Ford Explorer stalling problems

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 16, 2026 · Transmission · 72,000 miles · SC

The contact owns a 2020 Ford Explorer. The contact stated that on more than one occasion, the vehicle stalled while driving. The contact stated the vehicle experienced difficulty shifting into gear. The vehicle was taken to an independent mechanic, where diagnosis confirmed the transmission failed and required replacement. The vehicle was repaired. The manufacturer was notified of the failure. The contact associated the failure with the federal safety agency Campaign Number: 26V402000 (Power Train). The failure mileage was 72,000.

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 4, 2026 · Lights · MI

Drivers side low beam intermittently does not operate. Becoming more and more common. Now, passenger side lamp is doing the exact same thing, and both shut down while in motion at night. These lamps should not fail like this. There is an existing recall for 2026 vehicles with the exact same issues.

Filed Oct 3, 2026 · Transmission · TN

While driving the vehicle, in any mode, the car will stutter or "cough" causing it to slow down. I have to pull the vehicle to the slow lane until it eventually corrects itself. Also, on multiple occasions when I hit the gas the car stalls until I let off the gas pedal and let the car "think" for a moment and then it will drive. This happens a lot at stop signs or when the light changes. I will hit the gas to go and the car does nothing. It feels like the engine stalls even though the car is still on. On a few occasions I will be driving at high speeds on the interstate and I will punch the gas to go around a car and it stalls. On EVERY occasion when this happens, whether I am pulling out at a busy intersection or am driving with the flow of traffic on the interstate, I am around multiple cars and cars are having to hit their brakes or swerve to avoid my vehicle. When this happens it only takes about 10 seconds for the car to go again but that is still long enough to get hit. I am scared to drive my car with my children in it because of this. A have contacted the dealership but they say to bring it in when it is acting up but it does not do it everyday so there is no way for me to do that. They also said they could keep it and drive it but they do no offer a loaner vehicle so I cannot be without my only vehicle for multiple days at a time. On other occasions the vehicle seems like it looses momentum and is very sluggish. Sometimes the car jerks into gear instead of a smooth transition.

Filed Sep 21, 2026 · Fuel system, Transmission · KS

While driving with the cruise on at 74 mph the vehicle jerked as if the brakes had been tapped. I shut off the cruise and tried to accelerate but nothing happened. At this point I signaled to change lanes and pulled to the right shoulder. There were no dash lights or warning alarms prior to the engine stalling. Clearly an engine stalling at this rate of speed could have ended bad for all 5 passengers and surrounding vehicles. Vehicle is being towed to Augusta, KS Ford dealer this morning 9/21/26. Vehicle was scanned and is showing a hard code for low pressure to fuel pump. This vehicle is not currently included in the NHSTA Campaign 25V455000.

Filed Sep 8, 2026 · Engine · MI

I am writing to report a severe, inherently dangerous engineering defect regarding the internal water pump design on the 2016 Ford Explorer equipped with the 3.5L naturally aspirated V6 engine.On September 8, 2026, my vehicle experienced a sudden, catastrophic primary seal failure of the internal water pump while operating. The vehicle immediately began dumping large quantities of engine coolant onto the ground from the designated engine block weep hole located on the lower passenger side. Because Ford engineered this specific engine with the water pump hidden entirely behind the front timing cover and driven directly by the engine's timing chain, any mechanical failure of the pump poses an immediate, severe safety risk to the driver and occupants. If the secondary pump seal fails or the weep hole becomes obstructed, coolant dumps directly into the engine crankcase, mixing with the engine oil. This sudden loss of lubrication can cause the internal pump bearings to seize rapidly, leading to the timing chain snapping or jumping tracks.The consequences of this design create two distinct, critical safety hazards:Sudden Engine Stall at Speed: A seized water pump or broken timing chain will cause an instantaneous, un-commanded engine shutdown while traveling at highway speeds. This immediately cuts off the vehicle's power steering assist and power brake booster, placing the driver at extreme risk of a high-speed collision. Passenger Cabin Hazmat Hazard: A major coolant dump underneath the engine bay onto hot exhaust components generates blinding steam and toxic chemical fumes that can enter the vehicle’s HVAC system, severely impairing driver visibility and breathing.This internal, chain-driven water pump design is a known, systemic manufacturing defect that forces vehicle owners to pay between $3,000 and $5,000 in preventative labor to fix an auxiliary cooling component before it destroys the entire engine block. I urge the federal safety agency to open a formal safety investigation int

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)

Filed Aug 15, 2026 · Engine, Fuel system · MO

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.

Filed Aug 6, 2026 · Driver assistance · 65,000 miles · IA

The contact owns a 2015 Ford Explorer. The contact stated that the rear-view camera turned on and off unintendedly. There were no warning lights illuminated. The contact received notification of the federal safety agency Campaign Number: 25V695000 (Back Over Prevention). The contact stated that the vehicle stalled. The local dealer was contacted, but the vehicle was not diagnosed or repaired. The dealer informed the contact that the part for the recall repair was not available. The dealer confirmed that Mustang vehicles were being repaired. The vehicle was not diagnosed or repaired. The manufacturer was contacted and notified of the failure. The failure mileage was approximately 65,000.