2021 Ford Explorer Engine Problems

Your police Ford Explorer started running rough at low speeds and stalled on the road. The dealer replaced spark plugs and wires multiple times, but the same problem kept returning. It was eventually discovered that cylinder 5 has no compression and needs replacement. A catalytic converter code also appeared during diagnosis, but the dealer never inspected it despite Ford extending warranties on catalytic converters for this known issue. Additionally, your vehicle matches the specifications for recall 24S55 (3.0L engine, built in Chicago during the specified timeframe), which warns that a faulty valve could cause engine failure — you even received the recall postcard and brought it to the dealer.

Your 2021 Ford Explorer is leaking engine oil from the engine area, losing about one drop per day. A Ford dealership confirmed the leak during service and identified it involves the intermediate shaft seals and possibly the engine oil pan, which are known issues covered by Ford technical bulletins. The oil leak creates a safety risk because oil could contact hot engine parts, reduce engine lubrication over time, or drip onto the road and reduce traction for other drivers. Ford has declined to repair the vehicle outside of warranty coverage. The fix will likely involve replacing or resealing the leaking components identified by the dealership.

Your 2021 Ford Explorer has an engine problem that the dealership says matches a known recall issue, but your VIN wasn't included in that recall. You had to pay out of pocket for an engine replacement even though the same defect affected other vehicles. Both the dealership and manufacturer refused to help cover the cost because your vehicle's identification number wasn't on the recall list.

The contact owns a 2021 Ford Explorer. The contact stated that the VIN was included in NHTSA Campaign Number: 24V598000 (Engine). The local dealer was contacted and declined to complete the recall repair. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The contact had not experienced a failure.

My explorer is only 4 years old and it suddenly suffered catastrophic engine failure due to low engine oil. The engine started knokcing and clattering BEFORE any warning lights came on the dash. This could also be due to premature bearing failure which is common in the 3.0 ecboost engines.

The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 30 MPH, the check engine warning light illuminated, and there was a burning odor coming from the vehicle. The contact pulled over and parked and allowed the vehicle to cool down before driving back to the residence. The vehicle was towed to the dealer and was diagnosed with coolant intrusion into the engine and the oil main bearings, causing engine failure. The contact was informed that the engine needed to be replaced. The contact received a notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

The contact owns a 2021 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as needed and then lost motive power. The engine made ticking sounds, and the vehicle was running rough. No warning light was illuminated. The contact coasted the vehicle into the driveway. The vehicle was towed to the dealer, who discovered that the timing chain, spark plugs, and intake valves were fractured. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 80,000.

Recall Action Soon Issue Since 06-20-2025 Unrequested second-row seat movement Unrequested second-row seat movement Recall incomplete Recall service not available right now. We have a remedy but parts are not available right now. We will inform you when the service is available. Or, you can contact your dealer. Contact Dealer Issue Date 2025-06-13 Campaign 25S67/25V393 Description On your vehicle, it is possible that the easy entry seat fold switch on the second-row outboard seats may bind or stick if its surrounding trim bezel was installed incorrectly. If the button is stuck in the down position, the seat may unlatch, fold and or slide unexpectedly, potentially while driving. Safety Risk A seat that unexpectedly folds or slides while driving could increase the risk of injury, particularly in a crash. Remedy Ford Motor Company is working to provide parts for this repair. When the remedy becomes available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge.

The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: 21E11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.

The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

We were driving the vehicle when we experienced a sudden loss of power and acceleration. We also noticed odors of gas. We took it to a Ford authorized dealership and they said it was due to antifreeze in the oil from what they said was a leaking water pump. They recommended a new engine due to the difficulty of changing the internal water pump and the fact it leaked antifreeze into the engine oil, possibly damaging the engine itself. This was the explanation for the fault codes, random gas odors, and loss of power. It was explained this was normal when the sensors detect something wrong with the oil in the engine. Estimated cost provided by the dealership was $11,000 to replace the engine.

I had complete engine failure on my 2021 115,000 mi Ford Explorer ST. The truck was only 3 years old. I heard a knocking noise and pulled over. Throughout the summer smoke had been coming out of the exhaust pipe every time I turned on the car before work. There was a cloud of smoke. A week before the engine failure I had the vehicle in the ford shop. They said everything was fine. I towed the vehicle to Currie Ford in Frankfort and they stated that there was catastrophic engine failure. Nothing could be done but I needed to put a new $12,000 engine in a $63,000 car. They said the warranty did not cover nor do I have any recourse. The safety of my family was placed at risk., I was travelling with my family, my wife, son, daughter, nephew who is [XXX] old and niece who is [XXX] . It left us stranded. There were no warnings. The dealership inspected the car a week before and said it was good to go. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Ford Explorer. The contact stated that while driving approximately 40 MPH, the vehicle lost automotive power. The contact stated that there was an abnormal shaking and vibrating coming from the engine compartment. The vehicle was taken to a nearby mechanic to be diagnosed. The contact was informed that cylinders #3 and #4 had lost compression, and the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in NHTSA Campaign Number: 24V598000 (ENGINE). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 105,000.

The contact owns a 2021 Ford Explorer. The contact stated while coming to a stop, the vehicle stalled with an engine misfire. The contact stated there was a knocking sound coming from the engine with the check engine warning light illuminated. The vehicle was restarted; however, the failure recurred. The vehicle was taken to the dealer where it was diagnosed that valve springs in the engine cylinder needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not included in NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling). The contact was referred to the NHSTA Hotline for assistance by the manufacturer. The approximate failure mileage was 74,000.

The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling); however, the part to do the recall repair was not yet available. The contact stated prior to the failure, the oil was changed 2-months prior at approximately 27,000. The contact stated that while driving at an undisclosed speed, there was an abnormal knocking sound coming from under the hood. No warning light was illuminated. The vehicle was towed to a local dealer where it remained for further diagnostic tests. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 31,000. VIN tool confirms parts not available.

On [XXX], I was driving to my destination. I looked in the rear view mirror and saw a large amount of grayish smoke coming from both tailpipes. Less then 1 mile after that, the Explorer was unable to accelerate. The vehicle was towed to Don's Ford in Utica NY where on October 8th they diagnosed the problem as a blown turbo within the engine. There were no symptoms that illuminated in the vehicle, made any noises and/or other issues that would have prompted me that there was a problem. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Ford Explorer. The contact stated while driving at an undisclosed speed, the exhaust pipe detached and fell onto the ground underneath the vehicle. The vehicle was towed to the residence. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact researched online and discovered Customer Satisfaction Program: 21B35 (Certain 2020 Model Year Explorer Police Vehicles Equipped with a 3.0L EcoBoost Engine Right-Hand Catalytic Converter and Right-Hand and Left-Hand Exhaust Flexible Pipe(s) Inspection); however the contact was informed that the vehicle could not be repaired under the program. The manufacturer was made aware of the failure. The failure mileage was approximately 53,300.

The contact owns a 2021 Ford Explorer. The contact stated that while the vehicle was idling at a traffic light, the vehicle made an abnormally loud sound. The vehicle was taken to the dealer the following day. The dealer diagnosed that both exhaust flex pipes had failed and needed to be replaced. The dealer informed the contact that it was a known failure. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 60,000.

I have a catastrophic engine failure. The dealership (Doherty Ford) in Forest Grove Or acknowledges it. They are working with me. However, Ford has not responded to the dealers request for warranty work. It will be two weeks since I took the car to the dealer with a loud ticking noise. Dealer found a BUNCH of metal in the oil. I'm waiting to hear how Ford will fix it. The car has 45k on it. They also gave me an extended warranty because of all the issues I had with the car when I first got it. The [XXX] steering coupler to the rack was loose and almost came off when I drove it home. I have had a number of other issues. All dealer repaired. The car has also been to Doherty Ford almost exclusively for all its oil changes. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Ford Explorer. The contact stated that while driving 70–75 MPH, the vehicle lost motive power and stalled. There were no warning lights illuminated. The vehicle was towed to the local dealer but was not diagnosed or repaired. The manufacturer was not contacted. The approximate failure mileage was 54,500.

The oil crank case is getting fuel inside. In approximately 1000 to 1500 miles there is a 1 quart and a half of fuel in the oil making the oil level overfill. This oil diluting the fuel issue. Seems like it could be a safety issue if it continues to pour gasoline into the oil crank case. My local Ford dealer, Gary Yomans Ford in Daytona Beach Florida. Verified the concern and told me there’s no repair available yet. The technician further stated that it will eventually destroy the engine from the inside. This issue only started this year. There is at this time 30,959 miles on the vehicle.

The contact owns a 2021 Ford Explorer. The contact stated while driving approximately 30 MPH, the contact heard an abnormal sound coming from under the floorboards. The contact slowed the vehicle to listen for the sound, when the contact depressed the accelerator pedal to move forward, he heard the abnormal sound and described it as the sound of a motorcycle exhaust. The contact stated that he drove forward for a few minutes more when the abnormal noise from under the vehicle was louder and he felt that some object was trapped underneath the vehicle and was hitting the underside causing a loud banging noise. The contact stopped the vehicle and looked underneath the vehicle and observed that the passenger’s side exhaust pipe had detached from the catalytic converter. The contact then checked the driver's side and saw that a crack had opened approximately one inch from where the exhaust pipe was connected to the catalytic convert. The contact stated no warning light was illuminated. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the damage appeared to have been made during an attempt to steal the catalytic converter and referred the contact to a muffler specialist. The vehicle was not repaired. The contact took the vehicle to a muffler repair shop where it was diagnosed that the exhaust pipes had rusted, and the passenger’s side exhaust pipe had detached from the vehicle. The contact did not believe that the rust was the cause in the fracturing of the exhaust pipe from the catalytic converter. The contact researched online and related the failure to manufacturer Customer Satisfaction Program Number: 21E11 Emission Recall (Engine). The manufacturer was informed of the failure. The failure mileage was 58,691.

The contact owns a 2021 Ford Explorer. The contact stated while driving approximately 60 MPH, there was a rattling sound coming from the vehicle. The contact stated that the vehicle started shaking and vibrating before the vehicle lost motive power and stalled. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 69,000.

Last month out of the blue, my 2021 Ford Explorer ST with 15,500 miles would not start. Attempts to jump it were futile. I then had it towed in to the local Ford dealer. At first, they were thinking the starter. A few days later, I got a call saying they could not hand crank the motor as it seized up. In addition to that, they found pieces of metal from the piston in the oil pan. The dealer took apart the intake manifold and found that the valve keeper failed thus dropping the intake valve into the #5 cylinder. This necessitated replacement of the engine, both turbos and even the flywheel and torque converter. This is a known issue with the 2021 Broncos and is even being investigated by the NHTSA. I just wanted to bring awareness that this can happen to the 2021 Explorer with the 3.0 Ecoboost as it was built in the same factory as the Bronco 2.7 and is a similar engine. I can provide the repair invoice upon request. I couldn't get it to upload.

Defective Starter - car will not start, battery, alternator check off ok.

When driving at lower speeds, typically under 30 MPH, the vehicle jerks & lurches. Also sometimes lurches, hesitates or doesn’t react on rapid acceleration such as highway merging or passing. Have had many near-misses. Parking, Reverse & Drive do not always engage immediately upon shifting. I nearly ran over my husband when the car was supposed to be in park and it was still in drive. Car will become extremely hot after extended driving causing the A/C to automatically turn to hot air in order to cool the engine. It smells bad and is not at all comfortable on long summer road trips.

Vehicle began smoking after a cold start at around 9000 miles. Dealer confirmed the issue was happening and the engine was replaced, but the smoking problem remains. No warning lamps, indicators, or DTCs have been thrown to help in diagnostic. Thus far, there has been no safety impact due to the issue.

Gear(transmission), when put in reverse the car goes forward instead of reverse, and Jerks in reverse after 7-15 sec. And it also jerks while accelerating.

A police officer complained of a strong odor of exhaust coming through the hvac vents. Officer complained of a light dizziness feeling. Suv was grounded from service. Complaint was verified. Upon opening of the hood a odor of exhaust gas was smelled on the right side of the motor. No visible leaks could be heard or seen. Suv was driven to our local Ford dealer for repair.