NHTSA Complaint #11623224 — 2020 FORD EXPLORER

We bought this our ST in April and just our luck it has passed the 5-year mark.....no powertrain warranty for us, darn. On Wednesday, during the 30-minute drive home from work, my spouse reported a fault indicator on the dash related to 4WD or AWD being inoperable. This did not trigger the MIL, but diagnostics showed DTC C0631, identified in TSB 23-2114/2174. After a costly fix replacing the FADA with an intermediary shaft, the SUV will no longer be an "Intelligent 4WD" vehicle—seems like creative and false advertising masking a known engineering failure identified by many on the internet [XXX] ). The first sign is a FADA leak. The TSB states that customers can continue to drive, so I took the vehicle for a drive, only to find myself abruptly stalled in traffic after about a mile. I tried to restart the vehicle several times, but nothing happened. After waiting about five minutes and calling my spouse, I tried again and was able to start it. It felt like it was in "limp" mode, as it had issues accelerating, so I slowly drove home. When entering the driveway, the vehicle could barely make it into the parking spot. As I pulled in and applied the parking brake, the vehicle was idling and started squealing so ear-piercingly loud (maybe SSM 51419?) that I was shocked and quickly shut it off. Later, I started the vehicle again and noticed it was knocking now, but the squeal was gone and didn't reproduce. The vehicle was towed to the local Ford dealer, and after reporting my experience and their troubleshooting, I've been given an incredible ~$8,000 estimate for repairs. The technician claims that the VTC phasers, a fix from TSB 23-2058, are the additional corrective action for the stalled engine, lack of power, and engine knock noise. Ford knows the VTC phasers are design flawed, they've redesigned them multiple times; Ford TSBs have been available for this issue on this website for other engine models for over 10 years. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)