2021 Ford Explorer: fire, smoke or burning smell

Filed Oct 26, 2026 · Engine · PA

On October 21, 2026, after an approximately one-hour round trip in our 2021 Ford Explorer, we arrived home and noticed smoke coming from under the hood. When we opened the hood, we found oil spread throughout the engine compartment. The smoke and oil leak raised concerns about a possible fire and the safety of continuing to drive the vehicle. The vehicle had recently received its second replacement engine, installed by Stuckey Ford of Bellefonte on September 2, 2026. We brought it back to that dealership on October 23. Service staff told us they believed the oil leak involved the valve cover gasket on the recently installed long block. This is a preliminary diagnosis; we have not received written confirmation of the cause. As of October 26, the vehicle remains at the dealership awaiting repair and is available there for inspection upon arrangement. Whether Ford has independently inspected this new issue is unknown. The vehicle has a history of repeated oil loss and low oil pressure warnings. The original engine was replaced under warranty in June 2024 at approximately 39,574 miles after the dealership documented oil in cylinder 2 and heavy cylinder wall scoring. In June 2026, we again reported almost no oil and a low oil warning. In July 2026, at 77,206 miles, the dealership documented excessive oil consumption and internal oil burning in cylinder 3, leading to the September replacement. Shortly after that replacement, the vehicle also displayed an overheating warning and required towing. The dealership found that a coolant hose had come off and repaired it in September. Whether warning lights or messages appeared before the October 21 oil leak and smoke incident is unknown. The repeated engine problems and this new incident have left us concerned about safely using the vehicle.

Filed May 23, 2025 · 75,000 miles · VA · fire

The contact owned a 2021 Ford Explorer. The contact stated that the vehicle was parked in the driveway for over three hours before the vehicle caught on fire. The origin of the fire was unknown, however, the contact believes the fire originated from faulty electrical wiring. The vehicle was unoccupied during the fire. The location of the fire was the rear end of the vehicle. The fire department arrived to extinguish the fire. A fire department report was filed. A police report was not filed. The vehicle was destroyed. The local dealer was contacted, and the vehicle was not diagnosed as it was determined to be a complete loss. The manufacturer was notified of the failure. The approximate failure mileage was 75,000.

Filed Oct 16, 2024 · Engine · NY

On [XXX], I was driving to my destination. I looked in the rear view mirror and saw a large amount of grayish smoke coming from both tailpipes. Less then 1 mile after that, the Explorer was unable to accelerate. The vehicle was towed to Don's Ford in Utica NY where on October 8th they diagnosed the problem as a blown turbo within the engine. There were no symptoms that illuminated in the vehicle, made any noises and/or other issues that would have prompted me that there was a problem. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Aug 22, 2024 · Electrical, Engine · NJ · fire

[XXX] after driving less than 10 min. warning signs flashed on screen. I immediately pulled off the road where the vehicle completely shut down and realized my 2021 Ford Explorer was on fire. Bystanders attempted to put the fire out with fire extinguishers but were unsuccessful. My passenger and I opened our doors, I exited and attempted to open trunk to remove wheelchair but could not (because door is electrical). My passenger flung himself onto the ground until bystanders came with a rolling office chair to remove him away from the burning vehicle. Had the bystanders not been there I do not know how I would have been able to move my passenger (25 year old, 200 lb male) away from the burning vehicle. Fire Marshall could not determine cause of fire because vehicle was completely melted/too damaged. Ford Motor Company reviewed photos I sent to them but claims they could not determine cause of fire. The vehicle was properly maintained with routine oil changes. There were no issues with the vehicle prior to this incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jul 18, 2023 · Electrical · IN

The fuse box got wet after a routine car wash. The hood was not opened at any point prior to the car wash, nor directly afterwards until the incident occurred. A few hours after the car wash, the horn went off on its own continuously for 5-10 minutes and had to be shut off manually via disconnecting the battery. The car was not running or turned on in any way at this point. Prior to disconnecting the battery, the car was turned on to try and deactivate the horn. The horn was still blaring and the car would not shut off. Upon inspection, there was smoke coming from the fuse box. Multiple vehicle alerts went off on the dash including Hill start assist warning, Powertrain malfunction/reduced power and pre-collision assist warning lights. The car was taken to the dealership for repairs. The following "story" was conducted at the dealership: Unhooked battery. Removed front cowl battery junction box. Removed battery junction box. Battery junction box is burnt up and engine bay harness is melted. Engine bay harness needs replaced. Have to remove engine assembly to gain access to harness. Removed engine transmission and subframe assembly. Removed inner plastic firewall. Removed harness and replaced. Reinstalled drive train assembly replaced all one time use fasteners. Reassembled car. Found horn is INOP. Diagnosed and found horn is burned up from being stuck on from melted harness. Removed front bumper cover. Replaced Horn and reassembled. Horn works now. Cleared all DTCs. No DTCs returned. Test drove car. Everything is working properly now and no codes returned. Total repairs are $3,300. I did not feel safe in any regards while driving it to the dealership. Through casual conversation with a friend who works at the dealership, they witnessed something similar happen with a Ford F-150. I don't believe that this has been inspected by the manufacturer, police or insurance representatives. There were no warning lamps, messages or other symptoms prior to the incident.

Filed Mar 13, 2023 · Engine, Transmission · CT

At 13,000 miles this New vehicle started smoking blue gray smoke on startup I have videos. Yes the Dealer reproduced the problem. The dealer stated that both turbos were defective and leaking oil into the hot exhaust on both sides of the engine which could have lead to a fire and endangered our lives. The dealer removed the engine and transmission from the vehicle in the process broke numerous bolts and repaired with inferior quality parts.after four attempts to pick up the car hoses were left loose and short on antifreeze and Turbo boost hose fell off,now there is a antifreeze burning smell and a rough idle. There were no warning lights or messages. This car was meticulously maintained since brand new I have all records to back up . Ford Corporate has just denied a buy back request and said I don’t qualify for state Lemon law after 2 months at dealer.

Filed Mar 31, 2022 · Electrical, Engine · CA · fire

Got it in the car and pushed the push start button. The cars engine turned over only half way and started to restart and turn over multiple times even though the motor was running halfway. This went on for 15 minutes until i opened up the hood and looked down and after a couple minutes the engine seized and turned off and started smoking, shortly after started on fire from the bottom of the engine. The fire went on for 10 minutes until we turned it off.

Filed Feb 1, 2022 · Electrical · 3,807 miles · WA · fire

The contact owned a 2021 Ford Explorer which was used to haul a 2002 Opus OP. The contact stated that while the vehicle was at the RV dealer for installations to be performed the vehicle caught on fire and was destroyed. The contact was informed after the installation of an electronic brake controller was completed the vehicle was parked and approximately 20 minutes later flames were present coming from the engine compartment. The fire department was called to the scene and extinguished the flames. The vehicle was destroyed. Prior to the incident an electric brake controller was installed in the vehicle and wired DC to DC in order to send a charge to the tow vehicle. The manufacturer was made aware of the failure and a case was opened. The fire department indicated that the fire originated in the engine compartment. A fire report was taken at the scene. The failure mileage was 3,807.

Filed Nov 12, 2021 · TX

When vehicle is up to temperature, there is an overpowering burning smell coming through the vents into the cab. It only occurs at idle and dissipates when the vehicle is in motion. With the hood open, there is some small noticeable amount of smoke coming from the left side of the engine compartment. The smell is not plastic or rubber.