2022 FORD EXPLORER Fuel/propulsion System Problems

I own a 2022 Ford Explorer purchased in April 2025. Since purchasing the vehicle, I have experienced multiple defects affecting safety and normal use. The instrument cluster becomes foggy, making it difficult to clearly see my speed while driving. The infotainment screen intermittently malfunctions and affects the backup camera display, reducing rear visibility. I also experienced fuel contamination that was confirmed and repaired by the dealership. In addition, the rear HVAC air vents close and do not provide airflow to the back seats. The vehicle has been taken to the dealership four separate times for different issues. Despite these repair attempts, the problems have continued or new issues have appeared. Due to the ongoing defects and safety concerns, I do not feel safe or confident operating this vehicle.

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

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 same issue occurred repeatedly on October 23 and October 30, worsening each time. On November 3, we brought the car to a Ford dealership. They confirmed there is no available fix for the recall and said there’s “nothing they can do.” I explained this was a safety issue since I drive my son with a disability to therapy daily. They told me I would have to pay out of pocket for repairs even though the problem is linked to the recall. On November 8, while driving in Arizona, my vehicle again failed to start after refueling. Later that day, it lost power on the road, the speed dropped suddenly, and it would not accelerate. The same stalling and jerking occurred again on November 10 while my husband was driving. We contacted Ford Corporate and NHTSA, but both said nothing could be done because the recall label says the car is “still drivable.” This is inaccurate and dangerous. The car stalls and loses acceleration randomly, creating a serious risk of an accident. On November 21, the car again failed to start after refueling. This has happened multiple times each week, and Ford continues to delay a fix. My vehicle is unsafe to drive, and this unresolved recall poses an ongoing safety hazard to my family and others on the road.

When i accelerate, the car jerks back and forth and stalls. ford has said the car was throwing codes but the TECH didnt feel the issue so they sent me on my way.... well fast forward to today, i am informed my car has thrown codes 4 times in the past few days and this morning i was scared to drive my car it was bad... and i have a [XXX] daughter. Our safety is my top priority and it doesnt seem to matter to anyone else INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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.

My wife was driving the car all of a sudden the check engine light came on, and it started to flash on and off. The car started sputtering. She pulled over turned the car off and called me. I informed her to wait a little bit and restart the car. She did – and then the check engine light came on, but was no longer flashing, and a car started running as if no problem. I had the code checked out it is P0300 – which is an error code of random misfire detected in the engine. Fortunately, she was not evolved in an accident, even though she was traveling on the highway. I am taking it to the dealer as his recommended. This happened when the mileage on the odometer read 40,144.

Purge valve has now failed twice since owning the vehicle (1 year and 5 months old). First purge valve went out when the vehicle was only 4 months old (Oct 2022). Second purge valve went out at 1 year old (June/July 2022). The main concern that I am reaching out for- Drivers side headlight - a small bird flew into the headlight and cracked it. Placed a hole in the headlight, causing water to get in and stop working. There is no way that a headlight should crack from a bird flying into it.

I smell exhaust/gas fumes when driving my car. It is a very intense smell. This happens several times a week.

Vehicle was pushing blue smoke, dealership replaced the turbo. Blue smoke returned furiously and dealership replaced the top end including valve assembly. While on a 900 mile journey through northern idaho, the engine completely failed at highway speed leaving me stranded. Ford believes they have cured the valve issue when in fact a new long block motor failed on first long distance trip. Please don't let anyone else go through this I lost thousands of dollars in out of pocket expenses, missed my best friends funeral among other things. These manufacturers need to be held accountable for poor workmanship!!!

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.