Vehicle: 2020 Ford Explorer XLT Active Recall: Ford #26S48 The transmission on my 2020 Ford Explorer has completely failed, leaving my vehicle inoperable and my family stranded. The vehicle is currently located at a local Ford dealership, just sitting there waiting for a fix. My vehicle started shifting gears randomly while driving, causing a lot of jerky movements. My wrench light came on the dashboard, and I instantly took my SUV to a local Ford dealership for inspection. After the inspection, the dealership described metal shards floating in my transmission fluid and stated that the only way to fix the issues is to pay for a brand-new transmission to be installed. Having both the dashboard warning light (wrench icon) and shifting issues alongside metal shards strongly points to active internal mechanical damage matching the 26S48 recall pattern associated with my exact VIN. Although my VIN is tied to active safety recall 26S48 for this exact component failure, the dealership refuses to repair it, stating that an official corporate remedy/parts are not available yet. Furthermore, the dealership attempted to quote me roughly $10,000 out of pocket for a transmission replacement for an emergency fix. When I contacted Ford Corporate, they confirmed the lack of a current remedy and refused to provide alternative transportation (such as a loaner or rental vehicle), instead telling me to pay out-of-pocket for a rental or independent repair and "hope" for a future reimbursement. As a single-income family currently navigating an extreme financial hardship due to medical issues, paying thousands out-of-pocket or taking on high debt for a manufacturer defect seems impossible and an unfair burden. Forcing a family to choose between severe financial strain or being left indefinitely without a vehicle due to a delayed manufacturer remedy defeats the entire protective intent of the safety standards enforced by NHTSA.

Source: NHTSA complaint ODI #11764997 · view all complaints for this vehicle at nhtsa.gov

I am writing to formally express serious concerns regarding the safety of a Ford vehicle that continues to carry a 5-star safety rating despite multiple known, safety-critical defects that emerged after relatively low mileage. Two major issues developed between approximately 62,000 and 72,000 miles. Both are documented by Ford Technical Service Bulletins (TSBs), yet neither has been addressed through a formal recall. My vehicle’s warranty expired at 60,000 miles, leaving me responsible for more than $3,000 in out-of-pocket repair costs. Issue 1 – Front axle seal leak (TSB 23-2174) The front axle seal began leaking fluid. According to the TSB, the original affordable seal is no longer available, requiring replacement of the entire axle assemblies at a cost of approximately $2,000. Failure to complete this repair risks axle lock-up and a potential collision. Issue 2 – All-wheel-drive module ground wire omission (TSB 23-2061) Ford failed to install a required ground wire on the AWD module. This caused multiple warning lights to illuminate, including powertrain failure and collision-assist system failure. I refused to allow my wife and children to ride in the vehicle throughout the winter because of these critical warnings. The repair, which required replacement of the AWD module, cost more than $1,000. These are not minor inconveniences. An axle that can lock up, loss of AWD capability in hazardous conditions, and the simultaneous failure of collision-assist systems present clear and foreseeable risks of serious crashes. A vehicle exhibiting these defects does not merit a 5-star safety rating, particularly when the problems are known to the manufacturer and affect used-vehicle buyers who may lack the financial means to perform the repairs. I respectfully urge the NTSB to investigate these issues, determine whether the continued 5-star rating is appropriate, and encourage Ford to issue formal recalls so that owners are not left to bear the cost and risk of repairs.

Source: NHTSA complaint ODI #11759840 · view all complaints for this vehicle at nhtsa.gov

I experienced catastrophic brake failure on July 14 2026. Total loss of brakes that led me to narrowly miss several vehicles. The Ford Dealership in Manor TX stated it needed the brake booster replaced and program reset. After researching this is a problem with my VIN that was offered free replacement until 2022 this should be a total unexpired recall. I could have lost my life or someone eles! It’s part of the Customer Satisfaction Program 20B51:

Source: NHTSA complaint ODI #11753747 · view all complaints for this vehicle at nhtsa.gov

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed on a six-hour trip, the low tire message was displayed, and the tire quickly deflated. The contact slowed down and pulled into a service center and inflated the tire. The vehicle was then driven without failure. While pulling into a parking lot, the driver's side rear wheel detached from the vehicle. The previous tire lug nut had been factored out for installation at a tire center. The towing company became aware that all five bolts had sheared off, and some of the bolts were in the parking lot. The vehicle was inspected by the local dealer, and it was determined that the rear passenger’s side wheel was missing lug nuts as well. The contact stated that three of the five lug nuts had sheared off. The failure recurred. The manufacturer was not contacted. The failure mileage was approximately 57,065.

Source: NHTSA complaint ODI #11758565 · view all complaints for this vehicle at nhtsa.gov

I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain 2020-2021 Explorer AWD vehicles. The bulletin specifically identifies C0631 and/or C00A6 and the front axle disconnect actuator/intermediate shaft and directs replacement with a revised intermediate shaft. I am concerned this is a safety defect because the failure resulted in AWD/drive-mode malfunction while multiple driver-assistance systems became unavailable. I request that NHTSA investigate this known failure and determine whether a safety recall is warranted.

Source: NHTSA complaint ODI #11764430 · view all complaints for this vehicle at nhtsa.gov