2020 Ford Explorer fuel, hybrid & EV propulsion problems

Related recalls

• Recall 20V730000Nov 24, 202017 vehicles
  FUEL SYSTEM, GASOLINE:STORAGE

  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.

  Risk: An incomplete weld securing the inlet check valve to the fuel tank shell could result in a substantial fuel leak during a crash, increasing the risk of fire.

  Remedy: Ford will notify owners, and dealers will replace the fuel tank shell, free of charge. The recall began December 8, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S68.

• Recall 19V859000Dec 4, 20193,857 vehicles
  FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

  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.

  Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.

  Remedy: Ford will notify owners, and dealers will install a longer protective sleeve on the liquid fuel line, as necessary, free of charge. Ford issued owners and interim notification on January 29, 2020. Recall began March 23, 2020. A second notice will be sent once parts are available, expected to be late in the first quarter of 2020. A renotification letter was sent on July 10, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S49.

What owners say

1. Filed Jun 26, 2026MNElectrical SystemFuel, Hybrid & EV Propulsion

   First the fuel pump control module went out and now for the 3rd time the electrical to the fuel pump control module has faulted

   NHTSA complaint #11746795 · source
2. Filed May 15, 2026MIFuel, Hybrid & EV Propulsion

   Cruise in vehicle was set to 58 mph. Vehicle shut off going around a curve and would not restart. At 40mph emergency brake set as car wasn’t running and it was coasting to a stop. I sat on the road barely off the shoulder as car would not restart and would not come out of park to be able to push the rest of the way off the road. Had it towed to a ford dealer where they replaced the fuel pump control module and they had concerns of it possibly not fixing the problem. I made…

   NHTSA complaint #11738010 · source
3. Filed Nov 14, 2025MDFuel, Hybrid & EV PropulsionLightingSuspension

   Left lowlight headlight stops working intermittently and then completely. Both front axles cracked. Right rear shock busted. Gas purge valve malfunctioned

   NHTSA complaint #11699473 · source
4. Filed Oct 13, 2025MIFuel, Hybrid & EV PropulsionOther / UnknownTransmission & Drivetrain

   On [XXX]., in heavy rush‑hour traffic on [XXX] , my vehicle (~75,417 mi) suddenly lost motive power w/o warning at ~55 mph. It became immobile in a live lane, creating a roadblock and rear‑end crash risk. Drivers swerved/honked. Accelerator had no effect; limited/no power‑steering assist; I coasted to an in‑lane stop (no safe shoulder) and activated hazards. Cluster displayed “SHIFT SYS FAULT—Service Required” and wrench icon. Attempts to restart failed; the vehicle remained…

   NHTSA complaint #11693195 · source
5. Filed Sep 24, 2025MAEngineFuel, Hybrid & EV PropulsionTransmission & Drivetrain

   On highway was accelerating to pass another vehicle the transition froze , engine revved with no acceleration ( transmission skipped) this has happened several times over the 5 years. The lasted event we documented the date and mileage it happened date 7/13/25 mileage is 34990. These skips have put us in extremely dangerous situations. Transmission has been making growling noise now under normal driving.

   NHTSA complaint #11689512 · source
6. Filed Aug 4, 2025MDEngineFuel, Hybrid & EV Propulsion

   This problem started about 2 months ago and it happened 3 different times so far. While driving, when pressing the gas, the vehicle will all of a sudden not go. You just drift as if the car is not getting gas. On 2 of the occasions, a shift error message appears on the dash but quickly disappears. This can be very dangerous while driving and cause an accident. I have not had the vehicle looked at yet because I feel it should apart of the new recall for the other Ford…

   NHTSA complaint #11678290 · source
7. Filed Jul 24, 2025112,000 miCTTowedFuel, Hybrid & EV Propulsion

   The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. There was no warning light illuminated. The vehicle was inspected using a scanner and provided an error code for the fuel pump module. The vehicle was towed to an independent mechanic, where it was diagnosed and determined that the high-pressure fuel pump had failed and needed to be replaced. The vehicle was not repaired. The dealer was…

   NHTSA complaint #11675837 · source
8. Filed Jul 21, 2025WAFuel, Hybrid & EV Propulsion

   There is hesitation when coming from a stop to accelerating there is a delay of power. This problem has been going on since we have had the car. It is safety issue especially when we accelerate to get onto the highway. It is very inconsistent. We recently took it in and found that an error code of P0496 the evaporator purge valve to be a problem. Not sure if this is a problem with other Fords like ours. So I thought you could investigate it for me. Thank you.

   NHTSA complaint #11675126 · source
9. Filed Jul 15, 2025NCFuel, Hybrid & EV PropulsionSuspensionTransmission & Drivetrain

   When my vehicle reaches 60 mph the back end of my vehicle begins to sway excessively. Something may be wrong with the axle. It’s actually very frightening. Also, when my vehicle is running, I feel a slight puttering and then it quickly goes away as if somethings going on with the fuel pump. Lastly, my rearview camera sometimes looks a little blurry. I did take my vehicle to team Chevrolet in Swansboro, North Carolina where I purchased the vehicle. They stated something is…

   NHTSA complaint #11673590 · source
10. Filed May 16, 2025MNEngineFuel, Hybrid & EV PropulsionTransmission & Drivetrain

    Fuel purge valve not working properly causing the vehicle to not start after filling with gas, needing to keep vehicle running while filling with gas, safety issue. Turbo faulty causing car to loose power while driving and towing. Safely concern for multiple reasons. Flex exhaust pipe broken and mesh ripped causing burning smell and dangerous debris.

    NHTSA complaint #11661507 · source
11. Filed Apr 15, 2025FLFuel, Hybrid & EV Propulsion

    Fuel does not pump in correctly and causes spit back. The car has been taken into ford numerous times without a solution & parts have been replaced. The problem still exists. This causes gas to leak at the gas station as it doesn’t flow fast into the tank even on the lowest flow possible. You are also unable to move the nozzles around, in or out to make it work.

    NHTSA complaint #11654747 · source
12. Filed Jan 26, 2025FLEngineFuel, Hybrid & EV PropulsionTransmission & Drivetrain

    I have recently have experienced engine failure with the 2020 Ford Explorer 2.3 ecoboost engine. I was driving on a 4 lane highway, specifically on a bridge, and I experienced loss of power and acceleration. At that time, the engine light came on. I managed to get home, with the vehicle seemed as if in limp mode. I had my vehicle towed to the Ford Dealer ship. The service manager stated that they believe it is complete engine failure. He believes the failure is in the…

    NHTSA complaint #11638610 · source

Source: U.S. National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation public data. Complaints are submitted by owners and are not verified by NHTSA or by us; a complaint does not prove a defect exists. View this vehicle on NHTSA.gov Methodology