2022 Ford Explorer FUEL/PROPULSION SYSTEM

Component/System: Low-pressure fuel pump/fuel delivery system related to Recall 25S75. Vehicle is a 2022 Ford Explorer Hybrid. Description: My vehicle is subject to Recall 25S75 involving the low-pressure fuel pump that can cause loss of fuel pressure and engine stalling. The vehicle has stalled six times between about 15,000 and 35,000 miles. The issue is intermittent but ongoing. The vehicle is available for inspection. What failed or malfunctioned: The fuel delivery system appears to lose pressure consistent with Recall 25S75, leading to engine stalling and temporary inability to restart. Safety risk: One stall occurred while driving on a highway on 9/30/23 at about 15,000 miles. The engine lost power without warning and I had to coast to a gas station. Sudden loss of propulsion in traffic creates a serious crash risk. Other stalls happened in driveways or parking lots after the vehicle had been running. In several cases the vehicle would not restart for 20–60 minutes, which could be dangerous if it occurred in traffic or an unsafe location. Reproduction or dealer confirmation: Two incidents required towing to Ford dealerships. The vehicle has been taken to Ford dealers multiple times. Earlier incidents were not linked to a recall at the time. Now that Recall 25S75 has been issued, the symptoms match. Ford has not repaired it because the remedy is still under development and parts are unavailable. Inspections: The vehicle has been inspected by Ford dealerships and towed twice by AAA for diagnosis. No permanent fix has been made because the recall remedy is not yet available. Warnings or symptoms: Stalls often occurred after the vehicle had been running. The vehicle then would not restart for 20–60 minutes. In one event there were dashboard errors. There was not always a clear warning before a stall. Reason for complaint: The recall has been open since July 2025 with no remedy available. The vehicle continues to stall. I do not feel it is safe to operate.

The fuel level indication on my 2022 Ford Explorer behaves erratically and inaccurately. The issue occurs regardless of whether the vehicle is parked uphill, or downhill, just any time I’m on an incline, and it happens even when the fuel tank is full. The fuel gauge and/or “miles to empty” reading changes unexpectedly and does not reliably reflect the actual amount of fuel in the tank. This behavior is not limited to low fuel conditions. The problem appears consistently raising concerns about inaccurate fuel level reporting and potential fuel system malfunction. The vehicle has not displayed warning lights, and the issue is resolved by refueling, but changing parking orientation does not reset or cause the fuel gauge to show accurate reading. I have had one instance of needing to call roadside assistance as it falsely read I was out of fuel.

The exhaust/ downpipe broke while driving down the road.

I can’t get my gas tank below 1/4. It always starts lagging and has a late reaction time. I also have to use better gas and get treatments to help. With no solution in sight

Charcoal canister and vapor purge valve failure. Broke down twice after putting gas in my car right at the pump. One time in not the greatest neighborhood that I have to drive through to get to work. Putting myself at risk by sitting at a gas pump with a car that sounds like it wants to start but keeps just choking. After fueling a few times prior I noticed the idle of the car getting very low and reported it to the dealer. They replaced both cats. Problem didn’t go away. Got an emissions warning when I tried to start the car at the gas station after fueling. Car has 70,000 miles on it.

This vehicle is used as a law enforcement vehicle. The officer was attempting to make a traffic stop on a speeding motorcycle. The officer turned around and accelerated relatively fast considering the speed and potential to not stop. When the pedal reached its maximum downward position, it just snapped off. The pedal appeared to only be connected by two small plastic rings which broke off. see the attached photos.

Upon cold start exhaust burns blue smoke. Vehicle was taken to dealership and diagnosed with a bad turbo seal, resulting in motor being removed and turbo replaced on passenger side at 2865 miles. Now a 6439 miles the drives side turbo seal is causing the same issue, blue smoke pouring out of the exhaust on cold starts. Car is driven with care and not abused in anyway. Other owners of the same version of this vehicle with two turbos are also experiencing the same issue. For both environmental and safety reasons, these engines should be recalled and inspected for this premature failure.