The 2016 Explorer suffers from catastrophic transmission cooling system failures and PT unit (PTU) issues that can grenade drivetrains. EcoBoost engines are prone to carbon buildup and coolant intrusion problems that lead to expensive rebuilds.
Transmission Oil Cooler Line Failure and Transmission Contamination
Common · high severity
Typical onset: 60,000-100,000 mi
Symptoms: Transmission fluid in coolant reservoir (strawberry milkshake appearance), Coolant in transmission pan (death sentence for transmission), Erratic shifting or complete transmission failure, Overheating transmission or engine, Check engine light with transmission codes
Fix: The internal transmission oil cooler in the radiator fails, allowing coolant and ATF to mix. Requires radiator replacement, transmission flush at minimum. If coolant contaminated the transmission (common), full transmission rebuild or replacement needed. 8-15 hours labor depending on damage extent.
Estimated cost: $3,500-7,500
Power Transfer Unit (PTU) Seal Leaks and Failure
Common · high severity
Typical onset: 50,000-90,000 mi
Symptoms: Fluid dripping from front-center of vehicle, Whining or grinding noise from front differential area, Vibration during acceleration, AWD malfunction warning light, Burning smell from PTU area
Fix: PTU runs hot and Ford's service interval is inadequate (never, per manual). Seals fail, unit runs dry, bearing and gear damage follows. Requires PTU replacement or rebuild. Half-shaft seal replacements often needed simultaneously. 4-6 hours labor for PTU R&R.
Estimated cost: $1,800-3,200
3.5L EcoBoost Carbon Buildup and Coolant Intrusion
Occasional · high severity
Typical onset: 80,000-120,000 mi
Symptoms: Misfires and rough idle, Loss of power and hesitation, White smoke from exhaust on startup, Coolant loss without visible leaks, Check engine light with misfire codes P0300-P0306
Fix: Direct injection causes severe intake valve carbon buildup. Separate issue: cylinder head defects allow coolant into cylinders, washing oil off cylinder walls and scoring pistons. Carbon requires walnut blasting (6-8 hours). Coolant intrusion requires head gasket replacement or full engine rebuild with updated heads and pistons. 20-35 hours for rebuild.
Estimated cost: $800-1,200 for carbon cleaning; $6,500-12,000 for engine rebuild
Rear Suspension Toe Link Fracture
Occasional · high severity
Symptoms: Clunking noise from rear on bumps, Vehicle pulls to one side, Rear tire wear on inside edge, Wandering steering feel, Catastrophic handling loss if link separates completely
Fix: Ford recalled this (NHTSA 16V-583) but many weren't caught. Rear toe links corrode and fracture at mounting point, especially in salt states. If link breaks while driving, rear suspension geometry collapses. Requires both rear toe links replacement. 2-3 hours labor.
Estimated cost: $400-700
SYNC 3 / APIM Module Failure
Occasional · low severity
Symptoms: Touchscreen black or frozen, No response to inputs, Backup camera not working, Climate controls unresponsive (if integrated with SYNC), Bluetooth and navigation failures
Fix: The APIM (Accessory Protocol Interface Module) behind the touchscreen fails due to heat or software corruption. Sometimes recoverable with master reset or software reflash, but often requires APIM replacement and programming. 1.5-2.5 hours labor.
Estimated cost: $800-1,400
Water Pump Failure (3.5L EcoBoost)
Occasional · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Coolant leak from front of engine, Overheating, Squealing or grinding noise from front of engine, Coolant warning light, Steam from under hood
Fix: Internal water pump on EcoBoost engines fails bearing or seal. Buried behind timing components. Requires timing chain removal for access. Always replace thermostat and flush coolant during this job. 6-8 hours labor.
Estimated cost: $1,200-2,000
Owner tips
Change PTU fluid every 30,000 miles with Motorcraft XL-12 or equivalent — this single step prevents most PTU failures
Inspect transmission cooler lines and radiator neck for seepage every oil change; catch the mixing early and you might save the transmission
Use Top Tier fuel and Italian Tune-Up (occasional highway runs to redline) to minimize carbon on EcoBoost engines
Check rear toe links for corrosion annually if in salt states, even if recall was performed
Monitor coolant level weekly on EcoBoost — unexplained loss means stop driving immediately
Pass on the EcoBoost models unless you have records of PTU services and clean compression tests; the naturally aspirated 3.5L V6 is more reliable but still vulnerable to transmission cooler and PTU failures — budget $3K-5K for deferred maintenance on any used example.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
Consequence: An electrical short circuit can increase the risk of a fire.
Remedy: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.
STRUCTURE:BODY · 25V347000
2025-05-23
Ford Motor Company (Ford) is recalling certain 2016-2017 Explorer vehicles. The driver and front passenger B-Pillar door trim may detach while driving.
Consequence: Door trim that detaches while driving can create a road hazard, increasing the risk of a crash.
Remedy: The remedy is currently under development. Interim letters, notifying owners of the safety risk, were mailed June 5, 2025. A second notice will be sent once the final remedy is available, anticipated November 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S53.
STRUCTURE:BODY:ROOF AND PILLARS · 24V031000
2024-01-19 · PE23001
Ford Motor Company (Ford) is recalling certain 2011-2019 Explorer vehicles. The A-pillar trim retention clips may not be properly engaged, allowing the trim to detach.
Consequence: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.
Remedy: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. Owner notification letters were mailed on July 18, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.
SUSPENSION:REAR · 21V537000
2021-07-15
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin, and the District of Columbia. Exposure to road salt can cause the cross-axis ball joint to corrode and seize, resulting in a fracture of the outboard section of the rear suspension toe link.
Consequence: A rear toe-link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Dealers will inspect and replace as necessary, the cross-axis ball joint (CABJ) knuckle, and replace the rear suspension toe links, free of charge. This recall is an expansion of previous NHTSA recall numbers 16V-245, 19V-435, and 20V-675. Certain vehicles previously repaired will need to return for the new remedy. An interim notification letter notifying owners of the safety risk were mailed on September 10, 2021. Owner notification letters were mailed on March 16, 2022. Owners may contact Ford's customer service at 1-866-436-7332. Ford's number for this recall is 21S32.
STRUCTURE:BODY · 21V316000
2021-05-05
Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The retention pins could loosen and allow the roof rail covers to detach from the vehicle.
Consequence: A detached roof rail cover can create a road hazard, increasing the risk of a crash.
Remedy: Dealers will install push-pins and replace any damaged rail clips and roof rail covers, as necessary, free of charge. The interim owner notification letter was mailed on June 22, 2021. Owner notification letters (remedy available) were mailed on October 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S22.
SUSPENSION:REAR · 20V675000
2021-03-12
Ford Motor Company (Ford) is recalling certain 2013-2017 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin that were previously repaired under a prior recall numbers 16V-245 or 19V-435. The outboard section of a rear suspension toe link may fracture.
Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will inspect the cross-axis ball joint (CABJ) knuckle attached to the rear suspension toe link and replace it as necessary, free of charge. The recall began November 27, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S62.
POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT · 20V692000
2020-11-10
Ford Motor Company (Ford) is recalling certain 2014-2016 Explorer, 2014-2015 Taurus and 2014 Edge vehicles equipped with 2.0L or 2.3L engines and front wheel drive. The support bracket for the front drive axle halfshaft may fail.
Consequence: The failed bracket could result in a loss of park function which can cause unintended vehicle movement, and loss of motive power while driving which increases the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the link shaft bracket, free of charge. Parts are not currently available. Owners received an interim notification detailing safety risk December 8, 2020. A second letter will be mailed when parts become available in January 2021. The recall began February 2, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S63.
SUSPENSION:REAR · 19V435000
2019-06-10
Ford Motor Company (Ford) is recalling certain 2011-2017 Explorer vehicles. The rear suspension toe links may fracture due to stress on the rear suspension.
Consequence: A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, and inspect both rear toe link ball joints, replacing the rear wheel knuckle(s), if necessary, free of charge. The recall began June 26, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S17.
SEATS · 17V767000
2017-11-29
Ford Motor Company (Ford) is recalling certain 2016 F-150 and Explorer vehicles. Loose power seat adjuster pivot bolts may cause the front seat cushions to detach and not properly restrain the seat occupant in the event of a crash.
Consequence: In the event of a crash, a seat occupant that is not properly restrained has an increased risk of injury.
Remedy: Ford will notify owners, and dealers will inspect the tightness of the power seat track upper pivot link bolt, either applying threadlocker or replacing the lift link and hardware, free of charge. Interim letters are expected to go out January 15, 2018. Owners will receive a second notice when the remedy becomes available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 17S40.
WHEELS:HUB · 17E048000
2017-08-28
Ford Motor Company (Ford) is recalling certain Wheel Hub Bearing assemblies, part number HB5Z-1104-C, incorrectly listed as being for installation on the rear axles of 2011-2017 Ford Explorer 4X2 vehicles. These bearings assemblies were manufactured without a self retention feature, possibly resulting in the separation of the wheel or wheel end.
Consequence: A loss of the wheel or wheel end can increase the risk of a crash.
Remedy: Ford will notify the distributors of the hubs specifying that they are to only be used on drive axles. It is believed that none of the hubs were purchased from Ford dealers for the incorrect application. Owners may contact Ford customer service at 1-866-436-7332.
SEATS:FRONT ASSEMBLY:RECLINER · 16V475000
2016-06-28
Ford Motor Company (Ford) is recalling certain model year 2016 Ford Explorer and F-150 vehicles equipped with a manual recline driver's seat. The seat back frame may have insufficient welds which may not meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 202, "Head Restraints" and 207, "Seating Systems."
Consequence: The seat back may not adequately restrain the occupant during a crash, increasing the risk of injury.
Remedy: Ford will notify owners, and dealers will inspect and, if necessary, replace the seat back frame, free of charge. The recall begin on August 18, 2016. Owners may contact Ford at 1-800-392-3673. Ford's number for this recall is 16C11.
ENGINE AND ENGINE COOLING:ENGINE · 16V183000
2016-03-31
Ford Motor Company (Ford) is recalling certain model year 2015-2016 Lincoln MKC vehicles manufactured November 25, 2013, to January 25, 2016, and 2016 Ford Explorer vehicles manufactured October 20, 2014, to January 28, 2016. The affected vehicles are equipped with 2.3L GTDI engines and engine block heaters. These engine block heaters have elements that may overheat while plugged in.
Consequence: Overheating of the engine block increase the risk of a fire.
Remedy: Ford will notify owners, and dealers will replace the engine block heater, free of charge. Dealers will also inspect and replace the electrical cord, as necessary. The recall began on May 18, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S14. Note: Owners should not use the engine block heater until the vehicle has been remedied.
Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Lincoln MKS, and 2016 Ford Explorer vehicles manufactured on July 24, 2015. During vehicle production, the fuel tank attachment bolts may not have been properly tightened. As a result, the fuel tank straps may fracture and the fuel tank could separate from the vehicle.
Consequence: If the fuel tank separates from the vehicle, a fuel leak may occur, increasing the risk of a fire.
Remedy: Ford will notify owners, and dealers will tighten the fuel tank attachment bolts, as necessary, free of charge. The recall began on October 19, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S26.
PARKING BRAKE · 15V464000
2015-07-24
Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Ford Flex, and Lincoln MKS vehicles manufactured May 4, 2015, to May 23, 2015, Lincoln MKT vehicles manufactured May 4, 2015, to May 21, 2015, and 2015-2016 Ford Explorer vehicles manufactured May 4, 2015, to May 23, 2015. The affected vehicles have a parking brake that may not fully engage when applied. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 135, "Light Vehicle Brake Systems."
Consequence: If the parking brake does not fully engage and the transmission is left in a gear other than 'Park' while on a slope, the vehicle may roll away, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will test the operation of the parking brake system, and if necessary, replace the parking brake control assembly, free of charge. The recall began on September 4, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15C07.
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