NHTSA Complaint #11641806 — 2020 FORD EXPLORER

1. Component: AWD system – Front Axle Disconnect Actuator / Intermediate Shaft • Failure Type: AWD system failed, preventing power transfer to front wheels • Availability for Inspection: Yes, diagnosed and confirmed by Zeigler Lincoln Ford 2. On Thursday, [XXX], while driving in a snowstorm with my two children, my 2020 Ford Explorer AWD system failed completely, leaving us stranded on an icy hill with no traction or ability to move. • My vehicle lost all AWD functionality, causing it to become immobilized on an active roadway in hazardous conditions. • We were trapped between two semi-trucks that were also stuck, creating a high-risk situation where a collision or multi-vehicle pileup could have occurred. • With freezing temperatures and no way to move, we were at risk of hypothermia while waiting for a tow truck. This was not an isolated issue. Ford acknowledges this AWD system defect under TSB 23-2174, meaning this failure can happen to any driver under similar conditions, creating a major safety hazard. 3. Yes. The issue was diagnosed and confirmed by Zeigler Lincoln Ford, who determined it was covered under TSB 23-2174. • Ford has officially acknowledged this defect but has not issued a recall. 4. Yes. The vehicle was inspected by Zeigler Lincoln Ford, and the AWD failure was confirmed as a front axle disconnect actuator/intermediate shaft defect. • Ford issued TSB 23-2174 to address the defect, proving that this is a known issue. • However, instead of issuing a recall, Ford is making owners pay for repairs out of pocket, despite the serious safety risk. 5. Yes. Prior to the AWD failure, I received a wrench icon warning (Powertrain Malfunction Indicator) on my dashboard. • Error codes C0631 and C0633 were later retrieved by the dealership, confirming AWD disconnect failure. • I had experienced intermittent AWD traction loss in winter conditions, but the system failed completely during the snowstorm incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)