Ford is recalling 288,000 copies of the SUV that created the segment for one of the strangest problems we’ve seen in a long time. The Ford Explorer could have a problem with the trim that covers the roof rails, which could detach. Generally speaking, car parts detaching is bad, but it’s really bad if it happens at speed.
That’s obviously a safety issue, and if this all sounds familiar, it’s because the same thing happened back in 2021. Here’s what you need to know.
Two-Piece Roof Rails Could Separate At Speed
Ford Explorer Roof RailFord
The roof rails comprising the roof rack run front to back, and on the Ford Explorer (like most roof rails) they are made from more than one piece. The recall affects 2016-2019 Ford Explorers, which have two main pieces. One is the actual rail, which bolts to the roof and carries cargo, and the other is the trim cap (highlighted in yellow) that is being recalled because it can fly off.
This problem dates back to 2021, when Ford first recalled more than 615,000 Explorers from the same model years. The company said that the covers, which are almost as long as the roof of the Explorer, could “become detached” while you are driving.
What exactly is happening here? Ford told regulators that the molded clips might not have enough retention strength because of “improper interaction.” The rails could come loose and make wind noise, squeak, or rattle. Oh, and they could fly off completely.
Ford’s 2021 recall only applied to covers that were painted, either in black or silver. Higher-spec trims had plated racks. Ford said the plated racks weren’t a problem because they had more retention strength and weren’t as prone to heating up from the sun. Apparently, excessive heat from the sun was contributing to those molded clips not being up to par. And now, the plated rails aren’t holding up either.
Original Fix Might Not Have Worked Either
Press image of the 2016 Ford Explorer SUVFord
Ford also learned that some of the originally recalled vehicles were fixed in a way that, well, hasn’t worked. While many of the SUVs got four push-pins to hold down the rails, some got a two-part epoxy. It is the epoxy adhesive fix that could come loose over time.
So, this time, all the recalled vehicles will be checked to see if they have push-pin fasteners or not. If they don’t, the Ford or Lincoln dealers will replace any broken original clips and damaged covers, and fasten them with new push pins.
This latest saga wasn’t uncovered by Ford. It was the NHTSA investigating the automaker after receiving 46 questionnaires from owners alleging problems with the covers coming off on the affected vehicles. That included vehicles already recalled and fixed, as well as those not originally recalled.
Ford will begin owner notification through letters sent out in late August. The fix won’t be ready by then, but Ford said it should be ready by late September. Owners will get a second letter to let them know the remedy is ready, and those will go in the mail starting September 21.
If owners have questions about the recall, they can contact their dealer or Ford customer care.
