Ford Explorer engine failure problems

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 Oct 24, 2026 · Transmission · CO

About 3 years and 3 months after a Power Control Module reflash was done in March 2021 under the Customer Satisfaction Program (CSP) 20B27, vehicle was brought to Ford dealership on 06/07/2024 with mileage at 79,730 for multi point inspection due to vehicle runs rough and hard time accelerating. Diagnostic code was P0316. Service tech recommendation was to replace engine for $14,000.00 including parts and labor (declined recommendation). Brought vehicle to another dealership but found no codes. Instead replaced engine motor mounts, sparkplugs, and air filter due to noticeable vibrations. Dealership service tech inspected engine but found no abnormal findings. Went to another Ford dealership on 10/08/2026 to check Code P0299 that appeared on OBD test and for further inspection due to sluggish acceleration from full stop and slows down going uphill. Ford's guidance stated that torque converter failing due to mileage, acceleration/power loss from dead stop. Recommended fix was to replace the transmission for $8,461.03 (declined recommended service). On 10/23/2026, I picked up my vehicle from the dealership. During my return journey from the dealership, I encountered the same sluggish acceleration. A safety hazard that is attributed to a malfunctioning torque converter, a know problem for Ford. Consequently, Ford dispatched CSP 20B27 to assist in safeguarding the transmission converter from overheating. Regrettably, this intervention proved ineffective in mitigating the problem. Ford issued CSP 20N07 to extend warranty coverage of the automatic transmission torque converter for 12 months from RO date which in my case, RO date on CSP 20B27 was 03/19/2021. Despite the 12-month eligibility period not being met, my vehicle should have remained covered. Initially, Ford was aware of a transmission torque issue and was attempting to resolve it through CSP 20B27 and CSP 20N07. Currently, mileage is at 85K miles but I'm hesitant to drive due to safety concerns.

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 5, 2026 · Engine · VA

Sudden catastrophic engine failure due to coolant mixing. This resulted in a safety issue due to time and location of the event. From online consumer reports this event happens just after 100,000 miles to the 2017 Ford Explorer SUV's and is a KNOWN event that Ford has NOT disclosed. Regular maintenance can NOT prevent this event and stopping the use of the vehicle only helps if it is immediate and the problem known. That Ford hasn't disclosed this possibility of failure nor suggested preventative measures is a safety concern.

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 Oct 4, 2026 · Engine · VA

Engine hesitated, kept hesitating/slowing down until 2017 Ford Explorer just stopped. Towed SUV to Koons Ford Service Center. Charged $200 for diagnostic assessment. Informed that oil/coolant mix due to water pump failure. Diagnose: replace Engine Long Block and Hardware and thermostat. Costing $11,195.04 for job. Never mentioned what happened to cause this. At another dealership, mechanic told us of the federal safety agency Recall 25V685000 regarding this malfunction. Note: Koons Ford has had a "history" with this SUV, only working on recalls when we push the issue. Also, requiring a $200 diagnostic charge each time the vehicle is seen. This location is where we bought the vehicle.

Filed Sep 30, 2026 · Brakes, Steering · 110,000 miles · FL

The contact owns a 2012 Ford Explorer. The contact stated that while driving 50 MPH, the steering wheel seized. The contact pulled over to the side of the road, the vehicle was restarted; however, the failure persisted. The vehicle was towed to the residence, and an independent mechanic arrived to diagnose the vehicle. The contact was informed that the steering wheel had seized due to the electric power steering failure. The contact was informed that the electric power steering and ABS module needed to be replaced. The failure mileage was 110,000.

Filed Sep 17, 2026 · Engine · OK

The water pump on these explorers are internal and if not caught by a professional in time, the water pump will fail and cause catastrophic engine failure

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.