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.
2021 Ford Explorer engine problems
60 complaints (13% of all complaints for this car). Typical mileage when it fails: 60,000. 1 crash reported.
- owner complaints
- 60
- of this car's complaints
- 13%
- typical mileage
- 60,000
- crashes
- 1
- recalls
- 3
Which part fails
- Exhaust system3
- Exhaust system: emission control: catalytic convertor2
- Engine: other fuel types: turbo/supercharger1
At what mileage
Complaints by mileage at the time of the problem.
Ford Explorer engine problems in other years
Specific symptoms reported on the 2021 Ford Explorer engine
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Loss of power 19Stalling 19Engine failure 15Check engine light 13Won't start 9Knocking 6Overheating 5
Related recalls
Engine and engine cooling: engine: hard parts internal/mechanical
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.
- Risk
- A loss of drive power increases the risk of a crash.
- Remedy
- Dealers will perform an engine cycle test and replace the engine as necessary, free of charge. Owner notification letters were mailed July 3, 2025. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 24S55.
Recall number 24V635000 · Recall details
Engine
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer vehicles equipped with the Police Interceptor Utility Package. In the event of an engine failure, engine oil and fuel vapor may be released into the engine compartment and accumulate near ignition sources such as hot engine or exhaust components, possibly resulting in an engine compartment fire.
- Risk
- An engine compartment fire increases the risk of injury.
- Remedy
- Owners are advised to park and shut off the engine as promptly as possible upon hearing unexpected engine noises, or after experiencing an unexpected engine power reduction, or seeing smoke from the engine compartment. Dealers will update the Powertrain Control Module (PCM) software. In addition, dealers will inspect for connecting rod bearing failure and if necessary, replace the engine long block. All inspections and repairs will be performed free of charge. Owner notification letters were mailed August 15, 2025. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 24S52.
Recall number 24V598000 · Recall details
Engine
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer and Lincoln Aviator vehicles. The right hand motor mount fasteners may have been incorrectly tightened, and may loosen over time.
- Risk
- With a loose motor mount, motor vibration may cause the axle to disconnect from the engine and could result in loss of power, increasing the risk of a crash.
- Remedy
- Ford will notify owners, and dealers will remove and replace the right hand motor mount fasteners, free of charge. The recall began February 3, 2021. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 20S72.
Recall number 20V788000 · Recall details
Related investigations
Loss of Motive Power
On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the âNanoâ engine family. If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in âNanoâ engines, coordinated with the federal safety agencyâs Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited âgrinding burnâ or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplierâs manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production âspike periodâ of May 2021 â October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from âSilchrome Liteâ to âSilchrome 1â. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Fordâs assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with the federal safety agencyâs National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Fordâs assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with âNanoâ engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to
EA23002
What 2021 Ford Explorer owners say
Most recent owner complaints, unedited.
They have fixed zero recalls. I have no wipers at all. I’ve attempted to get a resolution multiple times with no care or concern nor resolution. This is ridiculous. A recall almost 8 months and people have zero wipers!!! And the engine recall. It’s going to blow up before it’s fixed!
Vehicle: 2021 Ford Explorer XLT - 2.3L EcoBoost I-4 VIN: [XXX] Odometer: 127,824 Date of failure: [XXX] Complaint Description: I am reporting a complete engine failure due to coolant intrusion on my 2021 Ford Explorer 2.3L EcoBoost. This is the known defect affecting 2016-2024 Explorer 2.3L engines. Independent shop diagnosis from attached receipt states: "Engine failure due to Head problem, which cylinder 3 + 4 and head in engine known for coolant intrusion. Cylinder Head failure, carbon build up plus Turbocharger also failure." Vehicle stored DTCs P0300, P0302, P0304, P0316 - random misfire and start-up misfire. Symptoms included rough idle on cold start, white smoke from exhaust, loss of power, check engine light. Mechanic confirmed coolant in cylinders 3 and 4 due to cylinder head failure. This matches Ford's own TSB process for coolant intrusion where if coolant is found, the long block must be replaced. Safety Risk: Loss of drive power, stalling, overheating. This occurred at 127k miles with regular maintenance. This is not wear and tear - this is the documented design defect where machining grooves in the head allow coolant to pool and leak into cylinders. I have requested Ford Customer Relationship Center (1‑866‑436‑7332) open a case for goodwill and check VIN for open recalls including 23S05 (PCM/10R60) and the June 2026 2.3L long block recall for roller finger failure. Ford has not yet issued a formal recall for coolant intrusion despite class action litigation. Request: the federal safety agency investigate and expand recall to include 2021 Explorer 2.3L EcoBoost coolant intrusion / cylinder head failures. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
I had a very serious safety failure of my 2021 Ford explorer. On Monday, XXX my 2021 Explorer suffered an unprompted, catastrophic failure matching recall 26S48, but Ford is denying coverage based on build dates. After driving roughly 35mph, pressing the brake, and nearing a stop sign, the explorer put itself into park. The engine compartment made noises and the vehicle continued to roll until the I quickly prompted activating the emergency brake before rolling into the intersection with heavy traffic. Even in park, the vehicle continued to roll (until the e-brake was activated). I had my [XXX] child in the vehicle with me, and thankfully nobody was injured. I had no dash warning lights, or any other signs of impending failure. I had it towed to my trusted (certified) mechanic who inspected the vehicle and diagnosed the following: The transmission output shaft is sheered off, right at the parking pawl. He states this would only happen if the vehicle put itself into park, while moving. This catastrophic failure could lead to a tragic accident, and could kill somebody. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
I am reporting ongoing safety-related powertrain and drivability concerns involving my 2021 Ford Explorer ST in Fresno, California. The vehicle has experienced recurring transmission and driveline problems, including harsh or delayed shifting, hesitation, abrupt gear engagement, jerking/surging, and inconsistent acceleration. These symptoms are similar to transmission concerns documented by Ford for 2021 Explorers equipped with the 10R60 automatic transmission, including harsh/delayed engagement or shifting and potential issues involving transmission controls, solenoid strategy, and main-control valves. The vehicle has also required CV axle/half-shaft repairs, raising additional concerns regarding driveline reliability. I am also concerned about the known rear differential/rear axle mounting-bolt defect affecting 2021 Explorers. Ford has documented that the rear axle mounting bolt may fracture, allowing the axle housing to move. This can result in severe vibration/noise and possible driveshaft or half-shaft disconnection, potentially causing loss of propulsion. The defect may also contribute to a vehicle rollaway hazard. These combined transmission, CV axle, and rear differential concerns create a significant safety risk. Delayed acceleration or engagement can prevent the vehicle from responding as expected when entering intersections, making left turns, merging onto highways, changing lanes, or avoiding hazards. Abrupt engagement after hesitation can cause unexpected vehicle movement. Failure of a CV axle, half-shaft, or rear axle/differential mounting component could cause sudden loss of propulsion or vehicle control. I am requesting that the federal safety agency investigate whether these recurring transmission and driveline problems represent a broader safety defect involving the 10R60 transmission, CV axles/half-shafts, rear differential mounting system, or related powertrain components.
There was no accident, but very close a few times.when I am stopped at a stop sign or light when I press down on the gas pedal the car hesitates I have to pump the pedal to get the car moving or it would stall in traffic. No check engine light is or has been on. I’ve been to 2 different ford dealerships and after there inspection they claim nothing wrong with my car. It’s already cost me a lot if money. When driving I can feel the car surge likes it’s not getting fuel sufficiently real bad at traveling at or below 50 mph. I’m afraid it will stall and get us t- boned but the mechanics say nothing wrong I disagree there is something wrong. I know another person who had the same problem and he got rid of the car, I can’t afford to do that, please do something to get a recall or something before we’re seriously injured or worse.this started about a year ago and getting worse.
The intermediate shaft has gone bad on my 5 year old car. Noticed it on 12/11/25 after owning for 1 year. I’m slowing losing oil which then can cause my engine to go out. I have read many things stating other peoples frustration with this $3.59 part going bad in the 2021 ford explorers but to get it fixed you have to drop the entire engine resulting in it costing $1,800. I think ford should be responsible for this and aware to make a better part.
While driving at highway speeds, the vehicle displays a "Drive Train Malfunction" warning message and the traction control warning light illuminates. Shortly after the warning appears, the vehicle loses power and may enter a reduced-power mode or stall, creating a serious safety hazard in traffic. This has occurred while traveling on the highway, forcing sudden deceleration and creating the risk of being struck by other vehicles. The check engine light is illuminated, and diagnostic code P0A1E is present. The problem is intermittent and unpredictable, making it difficult to determine when the next failure will occur. The vehicle has been taken to Ford for diagnosis multiple times, and significant money has been spent attempting to repair the issue. Despite these efforts, the root cause has not been identified and the problem continues to occur. This defect affects the drivetrain system and impacts the safe operation of the vehicle. The sudden loss of power on the highway places the driver, passengers, and surrounding motorists at risk. Based on discussions with other owners, this appears to be a common issue affecting Ford Explorer Police Interceptor Utility vehicles and warrants investigation by the federal safety agency.
2021 Ford Explorer used a work vehicle (house cleaning business) and family vehicle after hours (driving my daughter to soccer practice 4 times a week). Vehicle has been professionally and properly serviced since we first purchased it in 2021( we have been the only owners). Car has worked great not one single problem other then regular things like tires, brakes and battery all purchased and installed by Ford dealership. The day of the incident the car was working perfectly the entire day. As I drove on the freeway taking my daughter to soccer practice in the evening. I noticed the vehicle started to shake and lose all power the vehicle stopped almost completely in a matter of seconds causing cars behind us to almost crash us from behind it was a miracle no one crashed into us as we were traveling at freeway speed 60-65mph. With the little power the car had I cleared 2 lanes and parked on the side of the freeway. A friend of our picked up my daughter as we were both frightened by the incident. The vehicle gave me no alerts that there was something wrong no warnings on the Ford pass app nothing. I had the vehicle towed to Walnut Creek Ford for inspection. Ford did a diagnostic and found that the engine had a hole from the head to the block. They don’t know how this happened and say they have never seen this before. They said the vehicle is in great shape inside and out and even with 160,000 the car is very well maintained (serviced). This needs to be addressed to Ford as lives were in danger and people could have gotten hurt. They want 13,000 to repair engine, but it seems to everyone(ford technicians and second opinion mechanics) it was an engine factory defect. Vehicle suffered catastrophic engine failure while driving on freeway with no warning from the vehicle system, check engine light never came on nothing. It all happened in a matter of seconds. Engine light only came on after the vehicle was no longer drivable.
I own a 2021 Ford Explorer ST (3.0L EcoBoost) with 47,680 miles. The vehicle is exhibiting a severe metallic knocking noise at idle, a flashing Check Engine Light, and a dangerous loss of motive power while driving. A certified Ford dealership technician (Kendall Ford) diagnosed the vehicle with catastrophic engine failure, requiring a full engine replacement estimated at $13,000.My vehicle is exhibiting the exact mechanical failure described in Recall 24S55 (the federal safety agency Campaign 24V635000) regarding brittle engine intake valves. Although my vehicle shares the same build year, engine type, and failure symptoms as the recalled units, Ford states my specific VIN is not currently included in the 'repair' population.The sudden loss of engine power while operating at highway speeds creates an immediate crash hazard. I request that the federal safety agency investigate whether the scope of Recall 24S55 should be expanded to include this production range.Furthermore, Ford offered a 'goodwill' assistance of approximately $3,762, which I believe is an admission of a known manufacturing defect. At the time of this failure, the vehicle was only 17 days past the 5-year warranty period and well under the 60,000-mile limit. Despite this premature failure and the safety risk, Ford refuses to cover the full replacement, leaving me with a $9,000+ bill for a defect already acknowledged in 90,000 other units.
Questions about the 2021 Ford Explorer engine
Does the 2021 Ford Explorer have engine problems?
Owners have filed 60 complaints about the engine of the 2021 Ford Explorer, 13% of all its complaints.
At what mileage do 2021 Ford Explorer engine problems start?
The typical (median) mileage in owner complaints is 60,000 miles.
Is there a recall for the 2021 Ford Explorer engine?
Yes, 3 recalls: 24V635000, 24V598000, 20V788000. Check your VIN to see if your car still needs the free repair.
Other 2021 Ford Explorer problems
Transmission 128Driver assistance 56Visibility 51Electrical 48Fuel system 28Body 25Brakes 25Seats 18Acceleration 15Suspension 15Lights 8Steering 7Airbags 6Wheels 5Seat belts 3Tires 2Locks 1
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