Ford recall officials announced a new safety action affecting more than 288,000 Explorer SUVs after roof rail covers were found to potentially detach while the vehicles are in use.
Details of the recall
The National Highway Traffic Safety Administration’s recall report says the problem involves 2016‑2019 model‑year Explorers. Both satin‑ and chrome‑plated covers, as well as painted ones, may loosen, creating wind noise, squeaks and rattles. In some cases, a visible gap appears between the cover and the roofline.
The automaker will direct dealers to inspect each roof rail cover, replace any broken clips and install missing push‑pin fasteners. If the fasteners are absent, technicians will add them during service. The filing notes that only one accident has been reported that was linked to a detached rail.
History of repairs and earlier actions
Ford first identified the issue in 2020 and offered a one‑time repair under an extended warranty. That fix used a two‑part epoxy or adhesive to hold the cover in place.
Related: Toyota considers reinstating RAV4 button controls
By April 2021, after NHTSA discussions, the company issued a recall for certain Explorer SUVs because field data showed an uptick in loose and rattling roof rail covers.
Initially, the recall excluded the satin‑ and chrome‑plated versions because earlier warranty data suggested a lower rate of detachment. The automaker cited stronger retention and less susceptibility to solar loading for those finishes.
In March 2026, NHTSA’s Office of Defects Investigation received 46 owner questionnaires describing loose, rattling, and detaching roof rails on the affected models. Those reports included vehicles that had undergone the earlier warranty repair as well as those that had only received the recall fix.
Subsequent investigation revealed that the epoxy‑based repair did not reliably restore the original strength of the retention clips. Vehicles repaired with four plastic push‑pin fasteners, however, did not exhibit the same issue.
Related: Porsche Taycan Wagons to Stay Outside US
Future recall work will focus on swapping out the damaged components and ensuring the proper fasteners are in place.
The underlying cause appears tied to the original design of the roof rail attachment system and the variability of field repairs. The fact that the push‑pin solution has held up in testing suggests that the earlier epoxy method may have been insufficient for long‑term durability.
Owners who received the original warranty repair could still face the risk of detachment, especially if the epoxy was not applied correctly or cured under suboptimal conditions. The current recall emphasizes replacing the clips entirely rather than relying on adhesive fixes.
Impact on owners and next steps
Consumers can find more information about the recall on the NHTSA website, which maintains a searchable database of safety recalls. For reference, the official recall identifier is listed in the agency’s public records.
Leave a Reply