Ford Recalls Nearly 300,000 Explorers for Loose Roof Rails
Ford Motor Company has announced its 57th recall of the year, targeting a substantial number of its Explorer SUVs. This latest action addresses a persistent issue with roof rail covers that may become loose and detach, posing a safety risk. The recall encompasses 288,314 Explorer vehicles manufactured between 2016 and 2019, critically noting that some of these vehicles have already been subjected to prior repair attempts for the very same defect.
Details of the Extensive Ford Explorer Recall
On a recent date, Ford officially initiated a widespread recall affecting approximately 288,314 Explorer SUVs spanning the 2016 to 2019 model years. This significant measure was prompted by concerns over the potential detachment of roof rail covers. Alarmingly, this recall includes vehicles that Ford has previously attempted to repair for identical issues, highlighting a recurring problem in the resolution process.
The National Highway Traffic Safety Administration (NHTSA) shed light on the core problem, revealing that previous repair efforts were often "technician-sensitive." This designation implies that improper application of adhesive or failure to replace damaged retention clips during earlier service appointments contributed to the continued loosening of the roof rail covers. The defect is not limited to a specific type of finish, affecting both satin- and chrome-plated, as well as painted roof covers.
Owners of the affected vehicles may notice several warning signs, including an increase in wind noise, persistent squeaking, and rattling from the roof area. A more definitive indicator is the appearance of a visible gap or misalignment between the roofline and the cover itself. In response to these concerns, Ford dealers are now instructed to thoroughly inspect the roof rail covers. Any broken clips or damaged covers will be replaced, and push-pin fasteners will be installed if they are missing. Ford has acknowledged at least one incident of an alleged accident directly linked to a detaching roof rail.
The timeline of this issue traces back to 2020, when Ford first became aware of the potential defect and initiated a one-time extended warranty repair, utilizing a two-part epoxy to secure the covers. However, it wasn't until April 2021, following discussions with NHTSA, that Ford issued an official recall for certain 2016-2019 Explorer SUVs. This initial recall focused on painted roof rail covers, as field data at the time suggested a higher rate of detachment for these variants. Technicians were instructed to replace damaged parts and secure them with four plastic push-pin fasteners. However, a later investigation, prompted by 46 Vehicle Owner Questionnaires submitted to NHTSA's Office of Defects Investigation by March 2026, revealed that even vehicles repaired under the extended warranty or the initial recall continued to experience issues with retention degradation, particularly those relying on epoxy/adhesive. Only vehicles fixed with push-pin fasteners showed no signs of the problem.
This persistent issue underscores the critical importance of rigorous quality control and effective repair protocols in the automotive industry. For consumers, it serves as a crucial reminder to promptly address any recall notices and ensure that repairs are conducted thoroughly and correctly to prevent potential safety hazards.