziness -" all of which can be symptomatic of carbon monoxide exposure.Additionally, Ford provided 2,400 reports including owner complaints, warranty claims, dealer field reports, and legal claims, that involve 2,051 vehicles that may be connected to the exhaust odor issue.NHTSA's Vehicle Test and Research Center tested multiple vehicles, including complaint vehicles, during the investigation.ODI also conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on duty.When possible, data was collected to quantify carbon monoxide levels in the examined vehicles.Based on the information gathered to date, NHTSA upgraded this investigation to an Engineering Analysis (EA17-002).

  2. INVESTIGATION: Ford Explorer Exhaust Odor

    NHTSA Engineering Analysis #EA17002

    • Status:
    • Date Opened: July 27, 2017
    • Date Closed: N/A
    • Recall: No recall yet

    Component(s): Engine And Engine Cooling:Exhaust System:Manifold/Header/Muffler/Tail Pipe

    Summary: ODI opened Preliminary Evaluation (PE) 16-008 in July of 2016 after receiving 154 Vehicle Owner Questionnaire (VOQ) reports reporting exhaust odors in the vehicle occupant compartment of model year (MY) 2011 to 2015 Ford Explorers, which included one low speed crash event without injury.During the course of the PE, ODI identified additional VOQ reports concerning the exhaust odor issue, totaling 791 as of this writing.The complaints cover MY 2011 to 2017 Explorers.Eleven of the reports involve Police Interceptor vehicles, as do two other non-VOQ incidents ODI identified during PE16-008.Overall, ODI has identified three crash events and 25 injury incidents citing a total of 41 injuries.The alleged injuries, as affirmatively indicated on the VOQ reports, range from unspecified to loss of consciousness, with the majority indicating nausea, headaches, or light headedness.One police incident alleged a crash with related injuries, and a second police incident reported a physiological injury allegedly from carbon monoxide (CO) exposure.Another reported police incident resulted in a rollover crash event with injuries.The Ford reports cited above were provided in the company-s August 24, 2016 response to an ODI Information Request letter sent during PE16-008.Therein, ODI identified 2400 reports (485 owner complaints, 1254 warranty claims, 606 dealer field reports, 55 legal claims), involving 2,051 unique vehicles, that appear to relate to the exhaust odor issue, and include 123 reports that are duplicative of the VOQ reports.A number of the Ford reports also discussed health effects similar to the VOQs, specifically nausea and headaches.During the PE, working in conjunction with NHTSA's Vehicle Test and Research Center (VRTC) in East Liberty, Ohio, ODI has tested multiple vehicles, including complaint vehicles.Additionally, ODI has conducted field inspections of complaint vehicles and crashes involving police units that occurred while the officers were on-duty.When possible, data has been collected to quantify carbon monoxide (CO) levels in the examined vehicles.During this Engineering Analysis (EA), the VRTC testing efforts and field inspections will continue.To date, no substantive data or actual evidence (such as a carboxyhemoglobin measurement) has been obtained supporting a claim that any of the alleged injury or crash allegations were the result of carbon monoxide poisoning, the alleged hazard.ODI has obtained preliminary testing that suggests, however, that CO levels may be elevated in certain driving scenarios, although the significance and effect of those levels remains under evaluation as part of the EA.Ford has issued multiple TSBs related to the exhaust odor issue, and in some cases revised those documents multiple times to provide dealership technicians with procedures to address complaints raised by consumers and police fleets.Concerns over the effectiveness of the procedures have been raised by vehicle owners in some cases.During the EA, ODI will continue to evaluate the effectiveness of the TSBs.Through cooperation with police agencies, ODI recently learned that the Police Interceptor version of the Ford Explorer is experiencing exhaust manifold cracks, which appear to present a low level of detectability, and may explain the exhaust odor.During the EA, the root cause, frequency, and safety consequence of these manifold cracks will be evaluated, as will the extent to which non-police Ford Explorers are experiencing cracked exhaust manifolds.

  3. INVESTIGATION: Front Brake Hose Failure

    NHTSA Engineering Analysis #EA15005

    • Status:
    • Date Opened: September 28, 2015
    • Date Closed: November 02, 2018
    • Recall: No recall issued

    Component(s): Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

    Summary: On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate a report alleging incidents of front brake hose failure in model year (MY) 2015 Ford Explorer Police Interceptor vehicles used by the Sacramento Police Department in its pursuit driving training program (VOQ 10705832).On September 28, 2015, ODI upgraded the investigation to an Engineering Analysis (EA15-005) to assess maximum front caliper crimp temperatures under various test conditions, test hose assemblies removed from police interceptor service for any signs of thermal degradation, and further assess field data for evidence of a defect trend related to the alleged defect.The alleged defect results from exposure to extremely high heat at the caliper-side hose crimp. NHTSA-s vehicle testing suggests that the conditions necessary to produce the critical temperatures in the subject components result from drive-soak intervals that can occur during the Sacramento training program.NHTSA's testing of hose assemblies returned from police interceptor service did not identify any evidence of thermal degradation.NHTSA has not confirmed any incidents of caliper crimp failures due to overheating in vehicles not subjected to the Sacramento training course driving.The low number of hose assembly failure reports and the absence of any verified incidents of heat related front brake hose crimp failures since 2015 suggests that the Sacramento PD incidents resulted from conditions unique to the training program.A safety related defect trend has not been identified at this time and further use of Agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The Agency will take further action if warranted by the circumstances.For additional information, see the Closing Report in the document file for EA15-005 on www.nhtsa.gov.

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