2016 Ford Explorer: engine stalls while driving

Filed Sep 8, 2026 · Engine · MI

I am writing to report a severe, inherently dangerous engineering defect regarding the internal water pump design on the 2016 Ford Explorer equipped with the 3.5L naturally aspirated V6 engine.On September 8, 2026, my vehicle experienced a sudden, catastrophic primary seal failure of the internal water pump while operating. The vehicle immediately began dumping large quantities of engine coolant onto the ground from the designated engine block weep hole located on the lower passenger side. Because Ford engineered this specific engine with the water pump hidden entirely behind the front timing cover and driven directly by the engine's timing chain, any mechanical failure of the pump poses an immediate, severe safety risk to the driver and occupants. If the secondary pump seal fails or the weep hole becomes obstructed, coolant dumps directly into the engine crankcase, mixing with the engine oil. This sudden loss of lubrication can cause the internal pump bearings to seize rapidly, leading to the timing chain snapping or jumping tracks.The consequences of this design create two distinct, critical safety hazards:Sudden Engine Stall at Speed: A seized water pump or broken timing chain will cause an instantaneous, un-commanded engine shutdown while traveling at highway speeds. This immediately cuts off the vehicle's power steering assist and power brake booster, placing the driver at extreme risk of a high-speed collision. Passenger Cabin Hazmat Hazard: A major coolant dump underneath the engine bay onto hot exhaust components generates blinding steam and toxic chemical fumes that can enter the vehicle’s HVAC system, severely impairing driver visibility and breathing.This internal, chain-driven water pump design is a known, systemic manufacturing defect that forces vehicle owners to pay between $3,000 and $5,000 in preventative labor to fix an auxiliary cooling component before it destroys the entire engine block. I urge the federal safety agency to open a formal safety investigation int

Filed Jul 13, 2026 · Transmission · OR

My 2016 ford explorers torque converter has failed. It causes a extremely rough idle while in drive or reverse, the rpms vary and at a complete stop the car will continue to lunge forward. If I were to continue to drive the vehicle at any point without warning my transmission could completely lock up causing me to stall in the middle of the road. The dealership has confirmed it as well as ford and ford has an active recall for my specific car but my vin isn't covered under the recall and ford is refusing any sort of fault.

Filed Jan 10, 2026 · Engine · MO

While driving the crankcase sensor malfunctioned and caused my vehicle to stall without warning, this is a safety issue because of you are driving at highway speeds this will prevent the vehicle from being controlled properly to get to the side of the road. This sensor does not give any engine codes suggesting that it needs replaced until it goes out completely. The check engine light did not come on until after the component failed. I ordered a new part directly through Ford and even they said "yes that part will go out without any warning at all and will shut the engine down completely". When this sensor went out, it also caused pressure to build up in the engine which in turn has led to several other components that now need to be replaced. I have a had a mechanic look at it, and it now requires a turbo intake hose and a new turbo because the pressure that was built up in the engine due to the crankcase sensor going out burst the turbo intake hose and prevented the turbo from working correctly. It's approximately $4,000 in repairs due to a $150 part going out.

Filed Jun 24, 2025 · Engine · 177,000 miles · NC

The contact owns a 2016 Ford Explorer. The contact stated that while her husband was driving at an undisclosed speed, the vehicle stalled after coming from a stop. No warning light was illuminated. The vehicle was able to be restarted. The contact stated that the water pump had previously been replaced twice, but the failure persisted. The vehicle was taken to an independent mechanic, who determined that there was coolant intrusion in engine and the water pump needed to be replaced for the third time. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 177,000.

Filed Apr 26, 2025 · Lights · OH

Issues with headlight housing unit getting moisture in it causing lights to malfunction. Driver headlight won't work and passenger headlight will turn off while driving then back on and off again. It does this continously at random making it dangerous for myself and other drivers at night. I've spoke with Ford explaining there is a recall for some 2016 models but not one under my VIN so they won't fix it since it's not. I'm hoping the recall can be extended to cover my VIN.

Filed Apr 6, 2025 · Engine · MS

Engine stalls out when accelerating, coolant is leaking into the motor. Got it checked out my mechanic, needs new engine due to improper manufacturing issue

Filed Dec 20, 2024 · Engine, Transmission · 50,000 miles · MD

The contact owns a 2016 Ford Explorer. The contact stated that the vehicle jerked while shifting into gear. The contact stated that upon shifting to drive(D) on several occasions, the vehicle failed to respond. There was no warning light illuminated. The vehicle was taken to the dealer, where the transmission was replaced. Additionally, the contact stated while driving 25 MPH, the vehicle shuddered, overheated, and stalled. There was no warning light illuminated. The contact was able to pull to the side of the road. The vehicle failed to restart and was towed to the residence, where a mobile independent mechanic diagnosed that the head gasket was blown. The vehicle was not repaired. The dealer was notified of the failure, but no assistance was provided. The manufacturer was notified of the failure and referred the contact to the federal safety agency Hotline for assistance. The failure mileage was approximately 50,000.

Filed Oct 17, 2024 · Transmission · 120,000 miles · IL

The contact owns a 2016 Ford Explorer. The contact stated that the vehicle hesitated to shift into reverse properly, the vehicle would reverse a few feet and suddenly stall or stop from reversing when reversing out of a parking lot while a crunching sound could be heard from underneath the vehicle. No warning lights were illuminated. The vehicle was driven to an independent mechanic where the vehicle was diagnosed that the PTU needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 120,000.

Filed Jun 11, 2024 · Engine · MA

water pump failure at 60K miles on a 2016 ford explorer, this model has the most reported water pump failures on record. this is a 15 hour repair job at the dealer, and the same complaint litters the internet. The failure on my vehicle was confirmed by dealer, $4k to fix. Not to mention the mess in my driveway where the coolant expelled without notice. If I drive it, the engine will be damaged, and there goes my car. In 2020 NY and MI class action lawsuits over this issue were settled & closed WITH payment to plaintiffs, yet no recall. WHY? too expensive for Ford? We see safety recall on clips yet nothing on an admitted engine problem than causes stalling or engine damage while running? There's a class action in Canada. Ford is dodging a known defect. Please do something about this.

Filed Jun 6, 2024 · Engine, Fuel system · MO

The power transfer unit is broken. Symptoms are vehicle shuddering, vehicle sounds like it is going to stall. This could cause a major accident at any moment.

Filed Apr 16, 2024 · Engine · 125,900 miles · IL

The contact owns a 2016 Ford Explorer. The contact stated that the check engine warning light was illuminated, and the vehicle was stalling because oil was leaking onto the crank case-control sensor. The contact changed the crank case-control sensor. The failure recurred and the vehicle was taken to the dealer where it was diagnosed with a front engine compartment, gasket leak. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 125,900.

Filed Mar 27, 2024 · Engine · SD

The contact owns a 2016 Ford Explorer. The contact stated that while driving at approximately 10 MPH, there was a burnt hydraulic fluid odor inside the vehicle when the vehicle shuddered and stalled. No warning light was illuminated. The vehicle was taken to an independent mechanic and was diagnosed, and the engine mount was replaced. The failure recurred; however, there was a rotten, sulfur like odor coming from the vehicle. The vehicle was not taken to the dealer or repaired. The manufacturer was contacted. The failure mileage was unknown.