Ford Explorer knocking problems

Filed Sep 24, 2026 · Engine · OH

Driving down road when motor started making noise. No lights on dash or anything then it started to buck and wouldn’t accelerate.i pulled over on the highway and shut it off and called a friend for a tow. Got the car checked out and turns out it was almost 5 quarts low on oil and has spun a rod bearing and almost locked up.

Filed Aug 28, 2026 · Transmission · CA

While driving my car, the transmission suffered a mechanical failure. The vehicle is shuddering when decelerating, causing sudden jolting and knocking sounds with no warning or error messages. Because of this defect, the vehicle poses an immediate hazard and cannot be safely driven. The vehicle was dropped off on Monday August 24 with the Ford dealership and the service team has made contact to confirm the transmission valve body, pump and park pawl are damaged and confirmed that this is a result of the federal safety agency Recall 26V402 (Ford Recall 26S48). The Ford service team have advised that they are able to complete a temporary repair to get the car working again only if I agree to pay them $4,400 despite the recall. Ford’s interim remedy involves replacing failed components with identical, un-remediated parts that possess the exact same engineering flaw, which fails to permanently resolve the safety crisis. Furthermore, I am facing severe difficulties obtaining immediate vehicle recovery, interim repairs, and alternative transportation (such as a loaner or rental vehicle) from authorized Ford dealerships while the vehicle remains grounded due to this manufacturer safety defect. Ford’s corporate office was also contacted on Tuesday to discuss after we were advised that we would need to pay to get the car drivable and the dealership refused a temporary vehicle or rental during repairs. A Ford corporate employee replied that they would make contact within 24 hours. When we did not hear back, we contacted the corporate office again on Thursday and spoke to a rep who stated they would escalate and we would hear back Friday (today). Ford has failed to make contact with any resolution. I am filing this complaint to document a premature, complete component failure under this recall, and to request that the federal safety agency review the manufacturer’s remedy timeline, as leaving safety-compromised vehicles un-remediated on the road or stranded presents an unreasonable risk to public safety.

Filed Aug 5, 2026 · Engine · MI

Exhaust manifold turbo charged cracked while driving. Exposing everyone in the vehicle to raw exhaust inside the vehicle every time it is driven. The replacement part is back ordered until September 16th from the dealership. I was told this is an extremely common issue with ford explorers. I don’t understand how this part is not recalled. It has slowly gotten worse and worse. No warning lamps came on. You can hear the engine or manifold rattling/ticking while the vehicle is running. The vehicle is available for inspection. I brought the vehicle to a repair shop called MIDAS. Where I was told exactly what was wrong with it. The problem is reproduced every single time the vehicle is on. The replacement part is also not covered under fords “emissions warranty”. Even though it is part of the emissions.

Filed Jul 10, 2026 · Lights, Suspension · MA

Faint popping and knocking sound coming from front suspension, LOUD clunk coming from rear suspension when going over bumps. Both seem to cause vehicle to be floaty while driving. Also headlights sometime flicker while driving with switch in auto position and sometimes will not shut off after exiting vehicle ( have to turn switch to off position and then back to auto to resolve ) Vehicle has approximately 21k miles on it but off warranty due to time. Will be bringing into local repair shop soon.

Filed Jun 16, 2026 · Electrical, Engine · CA

Description On your vehicle, it may be possible that one or more engine camshaft roller finger followers were not properly installed at the time of engine assembly. Safety Risk An improperly installed engine camshaft roller finger follower may result in engine failure, resulting in a no-start condition or a loss of motive power. A loss of motive power increases the risk of a crash. Your vehicle may also experience engine ticking or tapping noise, and or a low-volume oil leak due to this condition. Remedy A remedy is not yet available. Ford Motor Company is working to provide parts for this repair. When the remedy becomes available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge. The remedy is anticipated to be available 4TH quarter of 2026. Next Steps Contact your dealer for more information to schedule the free service.

Filed Jun 12, 2026 · Suspension · TX

Driving home from work at intersection of XXX and [XXX] after stopping at signal light heard loud knocking sound. Stop check tires and could find anything wrong visually. Drove off and vehicle making clunking noise from rear. Drove home parked vehicle. Called warranty agency Fidelity and had vehicle towed to Planet Ford I-45. XXX Fidelity denied claim state the rear differential mounting bushing failure caused by workmanship performed in previous recall repair 23S55/22S27. 5/1/26 Planet Ford submit claim to SSSC 5/8 SSSC claim denied. 5/12/26 Called Ford Customer Care - Case# XXX as of 6/12/ 26 pursuant to 49 USC Chapter 301 the persistent recall issue has not been repaired. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed May 20, 2026 · Steering, Wheels · NJ

When putting the car in reverse and moving backwards start to feel the vehicle look drive power and knock sounds. Sounds likes and feels like gear teeth or not aligned. When putting the car into drive the vehicle jumps a little and you hear a lout pop noise.

Filed May 7, 2026 · Engine · ID

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.

Filed Apr 3, 2026 · Steering, Suspension · GA

My 2023 Ford Explorer (VIN: [XXX] ) has a persistent front suspension clunk/rattle/knock when driving over small bumps or uneven pavement at low speeds (8–20 mph). The noise is repeatable and has progressively worsened. It matches the condition described in Ford Special Service Message SSM 52405, which identifies a manufacturing defect involving a loose internal pressure tube inside the front strut assembly on 2023 Explorers built between December 1, 2022 and August 31, 2023. My vehicle falls inside this build range. This defect affects vehicle stability, steering control, and suspension performance over bumps and uneven surfaces. The internal looseness in the strut assembly creates unpredictable handling characteristics, which is a safety issue. Multiple owners have reported the same symptoms, and Ford has not issued a recall. I am requesting that the federal safety agency investigate this defect and Ford’s handling of repairs, as owners are being asked to pay out‑of‑pocket for repairs related to a known manufacturing defect that affects safe vehicle operation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Mar 26, 2026 · Body · TX

the safety problem is a known recall that remains unfixed since 2024 and should have higher priority for FORD then they currently do. Since owning the vehicle there have been numerous occasions where when on highway speeds the trim flies off. First two times there was nobody behind us but the third time a piece flew off of the trim causing the car behind us dramatically. Luckily no accident was caused but potential for flying debris should be a higher priority for you and FORD as well. Debris should be a major concern specially in highway with speed up to 75mph debris can be deadly. Honestly this debris is a ticking time bomb for anyone driving with these trims that have not popped off yet. We dont need to wait for someone to be seriously hurt or killed in order to move up this repair in priority. I believe FORD and maybe even you guys consider this a low priority becaue it is "cosmetic" but flying debris can be deadly specially when we know its an issue last 2 years