NHTSA Complaint #11494620 — 2013 FORD EXPLORER

The PTU (Power Transfer Unit) was engineered without a drain plug and described by Ford as "Maintenance Free" for the life of the vehicle. Due to the close proximity of the PTU to hot exhaust components, small fluid capacity, and no recommendation by Ford to be serviced for the life of the vehicle, my PTU started failing within warranty under 50,000 miles. The propane smell within the cab of the vehicle is a tell tale of the PTU fluid breaking down under severe heat conditions, spewing out of the vent and flashing on the surrounding exhaust components. This was not diagnosed at that time by my local Ford dealer, so the problem continued until the PTU finally failed out of warranty at approximately 71,000 miles. Research confirmed that this PTU design failure has been recognized by Ford and that it can lead to a complete failure while the vehicle is in motion, causing loss of control and risk to lives. Recognition by Ford of this problem in the 2013 model year Explorer is self evident, as later model years incorporated air dams to direct air to flow over the PTU to help with cooling, and incorporated drain plugs and recommended service intervals to properly service the PTU. There have been thousands of premature PTU failures in Ford vehicles, but Ford has not yet issued a recall or replacement PUT's with a drain plug for serviceability for my 2013 model year. My PTU had to be replaced at my cost with another non-serviceable PTU, that will no doubt fail prematurely. I am concerned that my vehicle could pose risk to my family's safety in the future, because the repair that was done by my Ford dealer is not a long term, complete solution.