Ford Explorer Structure Problems
Owners have filed 4,912 complaints with NHTSA about structure problems on the Ford Explorer across 31 model years. The 2017 model year has the most (657). The words owners use most often: “pillar trim” (18% of reports).
- 4,912structure complaints
- —median miles at failure
- 54mention a crash
- 156mention an injury
- 12related recalls
- $680typical repair cost reported by owners
- 81%of reports with a speed happened at 50+ mph
What owners describe
Phrases that appear unusually often in these complaints compared with complaints about other cars.
- Pillar trim: mentioned in 898 of 4,912 complaints (18%)
- Structure contacted: mentioned in 457 of 4,912 complaints (9%)
- Flew off: mentioned in 448 of 4,912 complaints (9%)
- Side windshield: mentioned in 404 of 4,912 complaints (8%)
How much does it cost to fix?
Owners who wrote down what they paid or were quoted put the typical structure repair on the Ford Explorer at $680, and half of them between $440 and $1,050.
Based on 136 NHTSA complaints about this problem alone that state a repair bill or quote (2000–2026), converted to 2026 dollars with the U.S. consumer price index. These are owners' own figures, not a quote: they include dealer quotes, and owners who file complaints often faced larger repairs, so they can run higher than typical shop prices. Prices vary by shop, region and warranty coverage. How we calculate this.
At what mileage do structure problems happen?
Based on 2,776 complaints that reported the odometer reading.
How serious are the reports?
Of 4,912 complaints, 54 mention a crash, 18 a fire, 156 an injury.
Ford Explorer structure complaints by model year
| Model year | Structure complaints | Share of that year | Median miles |
|---|---|---|---|
| 2026 Explorer | 2 | 5% | — |
| 2025 Explorer | 7 | 7% | 1,600 |
| 2023 Explorer | 10 | 9% | 10,000 |
| 2022 Explorer | 11 | 4% | 39,000 |
| 2021 Explorer | 24 | 5% | 61,500 |
| 2020 Explorer | 45 | 4% | 40,302 |
| 2019 Explorer | 150 | 50% | 63,125 |
| 2018 Explorer | 288 | 39% | 60,950 |
| 2017 Explorer | 657 | 39% | 76,000 |
| 2016 Explorer | 591 | 24% | 82,750 |
| 2015 Explorer | 410 | 23% | 90,000 |
| 2014 Explorer | 276 | 16% | 92,500 |
| 2013 Explorer | 439 | 20% | 70,000 |
| 2012 Explorer | 144 | 17% | 96,500 |
| 2011 Explorer | 110 | 9% | 101,000 |
| 2010 Explorer | 1 | 1% | 6,900 |
| 2009 Explorer | 2 | 6% | 105,000 |
| 2008 Explorer | 1 | 1% | 7,000 |
| 2007 Explorer | 11 | 5% | 80,000 |
| 2006 Explorer | 11 | 2% | 19,695 |
| 2005 Explorer | 151 | 30% | 77,300 |
| 2004 Explorer | 426 | 33% | 72,000 |
| 2003 Explorer | 354 | 31% | 70,000 |
| 2002 Explorer | 486 | 15% | 66,400 |
| 2001 Explorer | 29 | 8% | 100,000 |
| 2000 Explorer | 29 | 3% | 93,310 |
| 1999 Explorer | 47 | 3% | 100,000 |
| 1998 Explorer | 48 | 2% | 112,000 |
| 1997 Explorer | 50 | 3% | 84,000 |
| 1996 Explorer | 63 | 4% | 123,743 |
| 1995 Explorer | 39 | 5% | 112,762 |
When owners reported it
Related recalls (12)
Structure:body
Model years: 2016, 2017, 2018, 2019
Problem: Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The roof rail covers may come loose and detach from the vehicle.
Risk: A detached roof rail cover can create a road hazard, increasing the risk of a crash.
Fix: Dealers will inspect the roof rail covers and as necessary, repair or replace the push-pins, rail clips, or roof rail covers, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 28, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S54. This recall expands previous NHTSA recall number 21V316. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.
Structure:body
Model years: 2016, 2017
Problem: Ford Motor Company (Ford) is recalling certain 2016-2017 Explorer vehicles. The driver and front passenger B-Pillar door trim may detach while driving.
Risk: Door trim that detaches while driving can create a road hazard, increasing the risk of a crash.
Fix: Dealers will repair the B-pillar trim, free of charge. 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:frame and members
Model years: 2025
Problem: Ford Motor Company (Ford) is recalling certain 2025 Explorer and Aviator vehicles. A mounting bolt for the front subframe may have been tightened improperly.
Risk: A loose subframe bolt may reduce the vehicle's performance in a crash, increasing the risk of injury.
Fix: Dealers will inspect and tighten the subframe bolts as necessary, free of charge. Owners may contact Ford Customer Service at 1-866-436-7332. Owner notification letters were mailed May 21, 2025. Ford's number for this recall is 25S43.
Structure:frame and members; power train:automatic transmission
Model years: 2025
Problem: Ford Motor Company (Ford) is recalling certain 2025 Ford Explorer and Lincoln Aviator vehicles. The transmission may be improperly secured due to loose cross member bolts.
Risk: An improperly secured transmission can result in a loss of drive power, increasing the risk of a crash.
Fix: Dealers will inspect and replace the transmission cross member bolts as necessary, free of charge. If the cross member bolts are missing, dealers will replace the cross member and install new bolts, free of charge. Owner notification letters were mailed January 29, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S03.
Structure:body:roof and pillars
Model years: 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019
Problem: 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.
Risk: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.
Fix: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model years. Owner notification letters were mailed between July 18, 2024 and December 16, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.
Engine; structure:frame and members
Model years: 2022
Problem: Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator and Ford Explorer vehicles. The engine rails may have been improperly heat-treated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, "Occupant Crash Protection" and 301, "Fuel System Integrity."
Risk: Improperly heat-treated engine rails may reduce the vehicle's structural protection in a crash, increasing the risk of injury. In addition, an engine rail may detach and contact the road while driving, increasing the risk of a crash.
Fix: Dealers will perform an engine rail strength test and replace the rails as necessary, free of charge. If the engine rails require replacement, owners will have the option for a vehicle replacement or buyback. Owner notification letters were mailed August 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C13.
Structure:body
Model years: 2016, 2017, 2018, 2019
Problem: 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.
Risk: A detached roof rail cover can create a road hazard, increasing the risk of a crash.
Fix: 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.
Structure:body:door
Model years: 2011, 2012, 2013
Problem: Ford Motor Company (Ford) is recalling certain model year 2011-2013 Explorer vehicles. In the affected vehicles, the interior door handle return spring may unseat, resulting in interior door handle that does not return to the fully stowed position after actuation.
Risk: If the interior door handle return spring is unseated, the door may unlatch in the event of a side impact crash, increasing the risk of personal injury.
Fix: Ford will notify owners, and dealers will inspect all four of the interior door handles and either repair or replace them, free of charge. The recall began on July 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S11.
Structure:body:hatchback/liftgate:hinge and attachments
Model years: 2002, 2003
Problem: On certain sport utility vehicles, the liftgate glass strut may become disengaged or the hinge may fracture allowing the glass to fall and possibly break.
Risk: If the hinge should fracture, there is a potential for the glass to fall and ultimately break and personal injuries could occur.
Fix: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the vehicles built from august 1, 2000 through march 3, 2002, the dealers will replace the hinges and liftgate strut bracket. On vehicles built from march 3, 2002 through june 23, 2003, the dealers will only replace the hinges. The recall began on september 30, 2004. A postcard was sent to owners on december 27, 2004, advising them that parts are now available. Owners should contact ford at 1-800-392-3673.
Structure
Model years: 2000, 2001, 2002, 2003
Problem: Certain pickup truck, van, and mini van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. These units contain a courtesy light or lights that might overheat when the wire harness is exposed to excessive moisture and road salt.
Risk: This overheating condition can cause the running board to melt or cause a fire.
Fix: Dealers will replace the wiring harness on these running boards. Owner notification began march 7, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact southern comfort at 1-800-745-6096.
Structure:body:hatchback/liftgate:support device/strut
Model years: 1995
Problem: Vehicle description: on certain sport utility vehicles, the hydraulic lift cylinder bracket welds could fracture.
Risk: With a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinder ball stud to disengage, unexpectedly allowing the liftgate to fall from an open position.
Fix: Dealers will install liftgate reinforcement brackets. Depending upon the condition of the liftgate sheet metal in the area of the bracket, dealers may also install a larger reinforcement.
Structure:body:hatchback/liftgate:support device/strut
Model years: 1996
Problem: Vehicle description: multi-purpose passenger vehicles. The liftgate assist gas cylinder bracket on the right hand bodyside outer panel was incorrectly welded.
Risk: The gas cylinder bracket may not properly support the liftgate increasing the risk of personal injury.
Fix: Dealers will reinforce the bracket attachment with two pop rivets.
What owners report
Short excerpts of recent complaints, with personal details removed. Full reports are on NHTSA.gov.
The contact owns a 2013 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V031000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that while driving at an undisclosed speed, the front passengerâs side A-pillar trim had…
The contact owns a 2021 Ford Explorer. The contact stated that the fabric inside the cabin of the vehicle covering the sunroof was detaching from the frame and lowering down to obstruct the view of the rear-view mirror and rear glass. The dealer was contacted and informed the contact that the…
manufacturer has failed or is unable to remedy this safety recall for your vehicle in a timely manner. They have only repaired 1 side of the trim. Dealer states driver side is on back order
2022 Explorer ST. Panaramic sun shade does not retract if sun roof is opened nor stay up at the ceiling when sun roof is closed. Sun shade sags down touching my head and just flops around if driving with a window open rendering the rear view mirror useless. Can't see out the rear window.
The contact owns a 2016 Ford Explorer. The contact stated that while driving 65 MPH, the A-Pillar trim detached from the vehicle. The local dealer was contacted; however, the vehicle was not diagnosed or repaired. The contact was informed that the vehicle was previously repaired under NHTSA…
Frequently asked questions
Do all Ford Explorers have structure problems?
No. NHTSA has 4,912 owner complaints about structure for the Ford Explorer. Complaint data shows that the problem is reported, not how many of all cars sold are affected.
Was there a recall on the Ford Explorer structure?
Yes: 12 safety recalls list structure. Check your VIN on NHTSA.gov to see whether the fix was done on your car.
How much does it cost to fix structure problems on the Ford Explorer?
Owners report a typical cost of $680 (half paid between $440 and $1,050), from 136 complaints that state a repair bill or quote, in 2026 dollars.
What do owners say about structure problems on the Ford Explorer?
The most frequent phrase is “pillar trim”, in 898 of 4,912 complaints, followed by “structure contacted” (457).
Other Ford Explorer problems
- Power Train problems (5,091)
- Steering problems (4,059)
- Tires problems (2,965)
- Engine problems (2,057)
- Electrical System problems (2,036)
- Engine and Engine Cooling problems (1,752)
- Suspension problems (1,690)
- Vehicle Speed Control problems (1,672)
See all Ford Explorer problems.