Ford Explorer fuel system problems, 2016–2027
216 of the 7,419 complaints owners filed with NHTSA about the Ford Explorer 2016–2027 name the fuel system (NHTSA’s “Fuel/Propulsion System” heading — fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors). The loudest years: 2016 (113), 2022 (37), 2021 (26). Filed under the same heading across these years: 1 manufacturer bulletin, 8 recall campaigns. Every figure is a linked federal record; none is a failure rate, none a repair cost, and none a verdict on one car.
Ford Explorer fuel system problems by model year
Source: NHTSA complaints, recalls, investigations and manufacturer communicationsOne row per model year on file, newest first. A year marked in depth has its own page: the complaints, the owners’ words and every document under this heading for that year.
| Model year | Complaints naming the fuel system | Share of the year’s | Typically at | On file under the heading | |
|---|---|---|---|---|---|
| 2027 | 0 | — | — | — | the year → |
| 2026 | 0 | — | — | 7 TSBs | the year → |
| 2025 | 0 | — | — | 15 TSBs · 1 recall | the year → |
| 2024 | 0 | — | — | 12 TSBs | the year → |
| 2023 | 0 | — | — | 1 recall | the year → |
| 2022 | 37 | 14% | — | 3 recalls | the year → |
| 2021 | 26 | 6% | — | 1 recall | the year → |
| 2020 | 0 | — | — | 2 recalls | the year → |
| 2019 | 17 | 6% | — | — | the year → |
| 2018 | 23 | 3% | — | 1 recall | the year → |
| 2017 | 0 | — | 32k | — | the year → |
| 2016 in depth | 113 | 5% | 11k | 1 recall | the record → |
Two things the counts carry that are not the car: how many of each year were sold, and how long each has been on the road — an older year out-counts a newer one before anything is wrong with it. The share column is the honest comparison across years: what part of that year’s complaints named the fuel system. Nothing here is a rate.
When the fuel system complaints were filed, and at what mileage
Source: NHTSA complaint databaseFiled per calendar year, every model year together: 2016: 40 · 2017: 29 · 2018: 13 · 2019: 18 · 2020: 4 · 2021: 7 · 2022: 11 · 2023: 18 · 2024: 14 · 2025: 25 · 2026: 37
Across the model years, half of the 151 owners who gave an odometer reading reported the fuel system problem between 7,000 and 48,000 miles. A median of reports, not the life of a part.
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the fuel system, from the model years with the most to say. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
Brand new 2016 Ford Explorer with only 6779 miles. Unable to accelerate from a stop through a busy intersection. No indication that anything was wrong prior to this. Several dash lights came on. Car went into limp mode not allowing me to accelerate above 15 MPH. Check engine light, power train light and airbag light all illuminated.
The inside of the SUV smells exhaust gas when you are merging into freeway on ramps and/or passing someone. Especially with the sunroof open
My check engine light has come on multiple times flashing and numerous issues with loss of power while driving. My vehicle will begin running rough and begin shaking while using the throttle.
Ford Explorer Recall – Ongoing Safety Hazard In July 2025, Ford issued a recall notice for my vehicle. Shortly after, the check engine light came on. Starting October 15, 2025, my vehicle began failing to start after refueling—making noise and taking multiple attempts to start.
The contact owns a 2021 Ford Explorer. The contact received notification of NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was not yet available.
What is on file about the fuel system, across the years
Source: NHTSA recalls, investigations and manufacturer communicationsRecall campaigns filed under this heading, any model year
- 25V455000 HighJul 7, 2025 · 850,318 vehicles
- Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
- 24V634000 HighAug 23, 2024 · 24 vehicles
- Ford Motor Company (Ford) is recalling certain 2023 Lincoln Corsair, 2023-2024 Escape, 2024 Mustang, and 2025 Explorer vehicles. The fuel injectors may have been assembled without O-ring support discs, which can result in a fuel leak.
- 22V685000 HighSep 14, 2022 · 69 vehicles
- Ford Motor Company (Ford) is recalling certain 2022 Explorer and Ranger vehicles equipped with 2.3L engines. The fuel line may be loose due to improper tightening of the fuel line connection.
- 22V088000 HighFeb 16, 2022 · 18,366 vehicles
- Ford Motor Company (Ford) is recalling certain 2022 Explorer and Lincoln Aviator vehicles. The fuel filler tube may detach during a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 301, "Fuel System Integrity."
- 20V730000 HighNov 24, 2020 · 17 vehicles
- Ford Motor Company (Ford) is recalling certain 2020 Explorer vehicles equipped with 2.3L engines and 19 gallon fuel tanks. The fuel tank inlet check valve may not be fully welded to the fuel tank shell.
- 19V859000 HighDec 4, 2019 · 3,857 vehicles
- Ford Motor Company (Ford) is recalling certain 2020 Explorer and Lincoln Aviator vehicles. Over time, the protective sleeve on the vapor fuel line may chafe through the plastic liquid fuel line and cause a fuel leak.
- 18V807000 HighNov 14, 2018 · 144 vehicles
- Ford Motor Company (Ford) is recalling certain 2018 Ford Explorer vehicles equipped with 2.3L or 3.5L GTDI engine. Due to an assembly error, the fuel pressure sensor may leak fuel.
- 15V605000 HighSep 28, 2015 · 203 vehicles
- Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Lincoln MKS, and 2016 Ford Explorer vehicles manufactured on July 24, 2015. During vehicle production, the fuel tank attachment bolts may not have been properly tightened. As a result, the fuel tank straps may fracture and the fuel tank could separate from the vehicle.
1 manufacturer bulletin filed under this heading, any model year
- Aug 3, 2026
- Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine, 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine, and 2020-2023 Lincoln Aviator vehicles equipped with a 3.0L EcoBoost hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable
Every one filed under the heading is listed. Quote the document number at a service desk — it is a diagnosis the maker has already written down.
Other systems with a record on the Ford Explorer
Source: the same files- transmission and drivetrain problems
- engine problems
- electrical problems
- backup camera and parking sensor problems
- brake problems
- visibility and wiper problems
- body and structure problems
- steering problems
Every system, every model year: Ford Explorer problems by year →
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsWhich Ford Explorer years have the most fuel system complaints?
2016, 113; 2022, 37; 2021, 26. Raw counts, and an older year has had longer to collect them; by share of each year's own complaints the loudest is the 2022 (14%).
Is there a recall for the fuel system on the Ford Explorer?
Yes — 8 campaigns are filed under this heading across these model years: 25V455000 (2023), 24V634000 (2025), 22V685000 (2022), 22V088000 (2022). A recall is matched by VIN, and applies to specific years; check yours at nhtsa.gov/recalls.
When do fuel system problems show up on the Ford Explorer?
Owners who gave an odometer reading reported it at a median of 17,700 miles across the model years; half of them between 7,000 and 48,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Fuel/Propulsion System" heading cover?
Fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.