NHTSA Complaint #11587838 — 2016 FORD EXPLORER

A loud clunking noise was heard when the vehicle was turned to the right. Diagnosis at the CarMax repair facility indicated that the steering rack was broken. Diagnosis was complicated by the fact that the damaged part was hidden under a rubber boot. The actual damage on the steering rack appears to be a broken retainer, sealing washer, or similar that circles the jack screw of the steering rack. This retainer or washer is visible in the attached pictures. I believe there was a potential for the damaged retainer or washer to become jammed in the steering rack when the rack is in the right turn position which would make it impossible or difficult to turn the steering wheel. This could have resulted in an accident. I authorized CarMax to complete the repair and was informed that the steering rack was back ordered from Ford and would not be available for approximately 3 weeks. CarMax gave me a loaner vehicle and completed the repair when the part arrived. The broken steering rack was returned to Ford. A steering rack is not a part that I expect to fail. The fact that the part was back ordered for three weeks suggests that this part is in high demand because this is a common problem with this vehicle. The fact that the damaged part was concealed by a rubber boot made it difficult to diagnose. Clunking noises in the front suspension of a vehicle can be caused by many problems and a failure to correctly diagnose this problem could have resulted in a serious accident. I thanked the CarMax technicians for there perseverance in getting to the true cause of the noise. It is my opinion that this is a serious safety issue and that Ford should issue a safety recall for affected vehicles.