2021 Ford Explorer Engine Problems

Which parts fail

• Exhaust system
  3
• Exhaust system › Emission control › Catalytic convertor
  2
• Engine › Other fuel types › Turbo/supercharger
  1

Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).

Mileage when the problem started

• Under 25k
  213%
• 25k–50k
  16%
• 50k–75k
  850%
• 75k–100k
  425%
• 100k–150k
  16%
• 150k+
  00%

Owner reports

Selected complaints filed with NHTSA by 2021 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owned a 2021 Ford Explorer. The contact stated while driving approximately 25 MPH he depressed the brake pedal to slow for a traffic signal and the vehicle experienced brake failure. The contact stated no warning light was illuminated. The contact drove over the median to avoid crashing into vehicles directly in front of his vehicle. The contact stated that he was pumping the brake pedal however, the vehicle seemed to accelerate independently. The contact stated that he attempted to shift the vehicle into neutral(N) however, the shifter dial would not move. The contact stated he had attempted to turn the vehicle off but could not turn off the vehicle. The contact stated he was finally able to stop the vehicle prior to crashing into traffic directional poles. The contact stated that the Police arrived on the scene and wrote a report. …

[redacted] after driving less than 10 min. warning signs flashed on screen. I immediately pulled off the road where the vehicle completely shut down and realized my 2021 Ford Explorer was on fire. Bystanders attempted to put the fire out with fire extinguishers but were unsuccessful. My passenger and I opened our doors, I exited and attempted to open trunk to remove wheelchair but could not (because door is electrical). My passenger flung himself onto the ground until bystanders came with a rolling office chair to remove him away from the burning vehicle. Had the bystanders not been there I do not know how I would have been able to move my passenger (25 year old, 200 lb male) away from the burning vehicle. Fire Marshall could not determine cause of fire because vehicle was completely melted/too damaged. …

The contact owns a 2021 Ford Explorer. The contact stated that while driving 80 MPH, the power train warning light illuminated, and the vehicle stalled. The contact was able to exit the highway and the contact was able to pull over to the side of the road. The contact stated that upon turning off and restarting the vehicle, the vehicle operated as needed. The contact stated that the failure had been recurring while driving. The vehicle was taken to Express Care Automotive, where it was diagnosed that a valve in the engine had failed. The mechanic informed the contact that the engine needed to be taken apart for additional diagnostic testing. The mechanic informed the contact that the failure could be related to Ford Campaign Number: 24S55. The vehicle was not repaired. The dealer was not notified of the failure. …

Last month out of the blue, my 2021 Ford Explorer ST with 15,500 miles would not start. Attempts to jump it were futile. I then had it towed in to the local Ford dealer. At first, they were thinking the starter. A few days later, I got a call saying they could not hand crank the motor as it seized up. In addition to that, they found pieces of metal from the piston in the oil pan. The dealer took apart the intake manifold and found that the valve keeper failed thus dropping the intake valve into the #5 cylinder. This necessitated replacement of the engine, both turbos and even the flywheel and torque converter. This is a known issue with the 2021 Broncos and is even being investigated by the NHTSA. I just wanted to bring awareness that this can happen to the 2021 Explorer with the 3.0 Ecoboost as it was built in the same factory as the Bronco 2.7 and is a similar engine. …

The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: 21E11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.

The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 40 MPH, the vehicle lost automotive power. The contact stated that there was an abnormal shaking and vibrating coming from the engine compartment. The vehicle was taken to a nearby mechanic to be diagnosed. The contact was informed that cylinders #3 and #4 had lost compression, and the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in NHTSA Campaign Number: 24V598000 (ENGINE). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 105,000.

The contact owns a 2021 Ford Explorer. The contact stated while driving at an undisclosed speed, the exhaust pipe detached and fell onto the ground underneath the vehicle. The vehicle was towed to the residence. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact researched online and discovered Customer Satisfaction Program: 21B35 (Certain 2020 Model Year Explorer Police Vehicles Equipped with a 3.0L EcoBoost Engine Right-Hand Catalytic Converter and Right-Hand and Left-Hand Exhaust Flexible Pipe(s) Inspection); however the contact was informed that the vehicle could not be repaired under the program. The manufacturer was made aware of the failure. The failure mileage was approximately 53,300.

The contact owns a 2021 Ford Explorer. The contact stated while coming to a stop, the vehicle stalled with an engine misfire. The contact stated there was a knocking sound coming from the engine with the check engine warning light illuminated. The vehicle was restarted; however, the failure recurred. The vehicle was taken to the dealer where it was diagnosed that valve springs in the engine cylinder needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not included in NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling). The contact was referred to the NHSTA Hotline for assistance by the manufacturer. The approximate failure mileage was 74,000.

The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the part to do the recall repair was not yet available. The contact stated prior to the failure, the oil was changed 2-months prior at approximately 27,000. The contact stated that while driving at an undisclosed speed, there was an abnormal knocking sound coming from under the hood. No warning light was illuminated. The vehicle was towed to a local dealer where it remained for further diagnostic tests. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 31,000. VIN tool confirms parts not available.

The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as needed and then lost motive power. The engine made ticking sounds, and the vehicle was running rough. No warning light was illuminated. The contact coasted the vehicle into the driveway. The vehicle was towed to the dealer, who discovered that the timing chain, spark plugs, and intake valves were fractured. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 80,000.

Related recalls

NHTSA investigations

Engine complaints in other Explorer years