Dive Brief:
- Ford Motor Co. has recalled more than 492,000, 2016-2017 Explorer models for exterior B-pillar door trim on the driver and front passenger side that may become loose or detach while driving, according to the National Highway Traffic Safety Administration.
- The recalled trim piece was introduced into production in June 2015. In April 2017, the automaker introduced assembly process improvements to ensure the part was adequately secured.
- According to the NHTSA, Ford currently does not have a remedy available for the nearly half a million recalled Explorer models, but it will notify customers about the recall and potential safety risk by June 9. A second letter will be mailed once a remedy is made available.
Dive Insight:
Ford has been aware of the problem since July 2019, when the company published a technical service bulletin instructing dealership service technicians on how to repair loose B-pillar door trim on the driver’s side of 2011-2019 Explorer models.
In the TSB, the automaker cited a potential lack of adhesion of the “front door upper molding to the door.” However, at the time, Ford did not consider the issue an unreasonable risk to safety due to the “low mass/geometry of the part,” and after prior discussions with NHTSA about a separate trim detachment topic in 2018, the details of which were not identified in the recall report.
On March 24, the NHTSA’s Office of Defect Investigations notified Ford of 38 Vehicle Owner Questionnaires (VOQs) it received with complaints of driver and/or passenger front door B-pillar trim partially or fully detaching on 2016-2017 Explorers. Following this notification, Ford’s Critical Concern Review Group (CCRG) opened an investigation on March 25.
From April through May, Ford’s CCRG and body exterior team investigated the root cause of the trim detachments, which included collecting Explorer doors from scrap yards for analysis at the automaker’s Central Labs facility. The investigation also included a review of photos of parts associated with warranty claims.
Ford concluded that the loose trim was a result of improper application of the adhesive wet-out during assembly. Ford’s Field Review Committee then approved a recall on May 16. An estimated 4% of the recalled Explorers are believed to have the defect, according to the recall report.
As of April 7, Ford is aware of 1,482 warranty claims received between Dec. 4, 2015, and Feb. 10, 2025, but is not aware of any accidents or injuries related to loose or detached door trim.
Ford has issued 69 recalls covering over 3.5 million vehicles since Jan. 1, according to the NHTSA. It’s the highest number of any automaker so far in 2025. In comparison, General Motors has issued 12 recalls.
