NHTSA Complaint #11716301 — 2020 FORD EXPLORER

The catalytic converters (both) on my 5-year-old Ford Explorer both failed due to cracked welds. This failure appears to be common with the v6 ecoboost engines. It happened sometime before 124000 miles, it was only noticed because my wife and daughters started complaining about headaches and sleepiness when riding in the vehicle. The failure was only noticed when a mechanic evaluated it, the failure was not noticeable otherwise. I believe this is a very dangerous condition, as the fumes were evidently getting into the vehicle somehow and causing symptoms of carbon monoxide poisoning. The estimate to repair both is $5000, but according to the repair shop, there are currently none available. Ford has acknowledged this defect in Customer Satisfaction Program 21B35 and the 2025 service bulletin covering cracked weld failures. At about the same time, the transmission suddenly. The failure is very specific, and is documented in Ford Technical Service Bulletin 22-2411 as a known defect. The vehicle experienced harsh shifting, delayed engagement, and ultimately complete transmission failure requiring full replacement at a cost of approximately $7000. This appears to be a widespread defect, and I believe it represents a safety concern due to unpredictable loss of drivetrain function.