Ford Recalls 1.88 Million Explorer SUVs for Trim Detachment

Ford Motor Company (NYSE: F) is recalling ~1.88 million (2.2 million globally) model-year 2011-2019 Explorer SUVs because the A-pillar trim retention clips may not be properly engaged. This allows the trim to detach creating a safety hazard for other vehicles, which Ford initially maintained was not a safety problem.

The recalled part was introduced into production on 17 May 2010 and was taken out of production on 3 March 2019. Replacement parts are not available to fix the safety defect. Interim letters notifying owners of the safety risk are expected to be mailed 13 March 2024. Second letters will be mailed once the safety defect repair is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 24S02 . (NHTSA recall 24V0310).

Chronology

• In 2018, Ford’s CCRG (Critical Concern Review Group) received an informal inquiry from NHTSA (National Highway and Traffic Safety Administration) related to exterior A-pillar trim parts detachments on 2012-2014 model year Explorer SUVs. The vehicle uses a plastic bracket bolted to the vehicle structure and the exterior A-pillar trim is attached to the bracket with seven  plastic clips. If all the clip attachments are not properly engaged, the parts can loosen and potentially detach from the plastic bracket. (25) VOQ’s (Vehicle Online Questionnaire) were identified as potentially related to loose, missing or detached trim. Ford provided an example part to NHTSA for review. Ford determined that this concern was not an unreasonable risk to safety due to the low mass/geometry of the part.
• On 20 April 2021, CCRG re-opened this safety defect inquiry based upon (8) new VOQ’s identified in the 2021 calendar year during an unrelated search. CCRG conducted a historical review of all VOQ’s (158 complaints) related to this defect. Ford’s CCRG closed this issue on 13 July 2021, based upon low mass/sharpness of part, overt visible and audible warning of the concern to the customer, and a decreasing trend in warranty and VOQ rates.
• On 15 February 2023, NHTSA opened a Preliminary Investigation (PE23-001) to investigate this problem. Ford opened an investigation in CCRG to manage the Preliminary Investigation response to NHTSA and prepared responses and documents for NHTSA’s questions.
• On 17 April 2023, Ford provided a response to PE23-001.
• In August 2023, Ford received an inquiry from Transport Canada including reports associated with the same problem.
• September 2023 – October 2023. Ford and NHTSA had on-going discussions regarding the concern and the potential causes of the concern. NHTSA indicated that it is NHTSA’s position that the potential occurrence of the trim part detaching while driving is a safety hazard to other vehicles.
• November 2023 – January 2024. In reviewing NHTSA’s position, Transport Canada’s inquiry, and the updated field data associated with Ford’s response, CCRG and engineering team reassessed their previous recommendations. Based upon the new assessment, a proactive action to inspect and replace exterior A-pillar trim parts as required on the suspect population of Explorer vehicles was recommended. Based upon the warranty data, the entire 2011 – 2019 model year vehicle population was determined to be susceptible to detachment and was included in the recommendation.
• On January 12, 2024, Ford’s Field Review Committee reviewed the problem and approved a field action. Ford is not aware of any reports of accidents or injuries related to this safety defect.
• As of 12 January 2024, Ford is aware of 568 VOQ’s and 14,337 warranty reports alleging missing or detached exterior A-pillar trim parts.