NHTSA Complaint #11635763 — 2020 FORD EXPLORER

At only 5 years old and at 113k miles in January 2025 I was told by my local dealership that the right side catalytic converter was cracked and needed replacement to pass inspection. In March 2023 the left side catalytic converter was replaced under a service bulletin 21E11. Prior to that both sides intermediate exhaust pipes and flex connectors were replaced in November 2021. I have searched online and read of many other Ford Explorer ST owners complaining of failed catalytic converters. Ford is doing nothing to address this if the vehicle is outside of the required 80k mile emissions warranty. It seems to me there’s a known problem and this ride side catalytic converter should also be recalled. No catalytic converter should be consistently failing this early in a cars lifespan. Catalytic converters are known to last over 10 years and 300k+ miles. I’ve also seen where the same Ford Explorer but under the Police Interceptor name has had the right side catalytic converter recalled.