2016 Ford Explorer Recall

On certain vehicles, the repairs completed by a Ford dealer during customer satisfaction program 20N11 may not be effective. As a result, a second repair is required. On certain vehicles, the roof rail covers could become loose and detach while driving. Note: This recall is an expansion of Transport Canada recall no. 2021-267. Vehicles repaired under that recall don't require this repair.

A roof rail cover that detaches while driving could create a hazard for other road users and increase the risk of a crash.

Ford will notify owners by mail and advise you to take your vehicle to a dealership to inspect and, if necessary, secure the roof rail covers.

On certain vehicles, the engine block heater could leak coolant. If this happens, the block heater could short circuit when it's plugged in. Note: This recall replaces Transport Canada recall no. 2025-554. Vehicles that were repaired under that recall don't require this repair.

A short circuit can create the risk of a fire.

To reduce the safety risk, Ford advises you not to use the engine block heater until the recall repairs have been completed. Ford will notify owners by mail and advise you to take your vehicle to a dealership to replace the block heater. Alternatively, owners can choose to have the dealership permanently disable the engine block heater.

On certain vehicles, the engine block heater could leak coolant. If this happens, the block heater could short circuit when it's plugged in.

A short circuit can create the risk of a fire.

To reduce the safety risk, Ford advises you not to use the engine block heater until the recall repairs have been completed. Ford will notify owners by mail and advise you to take your vehicle to a dealership to replace the block heater.

On certain vehicles, the exterior B-pillar trims on the driver and front passenger doors may not be properly attached. As a result, the trim(s) could loosen and separate from the vehicle.

Trim that detaches from the vehicle could create a road hazard for others and increase the risk of a crash.

Ford will notify owners by mail and advise you to take your vehicle to a dealership to inspect and, if necessary, secure the B-pillar trims.

On certain vehicles, the exterior A-pillar trim on either side of the windshield may not be properly attached. As a result, the trim(s) could loosen and separate from the vehicle.

Trim that detaches from the vehicle could create a road hazard for others and increase the risk of a crash.

Ford will notify owners by mail and advise you to take your vehicle to a dealership to inspect and, if necessary, replace the A-pillar trim.

On certain vehicles, the outer ball joint for the rear suspension toe link may seize. If this happens, the toe link could break while driving. This could cause a sudden loss of vehicle stability. Note: This recall only affects vehicles equipped with a rear ball joint manufactured by ZF.

A loss of vehicle stability could cause a loss of control and increase the risk of a crash.

Ford will notify owners by mail and instruct you to take your vehicle to a dealer to replace the rear suspension toe links and inspect the ball joints. If a ball joint requires replacement, the dealer will replace the rear suspension knuckle.

On certain vehicles, the roof rail covers could detach. If this happens while driving, the roof rail cover could separate from the vehicle. Note: This recall only affects vehicles with painted roof rail covers.

A roof rail cover that detaches while driving could create a hazard for other drivers and nearby people, and could increase the risk of a crash.

Ford will notify owners by mail and instruct you to take your vehicle to a dealer to secure the roof rail covers.

On certain vehicles, the front link shaft (intermediate shaft) bracket can break. If this happens, there could be a loss of power to the wheels. Also, if this happens and the vehicle is parked without the parking brake applied, the vehicle could roll away.

A loss of power to the wheels or a vehicle rollaway could increase the risk of a crash.

The company will notify owners by mail and instruct you to take your vehicle to a dealer to replace the front link shaft bracket.

On certain vehicles, the outer ball joint for the rear suspension toe link may seize. If this happens, the toe link could break while driving. This could cause a sudden loss of vehicle stability.

A loss of vehicle stability could cause a loss of control and increase the risk of a crash.

Ford will notify owners by mail and instruct you to take your vehicle to a dealer to inspect the ball joints for the rear suspension toe links. If a ball joint requires replacement, the dealer will replace the rear suspension knuckle.

On certain vehicles, the rear suspension toe link(s) could break. This could cause a sudden loss of vehicle stability. Note: This problem is more likely to occur on vehicles that are driven on rough roads.

A loss of vehicle stability could cause a loss of control and increase the risk of a crash.

The company will notify owners by mail and instruct them to take their vehicle to a dealer to install improved rear suspension toe links.

On certain vehicles, the front power seat adjuster assembly joint may become loose over time. A loose seat adjuster assembly may increase seat cushion deflection and not properly restrain the seat occupant in the event of a crash, which could increase the risk of injury. Correction: Dealers will inspect for proper torque of the power seat track upper pivot link bolt. If the bolt passes inspection, dealers will remove and clean the bolt, apply new threadlock and reinstall the bolt to the specified torque. If the bolt fails the torque inspection, threadlock will be added to the bolt and will be reinstalled as an interim repair until the final repair is available. The final repair will include replacement of the lift link, including new bushings and fasteners.

A failure of this component (seats and restraints) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles operated in Alberta, Saskatchewan and Manitoba, soil properties unique to these areas could cause an accumulation of soil to occur at the attachment point of the rear suspension toe link. This could impede the toe link's travel, causing bending stresses and potential fracture. A fractured toe link would affect vehicle handling and could increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will replace the toe links with revised parts.

A failure of this component (suspension) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

Certain vehicles equipped with a manual driver's seat recliner may fail to conform to Canada Motor Vehicle Safety Standard (CMVSS) 202 - Head Restraints and CMVSS 207 - Anchorage of Seats. There may be an inadequate weld between the driver's seat back and the manually operated seat back recliner mechanism, which may fail to meet the requirements of the standards. As a result, the driver's seat back may appear to be loose, twisted or lean to one side, and/or squeak/rattle. If this condition were present, in the event of a vehicle crash, the seat may not adequately restrain an occupant and would increase the risk of injury. Correction: Dealers will inspect and, if necessary, replace the seat back frame.

A failure of this component (seats and restraints) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles equipped with a 2.3 litre GTDI engine and an engine block heater, due to the engine’s orientation, the block heater could be susceptible to overheating. An overheated engine block heater may result in engine coolant leakage, or heat damage to the electrical connector of the block heater. Overheating of the engine block heater may increase the risk of an underhood fire causing injury and/or property damage. Correction: Dealers will replace the engine block heater element with one of a different design, and will inspect the block heater's electrical cord, and replace if required. In the interim, owners are advised to stop using their block heater until the campaign is completed. Note: This risk only exists when the block heater is plugged in and the vehicle is parked.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the fuel tank attachment bolts may not have been tightened adequately at time of assembly. This could result in insufficient clamp load that could lead to fatigue and fracture of the fuel tank straps. Fracture of the fuel tank straps could result in the fuel tank separating from the vehicle, which may result in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing injury and/or property damage. Correction: Dealers will torque the fuel tank attachment bolts to the required specification.

A failure of this component (fuel system) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

Certain vehicles fail to comply with the requirements of Canada Motor Vehicle Safety Standard 135 - Brake Systems. During the manufacturing process, the parking brake controller assembly bracket may have been improperly formed. This could result in the pawl to not engage the sector gear during actuation and the parking brake not fully engaging. If the transmission is in Park, there will be no unintended vehicle movement. If the transmission is left in a gear other than Park, and the vehicle is parked on a sufficient slope, a non-functioning parking brake could result in unintended vehicle movement, increasing the risk of a crash causing injury and/or property damage. Correction: Dealers will inspect, and if necessary, replace the parking brake control assembly.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).