NHTSA Complaint #11457248 — 2021 FORD EXPLORER

I'm writing to you to relay a serious safety issue that started with the 2021 Explorer ST manufacturing processes. When Ford designed the new Explorer ST, the rear subframe was engineered to allow the rear differential to be attached with four bolts (Attachment-A). This was needed to properly secure the differential in light of the ST motor putting out more horsepower than their other models. My 2020 Explorer ST had the correct subframe with two bolts (Attachment-B.) At some point during the manufacturing of the 2021 ST models, Ford started using base-model Explorer rear subframes that contained a single bolt (Attachment-C) on the rear portion of the subframe. This was likely done due to the global shortage of parts and materials that most automotive manufacturers encountered. The results were predictable, and many users in Explorer discussion groups have reported the single-bolt shearing off, dropping the differential and damaging the rear suspension components and exhaust (Attachment-D & E.) This is a glaring safety issue, especially with a performance car, as a failure at speed could result in loss of control of the vehicle. To date, Ford has not responded to my inquiries requesting more information and a resolution. They did recently release a Special Service Message acknowledging that this is an issue (Attachment-F.) The thread below on explorerst.org outlines the problem in detail. There are dozens of people there and in the Explorer ST groups on Facebook that have encountered this problem, with varying levels of successful resolution and attention from Ford. I'm happy to provide additional links to conversations about this, if needed. https://www.explorerst.org/threads/rear-end-damage.2602/ I represent a growing group of ST owners who would like Ford to issue a recall, and repair their vehicles before a failure occurs.