2020 Ford Explorer driver assistance problems

Filed Oct 21, 2026 · Driver assistance, Transmission · KS

Front axle disconnect actuator on my 2020 Ford Explorer 2.3L AWD is failing. The vehicle stores DTC C0631-7E (Actuator Stuck On) and previously stored C0631-7F (Actuator Stuck Off). When the fault is active, the wrench light comes on and the following safety systems are disabled: AdvanceTrac, Pre-Collision Assist, and Hill Start Assist. Ford has issued TSB 25-2373 / 25-2568 for this exact issue requiring replacement of the intermediate shaft with revised part N1MZ-3A329-A and AWD module reprogramming, but there is no recall. Owners must pay for the repair. The problem is intermittent and has been confirmed with a scan tool. This is a known design defect, not normal wear, and it affects safety systems.

Filed Oct 19, 2026 · Driver assistance, Electrical · WA

My 2020 Ford Explorer previously received a safety recall repair under Ford Recall 23S23 for the 360-degree/rearview camera system. Unfortunately, the camera system is malfunctioning again following that repair. The 360-degree display intermittently shows solid blue/teal or black areas instead of properly displaying the vehicle’s surroundings. The camera images also become washed out, distorted, or unusually dark, reducing visibility when reversing. Additionally, my instrument cluster displays the warning “Reverse Brake Assist Not Available – See Manual.” These problems raise serious safety concerns because the vehicle’s camera visibility is compromised while another safety system reports that it is unavailable. This creates potential risks when backing near children, pedestrians, other vehicles, or obstacles. I have photographs documenting the camera malfunctions and dashboard warning. Ford subsequently issued Recall 25S27 after discovering that certain vehicles previously repaired under Recall 23S23 may not have received the correct remedy, even though the repairs were recorded as completed. I have not yet received confirmation whether Recall 25S27 applies to my specific vehicle. On October 8, 2026, I visited Mullinax Ford of Olympia regarding the recurring safety problems. The dealership advised that I would have to pay out of pocket for a diagnosis. I subsequently submitted a written request asking for the recurring defect and applicable recall coverage to be reviewed, but received no response. I escalated the matter to the dealership’s General Manager on October 19, 2026. The underlying cause has not been determined. I am concerned that the original camera safety defect may not have been adequately corrected and that the vehicle continues to experience a related safety risk. I request that the federal safety agency review these recurring malfunctions and the adequacy of the previous recall remedy.

Filed Sep 15, 2026 · Driver assistance, Electrical · NJ

I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain 2020-2021 Explorer AWD vehicles. The bulletin specifically identifies C0631 and/or C00A6 and the front axle disconnect actuator/intermediate shaft and directs replacement with a revised intermediate shaft. I am concerned this is a safety defect because the failure resulted in AWD/drive-mode malfunction while multiple driver-assistance systems became unavailable. I request that the federal safety agency investigate this known failure and determine whether a safety recall is warranted.

Filed Aug 26, 2026 · Driver assistance · OH

I am writing to formally express serious concerns regarding the safety of a Ford vehicle that continues to carry a 5-star safety rating despite multiple known, safety-critical defects that emerged after relatively low mileage. Two major issues developed between approximately 62,000 and 72,000 miles. Both are documented by Ford Technical Service Bulletins (TSBs), yet neither has been addressed through a formal recall. My vehicle’s warranty expired at 60,000 miles, leaving me responsible for more than $3,000 in out-of-pocket repair costs. Issue 1 – Front axle seal leak (TSB 23-2174) The front axle seal began leaking fluid. According to the TSB, the original affordable seal is no longer available, requiring replacement of the entire axle assemblies at a cost of approximately $2,000. Failure to complete this repair risks axle lock-up and a potential collision. Issue 2 – All-wheel-drive module ground wire omission (TSB 23-2061) Ford failed to install a required ground wire on the AWD module. This caused multiple warning lights to illuminate, including powertrain failure and collision-assist system failure. I refused to allow my wife and children to ride in the vehicle throughout the winter because of these critical warnings. The repair, which required replacement of the AWD module, cost more than $1,000. These are not minor inconveniences. An axle that can lock up, loss of AWD capability in hazardous conditions, and the simultaneous failure of collision-assist systems present clear and foreseeable risks of serious crashes. A vehicle exhibiting these defects does not merit a 5-star safety rating, particularly when the problems are known to the manufacturer and affect used-vehicle buyers who may lack the financial means to perform the repairs. I respectfully urge the NTSB to investigate these issues, determine whether the continued 5-star rating is appropriate, and encourage Ford to issue formal recalls so that owners are not left to bear the cost and risk of repairs.

Filed Jul 6, 2026 · Brakes, Driver assistance · GA

Had recall for parking brake fixed, soon after I’d be on interstate or intersection and it would lose power wrench and check power train system light came on. Took to dealership and they said it was parking pawl sylenuod. Had repaired left the shop didn’t even get home and it did the same: Mechanic said it was gas pedal sensor repaired that and same thing happened it may go real fast or not go . I worked for uber and lyft and have been out of work for a few months. Car setting at dealership and the say I need to pay for a new power train module because my cars lost it brains. So I got recall fixed and my cars went to hell in a hand basket. Now another recall is issued but no resolution. It is a huge safety issue when your gas pedal gets a not responsive to your foot touching the pedal then it accelerating without touching the gas pedal. I’m lucky I didn’t die in it. This year model just needs to be lemoned out. Oh also when it starts messing up airbag not working driver assist not working all the safety features go haywire. I feel 💯 sure this is all related to the recall and ford will be hearing from me or a lawyer one.

Filed Jun 16, 2026 · Brakes, Driver assistance · CA

ABS and parking brake. Was confirmed by the dealer & tow truck driver. No warning when I parked it, only after putting it into reverse. There were flashing ABS & Parking Brake lights plus a beeping sound.

Filed May 20, 2026 · Driver assistance · IL

Service advance track 4 weel drive doesn’t work and I don’t have control on the weels

Filed Apr 13, 2026 · Driver assistance, Electrical · OH

Three alerts appeared on my dash after starting my car. These alerts are “Pre-Collision Assist Not Available,” “Service AdvanceTrac,” and “4WD Fault Service Required.” This has been an ongoing issue with this vehicle which directly affects the safety of drivers. After discussing with other consumers, this system failure is happening more and more. While these alerts are displayed, the front end collision assist is completely nonfunctional, thus increasing the risk of an accident. The Advanced Traction Control System is also nonfunctional. Based on other consumers with the same experience, the only solution is to replace the AWD module.

Filed Mar 11, 2026 · Driver assistance, Transmission · LA

SUMMARY OF FACTS FOR LEGAL CONSULTATION Bad Faith Redhibition Claim — Louisiana Civil Code Art. 2545 Prepared for Attorney Consultation 1. Vehicle & Transaction Information Vehicle2020 Ford Explorer ST — AWDPurchase DateMarch 2025Purchase Structure$17,000 trade-in applied + $17,000 remaining loan balanceAdditional Warranty$2,500 paid warranty purchased through dealership at time of saleSelling DealerIndependently licensed dealership (non-Ford franchise)Warranty ServiceWarranty work performed during coverage period 2. The Technical Service Bulletin (TSB 23-2174) Ford issued TSB 23-2174 in July 2023 — nearly two years before the vehicle was sold to the client. Key facts about the TSB: •Covers: 2020–2021 Ford Explorer/Lincoln Aviator AWD vehicles •Component affected: Front Axle Disconnect Actuator (FADA) — left side •Failure mode: FADA O-ring seal failure causing AWD malfunction, triggering powertrain warning light (wrench icon) with DTCs C00A6 and/or C0631 •Required repair per TSB: Full replacement of FADA with revised intermediate shaft AND reprogramming of transfer case control module •Result of proper TSB repair: Permanently eliminates front axle disconnect capability — a fundamental, permanent change to vehicle drivetrain operation •TSB was publicly available on [XXX] at time of purchase — free, searchable by VIN 3. Critical Pre-Sale Service Record — January 2025 The dealership's own service center performed the following repair on the vehicle approximately 1–2 months before the sale to client: Date of ServiceJanuary 2025 (approx. 1–2 months pre-sale)Work Order DescriptionLeft axle disconnect/hub actuatorParts ListedMotorcraft left axle seal ONLYLabor Hours9 hoursDTCs or TSB ReferencedNone listed on work orderAWD Module ReprogrammedNot indicated on work order Critical observation: The terminology used on the dealer's own work order — "left axle disconnect/hub actuator" — mirrors the exact component language of TSB 23-2174. A technician with suffici INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMAT

Filed Dec 31, 2025 · Driver assistance, Transmission · NY · crash · 1 injury

On December 26, at approximately 7:08 p.m., I was driving on the Belt Parkway during a snowstorm. I was traveling in the middle lane and began to safely change lanes to the right. During the lane change, the vehicle’s four-wheel-drive system suddenly displayed an error and appeared to malfunction. Immediately after this occurred, I lost control of the vehicle. The vehicle veered to the right, struck the median, and flipped over twice before coming to rest on its side. Prior to the system error, I was operating the vehicle normally and driving cautiously given the weather conditions. The loss of control occurred abruptly and without warning.