NHTSA Complaint #11532922 — 2021 FORD EXPLORER

The fuse box got wet after a routine car wash. The hood was not opened at any point prior to the car wash, nor directly afterwards until the incident occurred. A few hours after the car wash, the horn went off on its own continuously for 5-10 minutes and had to be shut off manually via disconnecting the battery. The car was not running or turned on in any way at this point. Prior to disconnecting the battery, the car was turned on to try and deactivate the horn. The horn was still blaring and the car would not shut off. Upon inspection, there was smoke coming from the fuse box. Multiple vehicle alerts went off on the dash including Hill start assist warning, Powertrain malfunction/reduced power and pre-collision assist warning lights. The car was taken to the dealership for repairs. The following "story" was conducted at the dealership: Unhooked battery. Removed front cowl battery junction box. Removed battery junction box. Battery junction box is burnt up and engine bay harness is melted. Engine bay harness needs replaced. Have to remove engine assembly to gain access to harness. Removed engine transmission and subframe assembly. Removed inner plastic firewall. Removed harness and replaced. Reinstalled drive train assembly replaced all one time use fasteners. Reassembled car. Found horn is INOP. Diagnosed and found horn is burned up from being stuck on from melted harness. Removed front bumper cover. Replaced Horn and reassembled. Horn works now. Cleared all DTCs. No DTCs returned. Test drove car. Everything is working properly now and no codes returned. Total repairs are $3,300. I did not feel safe in any regards while driving it to the dealership. Through casual conversation with a friend who works at the dealership, they witnessed something similar happen with a Ford F-150. I don't believe that this has been inspected by the manufacturer, police or insurance representatives. There were no warning lamps, messages or other symptoms prior to the incident.