Ford Explorer check engine light comes on

Filed Nov 2, 2026 · Engine, Fuel system · OH

Component Involved: Fuel Tube Support Bracket / Vapor Canister Purge Solenoid Bracket Assembly Part Number: GL3Z-9B325-B Diagnostic Code: P0496 / P1450 Description of Safety Hazard and Defect: I am writing to report a hazardous component defect on my vehicle that presents an immediate safety risk during standard operation. My vehicle triggered an active Check Engine Light with diagnostic trouble code P0496 (EVAP System High Purge Flow). An authorized Ford dealership technician confirmed that the internal mechanism within the purge solenoid bracket assembly (Part GL3Z-9B325-B) failed mechanically by seizing completely in the "stuck-open" position. The failure of this component introduces an uncontrolled, un-metered vacuum leak that continuously pulls raw, highly concentrated fuel vapors out of the charcoal canister directly into the engine's intake manifold. This creates an uncorrectable air-to-fuel ratio imbalance that manifests in severe, dangerous drivability hazards: 1. Engine Stalling in Traffic: The sudden influx of raw vapors disrupts combustion efficiency while idling or driving at low speeds, causing the vehicle to unexpectedly sputter, drop RPM, and stall out in active traffic conditions, creating an immediate crash risk. 2. Severe Hard-Starting/Refusal to Start: Immediately after refueling at a standard gas pump, the action of filling the tank forces massive amounts of vapor through the stuck-open valve. This completely floods the engine cylinders, causing the vehicle to aggressively crank without starting or stumble violently upon catching. This component is failing prematurely well before its intended design life across the EcoBoost engine lineup. Because a sudden engine stall in active intersections or on major highway corridors directly strips the driver of power steering and braking assistance, this systemic mechanical defect constitutes a clear vehicle safety hazard. I request that the federal safety agency log this failure data to advance a mandatory safety recall.

Filed Oct 30, 2026 · Transmission · 120,000 miles · CA

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from the vehicle, and the check engine warning light illuminated. The contact pulled over and was unable to shift out of park(P). The message "Remain in Park" warning message was displayed. The vehicle was towed to a service center, where it was diagnosed and determined that the lead powertrain control module had failed and needed to be replaced. The vehicle was repaired; however, the failure recurred. The contact later received notification of the federal safety agency Campaign Number: 26V402000 (Power Train); however, the part to do the recall repair was not yet available. The vehicle was towed to the dealer but was not diagnosed or repaired. The manufacturer was made aware of the failure. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The approximate failure mileage was 120,000.

Filed Oct 10, 2026 · Engine · MI

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)

Filed Oct 6, 2026 · Engine · CA

At approximately 17,000 miles the Explorer started misfiring, would not shift out of gear and check engine light would flash. Dealer replaced #1 spark plug. 1 week later the car misfiring occurred again, where #4 spark plug was replaced. 18,300 miles later, #1 and #3 spark plugs were replaced due to cracked spark plugs which caused misfire. All instances happened under engine load while merging onto freeway which caused a hazard due to lack of acceleration and reduced speed while getting onto freeway.

Filed Oct 5, 2026 · Engine · FL

My vehhicle has been tested by ford service center and found to be affected by the factory defect that allows coolant to leak causing a catastrophic engine failure where the only remedy is a new engine block. My vehicle has 69919 miles. The problem was recognized when the vehicle bagan to misfire causing the check engine light to come on resulting in expensive diagnostics. Ford has put my safety as well as the safety of my passengers in jeopardy by knowing but not disclosing this factory defect that can become catastrophic at any given time. Service advisories were sent out to employees but no notification to customers.

Filed Sep 22, 2026 · Suspension · CA

Car was purchased brand new from Ford Dealership in May 2023. In September 2026, brought car in for 20,000 mile service at Ford Dealership in San Jose, California to discover that both rear shock absorbers are already worn and shocks are leaking. Dealer recommended that they needed to be replaced. Upon research, this issue has very common with 2022 Ford Explorers (all trims). I believe this is a defective issue that should be investigated. No check engine or warning lights ever came up due to this issue.

Filed Sep 11, 2026 · Engine · 55,000 miles · LA

The contact owns a 2017 Ford Explorer. The contact stated that while driving 70 MPH on the interstate, the engine light illuminated and the vehicle stopped in the middle lane. The contact was able to maneuver and coasted the vehicle over to the side of the road. The instrument panel was illuminated afterwards. The contact stated that the failure was like the federal safety agency Action Number: DP26008 (Engine and Engine Cooling). The vehicle was towed by Firestone and then towed to the local dealer, where the engine was replaced. The manufacturer was contacted, and two letters were sent, three emails were sent to the CEO, and two phone calls were made to Ford Customer Service, who opened a case, but no further assistance was provided. The failure mileage was 55,000.

Filed Sep 9, 2026 · Engine · VA

The check engine light was on. A Ford dealership diagnosed the issue as a coolant intrusion manufacturer defect. There are a number of safety concerns associated with this issue. The primary danger of the coolant intrusion defect is catastrophic engine failure. Severe overheating, internal damage, misfires, fire hazard and oil contamination. There are no active recalls\campaigns\TSB for 2022 Ford Explorer XLT 2.3L EcoBoost engine. The car is available for inspection. Although, the vehicle has not been inspected by the manufacturer, police or insurance agent, the issue was presented to Ford and a claim was submitted to the insurance company that services my Mechanical Breakdown Insurance. So far the insurance company is not authorizing the work without an engine breakdown. They are not excepting the P0300 and P0316 code or the results of a barascope and other test. The Ford corporation will not provide a written statement that confirms the dealerships diagnosis is accurate. Some doctrine that states the engine long block had to be replaced to fix the coolant intrusion defect. Ford has recalled coolant intrusion issues on other engine models. I requested a formal Tiered Goodwill Review based on the Miller v. Ford framework and resolution terms. Since the service center’s portal does not display an automatic, VIN-specific internal factory code for a long block replacement. The request was denied. While the Miller v. Ford litigation established corporate accountability for structural block and cylinder coolant intrusion faults in 2.0L blocks, my 2022 2.3L engine shares a highly similar open-deck block geometry and suffers from the exact same systemic coolant failure. Furthermore, Ford has acknowledged manufacturing line coolant and block defects on 2021–2023 2.3L engines through Customer Satisfaction Programs 23B42 and 23B08. Yet there are no recalls associated with my VIN.

Filed Sep 8, 2026 · Engine, Fuel system · MA

On several occasions when trying to drive from a stopped position I press the gas and the car will move slowly but not shift into gear and then after turning off it struggles to restart. The check engine light is solid but goes away by the next day. This has happened after sitting idling in a parking lot most often but recently it happened 2 times as I was turning left onto a street where I luckily was able to slow roll to the side and not get hit. I brought it in once for service and they struggled to find the issue for hours and eventually said pins in the fuel injector were lose and replaced but it is continuing to randomly happen.

Filed Sep 5, 2026 · Engine, Fuel system · TX

I have a loss of fuel pressure and flow from the fuel tank due to fuel pump failure. Sometimes my engine stalls while driving, and when I go to fill my tank with gas, the engine will not start. I have to engage it for about 15 minutes before it will start. My check engine light comes on, and I will get the low fuel indicator light. But more importantly I cannot pass inspection. I need my car, I am a health care professional I have contacted my dealership, a Ford Motor company representative, and the only response and action I get in return is that they are still waiting on the part to come in. It has been over a year. I need this recall to be completed as indicated by Ford Motor corporation and its dealerships, please. My contact information is [XXX], [XXX], my email is [XXX]. My vehicle is the 2022 FORDÂ EXPLORER, VIN:Â [XXX], my Cell number is [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)