2020 Ford Explorer Engine

The car has 66,311 miles and both catalytic converters are cracked and leaking exhaust into the passenger compartment. The down pipe flex joint on the passenger side is leaking and the one on the driver’s side is deteriorating. Car is currently at the dealership being evaluated. This appears to be a known problem with the 3.0 Ford Explorer in the model years 2020-2022 but no recall has been issued. The problem has been identified by both the dealership and an independent transmission repair shop. There has been no warning lights just strong exhaust smell in passenger compartment when idling at stop signs or lights.

The contact owns a 2020 Ford Explorer. The contact stated that upon coming to a complete stop at a red traffic light, the vehicle inadvertently shut off in the middle of the roadway and failed to restart. The battery warning light was illuminated. No further information was available. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. After investigating the failure, the contact related the failure to NHTSA Action Number: EA23002(Engine). The manufacturer was notified of the failure and a case was filed. The contact was also referred to the NHTSA Hotline for assistance. The failure mileage was 112,000.

I was driving down upper pleasant ridge road caldwell id . Had cruise control on doing 50 and all of a sudden car just stopped in the middle of the road. No warning, no noise, no smoke , no check engine light nothing. I was in the middle of the road ,in the dark. Had to call the canyon county sheriff out to help me not get hit by a car waiting on the tow truck. Put jumper cables on battery my new battery bought in jan 2025 started smoking what ever happen fried my battery . Took it to dealership waiting on info

slipping gears between 1&2nd gear, harsh/delayed shifting, some power loss. Vehicle is around 120k miles

Ac compressor has gone out 3 times. This car year, make, is known to have this problem.

The weld which attaches the tail pipe to the muffler failed causing the pipe to strike the pavement while the vehicle was in motion which resulted in sparks and potential fire hazard.

The vehicle was purchased on 10/26/22 and the first occurrence of the issue and was reported to Autonation Ford Littleton and was dropped off by 11/02/22. The issue reported was that the engine to the vehicle would shut off and we were unable to turn it back on for a few minutes. This occurred while at a stop light in the middle of traffic. We dropped it off and they were unable to duplicate the issue. I then had the same issue reoccur and it was in the shop from 06/01/23 and the repair order was closed out on 07/31/23. They were unable to duplicate the issue again. We then had it occur again and we dropped the vehicle off on 06/28/25 and did not get it back until 08/19/25. Again, the issue was not able to be duplicated. The vehicle has shut off, and is unable to turn back on for minutes at a time, while we have been at a stop sign, a stop light, in parking lots, and even parked in our garage. The safety concern is sitting with hazards on in the middle of the road at a light surrounded by traffic. Every time it occurs, we call the dealership and set up an appointment. During the wait period, it usually happens 2-3 more times. We opt to not drive it when it begins happening this much. The vehicle has only been inspected by the dealership at this time and there were no warning lights. The engine would shut off and either go to just accessory power or no power at all. Between these repairs there was also a warning that stated: Gear Shift Malfunction. This occurred while I was on the interstate 3 different occasions and I would lose all power. I would have to keep pressing the gas pedal, hoping that it would begin accelerating. This was reported more than once as well and the entire transmission was eventually replaced.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at 35 MPH, the contact heard an abnormal sound coming from the engine. The vehicle was taken to a dealer, where it was diagnosed that the Right-Hand and Left-Hand Exhaust Flexible Pipes needed to be replaced. The vehicle was not repaired. The contact related the failure to Ford Customer Satisfaction Program Number: 21B35 (Right-Hand Catalytic Converter and Right-Hand and Left-Hand Exhaust Flexible Pipe(s) Inspection; however, the vehicle was not covered. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 40,000.

Manufacture hasn’t made a remedy available for the recall and it’s past its anticipated availability date. Manufacturer Recall Number 24S52 NHTSA Recall Number 24V598

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power after coming to a stop. The contact stated that the oil pressure message was displayed. The contact stated that the failure had occurred thirty days after an oil change. The vehicle was towed to the dealer, who determined that the engine had seized and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 130,000.

The contact owns a 2020 Ford Explorer. The contact stated while driving 40 MPH, there was an abnormally loud sound coming the rear end of the vehicle. No warning light was illuminated. The contact returned to the residence and inspected underneath the vehicle and became aware that the right exhaust had detached. The vehicle was taken to a dealer where it was diagnosed and determined that right exhaust needed to be replaced. The vehicle was not repaired. The contact related the failure to Customer Satisfaction Program: 21B35 (Right-Hand Catalytic Converter and Right-Hand and Left-Hand Exhaust Flexible Pipe(s) Inspection); however, the VIN was not included in the Customer Satisfaction Program. The manufacturer was notified of the failure but provided no assistance. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 40,416.

The contact owns a 2020 Ford Explorer. The contact stated that while driving 30 MPH, the vehicle lost motive power and stalled. An abnormal sound was coming from the engine. No warning light was illuminated. The contact was able to pull over to the side of the road where the vehicle failed to restart. The vehicle was towed to an independent mechanic who diagnosed the vehicle and determined that the front passenger’s side axle had detached, and the engine had failed. The vehicle was not repaired. The contact was provided NHTSA Campaign Number: 20V788000 (Engine). The manufacturer was made aware of the failure and confirmed that the VIN was not under recall. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 90,000.

The contact owns a 2020 Ford Explorer. The contact stated that while idling at a stop light or while the vehicle was parked, the vehicle was shaking abnormally. The check engine warning light was illuminated. The failure was intermittent at first but became a constant failure. The vehicle was taken to the dealer who diagnosed that the variable camshaft timing (VCT) system had failed and needed to be replaced. The failure was linked to an unknown Customer Satisfaction Program; however, the vehicle was not included. The vehicle was not repaired. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 60,000.

The contact owns a 2020 Ford Explorer. The contact stated while driving 45 MPH, the vehicle lost motive power and stalled. The contact stated that the engine coolant overheat warning light was illuminated. The vehicle was restarted, and the contact pulled over. The contact then continued driving at 10 MPH. The vehicle was taken to the dealer and was diagnosed with coolant sensor failure. The contact was informed that the coolant sensor needed to be replaced. The vehicle was repaired; however, the failure persisted. The manufacturer was notified of the failure and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 93,000.

At only 5 years old and at 113k miles in January 2025 I was told by my local dealership that the right side catalytic converter was cracked and needed replacement to pass inspection. In March 2023 the left side catalytic converter was replaced under a service bulletin 21E11. Prior to that both sides intermediate exhaust pipes and flex connectors were replaced in November 2021. I have searched online and read of many other Ford Explorer ST owners complaining of failed catalytic converters. Ford is doing nothing to address this if the vehicle is outside of the required 80k mile emissions warranty. It seems to me there’s a known problem and this ride side catalytic converter should also be recalled. No catalytic converter should be consistently failing this early in a cars lifespan. Catalytic converters are known to last over 10 years and 300k+ miles. I’ve also seen where the same Ford Explorer but under the Police Interceptor name has had the right side catalytic converter recalled.

The contact owns a 2020 Ford Explorer. The contact stated that upon starting the vehicle, there was an abnormal sound coming from the engine. The contact stated that the failure recurred increasingly. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the left and right catalytic converters were fractured. The dealer was then notified of the failure and informed the contact that only the left catalytic converter replacement was covered under warranty. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 92,000.

The contact owns a 2020 Ford Explorer. The contact stated while driving at approximately 40 MPH, there was an abnormal exhaust odor inside the cabin of the vehicle. The contact stated no warning light was illuminated. The contact stated that the odor was present while driving. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the left exhaust flex pipes needed to be replaced. The vehicle was repaired. The contact was advised by the dealer that the manufacturer had issued a Customer Satisfaction Program: 21E11 – Left side Exhaust Flexible Pipe(s) and Left side Catalytic Converter inspection and replacement (Engine and Engine Cooling), however, the vehicle was no longer covered under warranty. The manufacturer was informed of the failure. The failure mileage was approximately 39,000.

The contact owns a 2020 Ford Explorer. The contact stated while driving 60 MPH, the vehicle experienced a hard downshift and failed to accelerate as needed. The contact stated that several unknown warning lights were illuminated. The vehicle was towed to the dealer where it was diagnosed with catastrophic engine failure. The contact stated that the vehicle remained with the dealer unrepaired due to the cost of the repair. The manufacturer was notified of the failure. The failure mileage was unknown.

While driving on an interstate highway, my car slipped from drive to neutral on its own. Within a few seconds the transmission returned to drive. When the car reached its destination, it went into park, but wouldn't shift out of park for 20 minutes. It finally shifted into reverse, and drive as needed until reaching my home. While trying to shut off the car at my home, it showed that it was in park, put the car was rolling. Finally the car stopped rolling and appeared to be in park. The car hasn't been driven since that day. I had the car towed to the local Ford dealer who sold me the car. They determined that the parking pawl malfunctioned and part of it destroyed the transmission. When I researched recalls on this vehicle, I noticed NHTSA Recall #23v-069 appears to be the same problem that I experienced. The Ford dealership said that this recall didn't include my car's VIN #, so that is why I never received any notifications of this recall. I believe that my car should have been included in the recall and I wouldn't be facing an $8,000 + bill for a new transmission. Ford will not pay for the repair because the car has 66,000 miles, which is over the 60,000 limit. The service technician at the dealership said that I did nothing to cause the transmission to be destroyed. This obviously was a very dangerous situation, and this is why there is a recall on 2020 Ford Explorers. I believe that more cars need to be included in this recall.

There is an exhaust leak under the car that propagates into the ventilation system and also when a door is open while idling. This is a known issue for some models with the 3.0L engine under emission recall (21E11), but does not include my VIN even though the powertrain is identical. Dealer replaced some flex tubing to try and correct, but that did not work. It's a safety issue because the smell is strong and there's no way to tell how much carbon monoxide is present to the passengers.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull to the shoulder of the roadway, where the vehicle failed to restart. The low oil pressure and the check engine warning lights were illuminated. The vehicle was taken to an independent mechanic, who diagnosed that the engine had failed. Additionally, the mechanic informed the contact that there was a hole in the engine block. The vehicle was not repaired. No further information was available. The manufacturer was notified of the failure and a case was opened. The contact was referred to the NHTSA hotline for assistance. The failure mileage was 93,000.

Car went to dealer for engine noises and was told the motor needed replacement. Was never told what was actually wrong with the car in my paperwork. Then brought to another mechanic and was told the car needed a motor due to a bearing in the lower end had failed. Then noise went away was driving it to another dealer when the motor completely locked up.

The contact owns a 2020 Ford Explorer. The contact stated that while operating the vehicle, exhaust fumes were present inside the cabin of the vehicle and an excessively loud exhaust sound was coming from the exhaust system. The vehicle was taken to the local mechanic to be diagnosed. The contact was informed that the weld on the catalytic converter was cracked. The contact was informed that the catalytic converter needed to be repaired or replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 38,000.

The factory welds at passenger outlet on the exhaust broke.

The contact owns a 2020 Ford Explorer. The contact stated while driving 40 MPH, there were exhaust fumes inside the vehicle. There were no warning lights illuminated. The vehicle was taken to the dealer and a diagnostic was performed. The dealer stated there were 2 cracks in the exhaust system, causing the exhaust to enter the cabin of the vehicle. The dealer also stated that both flex pipes needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 27,000.