Off the Roof Rails – Ford Recalls 616,967 Explorer SUVs

Ford Motor Company is recalling 2016-2019 model Explorer SUVs. The retention pins on 616,967 Explorers could loosen and allow the roof rail covers to fly off the vehicle. The National Highway Traffic Safety Administration first asked about the issue in early 2020 following 11 reports of detachment of roof rail covers supplied by JAC Products of Saline Michigan.

This by AutoInformed’s count is the 22nd Ford Motor recall this year in the U.S. Ford said it is not aware of any reports of accident or injury related to this safety defect, perhaps the reason Ford took it’s time, according to the Chronology below.

“Incomplete or improper interaction between the roof rail cover and the molded retention pins can result in reduced retention strength. Insufficient over-travel of the roof rail cover to the clip on the base rail also can prevent the cover from being properly seated,” Ford said in the required NHTSA filing. “Pull force data confirms plated variants have increased retention strength and are less susceptible to solar loading, which is a contributing factor to this condition. Vehicles with plated roof rail covers are not included in this action.”

Dealers will install push-pins and replace any damaged rail clips and roof rail covers, as needed, free of charge because it is required by U.S. law. Production Dates are September 19, 2014 to March 03, 2019. For the 2020 model year, the Ford Explorer was redesigned using a different roof rack. Explorers with this safety defect may exhibit increased wind noise and/or squeaks and rattles. Certain Ford Explorer vehicles are built with plated roof rail covers. Pull force data confirms plated variants have increased retention strength and are less susceptible to solar loading, which is a contributing factor to this condition. Vehicles with plated roof rail covers are not included in this action.

The fix uses four additional push-pins per side to secure the existing roof rail to the vehicle. Affected vehicles are configured with the Base, Police, XLT, or Sport trim level with Black painted, Absolute Black painted, or Silver painted roof rail covers – roughly 9% of the total produced.

Chronology of Events Leading to Explorer Recall

• April 2020 – NHTSA inquired into 11 VOQs – complaints – related to roof rail cover detachment while driving. Ford reviewed warranty claims related to the affected component.
• May – August 2020 – The issue was brought to Ford’s Critical Concerns Review Group (CCRG) for review on May 12, 2020. The CCRG considered the rates of detachment, severity, and detectability of a loose or rattling cover. The CCRG determined this issue did not present an unreasonable risk to motor vehicle safety due to the low projected probability of detachment, low mass of the component, and high detectability of a loose roof rail cover through visual and audible means.
• September 2020 – Ford shared the CCRG’s analysis with NHTSA and made the agency aware of its recommendation to address the concern with a customer satisfaction program that would provide customers who experience the defect outside of warranty with a one-time repair.
• November 2020 – Ford’s Field Review Committee reviewed the concern and approved a one­time repair extended coverage action for 10 years/150,000 miles.
• December 2020 – March 2021 – Post-launch of the extended coverage program, Ford continued to monitor field data. Ford believed that the extended coverage program, in combination with the high detectability of this concern, would result in the proactive repair of vehicles prior to progression of the issue to a potential detachment.
• April 2021 – Ford met with NHTSA to review the updated data. NHTSA requested that Ford conduct a safety recall for this concern. Ford discussed with NHTSA the rationale for excluding vehicles with plated roof rail covers from a safety recall. Warranty analysis shows a significantly lower rate of detachment and loose/rattling claims on vehicles with plated roof rail covers. Projections indicate no trend of increasing rate for plated variants. Pull force data confirms plated variants have increased retention strength and are less susceptible to solar loading, which is a contributing factor to this condition.
• April 30, 2021 – Ford’s Field Review Committee approved a Safety Defect Recall.

Owner notification letters are expected to be mailed June 28, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S22. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov