NHTSA Complaint #11688028 — 2020 FORD EXPLORER

I recently had my vehicle serviced for reprogramming of the AWD control module after it failed. When the dealer returned the vehicle, I expected the issue to be resolved. Instead, I immediately noticed a new check engine light with code C00A6, related to the front axle disconnect. This was concerning because the dealer had assured me there were no active codes after programming the new module. After driving with the new fault, it became clear the vehicle was operating only in rear-wheel drive. I contacted Ford and was quoted $4,030 for repairs to the front axle disconnect. Given the cost, I researched whether this issue had a recall but found none, despite widespread reports from other owners experiencing the same failure. My main frustration is that this problem stems from Ford’s design of the intermittent AWD system, which engages the front wheels only when needed to improve fuel economy. The official “fix” eliminates this design entirely—converting the vehicle into a full-time AWD system. This requires removal of the front axle disconnect shaft, installation of a standard shaft, and reprogramming to support permanent AWD. The Technical Service Bulletin (TSB 23-2174) even directs technicians to cut and discard the electrical connector for the front axle disconnect actuator, confirming that the original intermittent system is abandoned rather than repaired. This is a major concern for owners. Many of us are facing the same issue, yet Ford’s solution shifts the burden of an expensive design flaw onto customers. I strongly urge Ford to address this problem responsibly and provide coverage for affected vehicles, rather than leaving owners to pay thousands for what appears to be a widespread defect.