Ford Explorer collision warning 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 20, 2026 · Brakes, Driver assistance · VA

On October 19, 2026, I experienced a serious braking malfunction while driving my 2025 Ford Explorer ST at highway speed. While my foot was on the accelerator, the vehicle unexpectedly began braking repeatedly without me pressing the brake pedal. The vehicle jerked and pulsated as though the ABS was activating. When I attempted to brake, the pedal felt unusually loose and did not immediately respond to the pressure I applied. I eventually managed to slow down and pull onto the highway shoulder. This created a dangerous situation that put me and other motorists at risk. Multiple warnings appeared, including Anti-Lock Brake System Fault, Electronic Parking Brake, Pre-Collision Assist Not Available, and Powertrain Malfunction/Reduced Power. The dashboard also displayed “Park Brake Not Applied,” although I had not activated the parking brake. FordPass reported that the ABS control module was sending invalid information to other vehicle modules and that the electronic parking brake had a fault. This was the second nearly identical incident. On September 29, 2026, I experienced similar unexpected braking and difficulty controlling the brakes. The dealership diagnosed a software glitch and charged approximately $690 for a system reboot and update, which they stated was not covered under warranty. Despite that repair, the dangerous braking malfunction returned less than three weeks later. The vehicle was towed back to the Ford dealership on October 19 and is awaiting further diagnosis. I am concerned about this recurring braking malfunction and the risk of a serious collision. I request that the federal safety agency investigate this potential safety defect.

Filed Oct 15, 2026 · Brakes, Driver assistance · GA · 1 injury

I was driving at approximately 5mph when my car suddenly slammed on breaks. The pre collision warning popped up. There was no obstical in site. Happened approximately 30 mins ago. Had immediate pain in my shoulder, neck and head.

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 21, 2026 · Transmission · AZ

Illuminated powertrain malfunction (wrench) indicator with DTCs C00A6 and C0631, caused by failure of the front axle disconnect actuator/intermediate shaft on an AWD 2020 Explorer at 46,821 miles. The vehicle displayed the wrench light along with "Service AdvanceTrac," "4WD Fault," "Hill Start Assist Not Available," and "Pre-Collision Assist Not Available." Multiple driver-assistance and stability systems disabled themselves simultaneously, including AdvanceTrac stability control and pre-collision braking. Loss of stability control and automatic emergency braking without warning is a safety concern, particularly at highway speed. The fault was intermittent at first. The dealer had the vehicle five days and could not duplicate it. Within a week of getting it back the condition became nearly constant. The repair is Ford TSB 25-2568, which replaces the front axle disconnect actuator/intermediate shaft with a revised, non-disconnecting design and a new halfshaft. Ford has published this bulletin repeatedly since spring 2023 — 23-2114, then 23-2174 (July 2023), then 25-2373, then 25-2568 (January 2026) — for 2020-2021 Explorer and Aviator AWD vehicles built on or before 30-Aug-2021. Ford has redesigned the part and eliminated the disconnect feature entirely, but has issued no recall or customer satisfaction program. Because this vehicle is out of factory warranty by age at 46,821 miles, the roughly $2,500 repair fell to me. I request that the federal safety agency review whether a known design defect that disables stability control and pre-collision braking warrants a safety recall rather than a service bulletin.

Filed Jun 23, 2026 · Driver assistance · MA

have been getting a warning coming up saying pre-collision sensor not available sensor blocked over 100 times brought it to the dealership and they said that the bracket for the sensor is broken due to road debris, impact or snow and ice buildup with no evidence of any damage

Filed Jun 4, 2026 · Driver assistance · MA

pre-collision warning light comes up, saying sensor blocked and sensor is not blocked. Brought it to the local dealership found that the cruise control module bracket is damaged no visible damage or strikes to the bumper dealership says not under warranty, and Ford is aware of a widespread issue with the bracket snapping on the sensor behind the front bumper

Filed Jun 1, 2026 · Driver assistance · NH

Precollision assist warnings on in the car saying system unavailable. Took to the dealer and showed me the sensor for this was broken and my cost would be $1800 to repair. My vehicle only has 16000 miles on it and is covered by an extended warranty and 3 year BTB warranty. Dealer claims the sensor was hit by an external force so it wasn't covered. I said we have hit nothing and my vehicle shows no damage. Internet says these can fail by bumper collision or hitting a pot hole. I think it is a vehicle safety issue that you don't design something that can withstand hitting a bump or pot hole or why wouldn't you give clearance for the bumper to flex. Ford can't tell me what happened to the sensor and to me that is a safety issue. I spoke with the service advisor and went up to service manager and called Ford customer care and they refuse to do anything about it.

Filed May 27, 2026 · Electrical, Transmission · NJ

I am filing a complaint regarding a recurring safety-related electrical and AWD defect in my 2020 Ford Explorer. My vehicle repeatedly displays the following warnings while driving: “4WD Fault Service Required” “Service AdvanceTrac” “Pre-Collision Assist Not Available” “Hill Start Assist Not Available” The issue began about a year ago occurring intermittently every few weeks and disappearing after restarting the vehicle. It has progressively worsened and now appears almost immediately after driving only a few feet. The defect affects multiple critical safety systems including AWD/4WD, traction/stability control, hill assist, and collision avoidance systems. I have contacted Ford multiple times. Ford only opens customer service cases but has not provided a permanent repair. Ford is aware this is a common issue with 2020 Explorers specifically, and later model years appear to have been corrected. Numerous owners report the exact same failures online. Ford has issued service information involving software reprogramming, module communication faults, and wiring harness issues, but only Ford dealerships can perform the required programming. This appears to be a widespread manufacturing or engineering defect and creates a serious safety concern while driving. Vehicle Information: 2020 Ford Explorer Mileage: Under 55,000 miles I respectfully request that the federal safety agency investigate this issue for a potential recall or mandatory corrective action.

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.