2016 Ford Explorer body and structure problems
597 of the 2,476 complaints owners filed with NHTSA about the 2016 Ford Explorer name the body and structure (NHTSA’s “Structure” heading — body panels, frame, roof rails, trim and glass as fitted). Filed under the same heading: 27 manufacturer bulletins, 4 recalls, 2 NHTSA investigations. Every figure below is a document in a federal file, linked; none is a failure rate, and none is a verdict on any one car.
What owners filed about the body and structure
Source: NHTSA complaint database4 of the 597 reports a crash · 1 a fire · 6 injuries. Self-reported, unverified.
Filed per year: 2016: 7 · 2017: 17 · 2018: 5 · 2019: 14 · 2020: 7 · 2021: 18 · 2022: 14 · 2023: 93 · 2024: 107 · 2025: 249 · 2026: 66
Half of the 294 owners who gave an odometer reading reported the body and structure problem between 50,000 and 110,000 miles. A median of reports, not the life of a part.
2,476 complaints in all about the 2016 Ford Explorer, 66 filed in 2026. The whole picture, every system →
Counts are owner reports to NHTSA, not verified defects, and scale with how many of these were sold; nothing here is a rate. NHTSA groups complaints coarsely, so “Structure” means the same area of the vehicle, not one fault.
Across model years: Ford Explorer body and structure problems, every year on file →
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the body and structure. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
The plastic pieces on the "a" and "b" pillar, driver and passenger side are coming off
The vehicle has 12-15 ppm of co in the interior while in operation. The vehicle was placed out of service after testing
The vehicle had co in the interior as high as 30 ppm. Unit was placed out of service due to the above conditions and officer headaches
I already submitted one complaint today about the cabin filling with exhaust fumes while accelerating but then I was reading other issues people were having and wanted to ensure you were aware of mine as well. I had to have the cooling fans replaced because they would come to a screeching halt when you would shut the motor off.
We took our 2016 Explorer limited back to the shop for the second time after smelling exhaust in the cabin again while in operation. During the first visit the dealer began discussing the Ford repair bulletin that came out 30 days or so ago that was to fix the exhaust leak.
What is on file about the body and structure
Source: NHTSA recalls, investigations and manufacturer communicationsRecalls filed under this heading
- 26V448000 HighJul 14, 2026 · 288,314 vehicles
- Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The roof rail covers may come loose and detach from the vehicle.
- 25V347000 HighMay 23, 2025 · 492,145 vehicles
- Ford Motor Company (Ford) is recalling certain 2016-2017 Explorer vehicles. The driver and front passenger B-Pillar door trim may detach while driving.
- 24V031000 HighJan 19, 2024 · 1,889,110 vehicles
- 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.
- 21V316000 HighMay 5, 2021 · 616,967 vehicles
- 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.
NHTSA investigations
- PE23001 Windshield trim molding Item detachmentopened Jan 27, 2023 · closed Feb 8, 2024
- On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this failure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injur…
- EA17002 Exhaust Odor in Passenger Cabopened Jul 27, 2017 · closed Jan 17, 2023
- During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and occupational safety fields. The agency conducted an in-depth investigation that encompassed the review…
27 manufacturer bulletins filed under this heading
The 0 newest are listed; every one is on the model year’s page. Quote the document number at a service desk — it is a diagnosis the maker has already written down.
Trouble codes named on this system
Codes a bulletin or an owner’s complaint about the 2016 Ford Explorer names on this model year; a code with a record of its own links it.
Other systems with a record on the 2016 Ford Explorer
Source: the same files- engine problems 500 complaints
- transmission and drivetrain problems 218 complaints
- electrical problems 131 complaints
- fuel system problems 113 complaints
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsAre body and structure problems common on the 2016 Ford Explorer?
They are documented: NHTSA holds 597 owner complaints naming the body and structure on this model year (24% of everything owners filed about it), and 27 manufacturer bulletins, 4 recalls, 2 NHTSA investigations are filed under the same heading. Whether it is a problem on one particular car is a diagnosis, not a count, and a count says nothing about how many were sold.
Is there a recall for the body and structure on the 2016 Ford Explorer?
Yes — 4 campaigns are filed under this heading: 26V448000, 25V347000, 24V031000, 21V316000. A recall is matched by VIN; check yours at nhtsa.gov/recalls.
When do body and structure problems show up on the 2016 Ford Explorer?
Owners who gave an odometer reading reported it at a median of 82,500 miles; half of them between 50,000 and 110,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Structure" heading cover?
Body panels, frame, roof rails, trim and glass as fitted. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.