Ford recalls more than 90,000 police Explorers over engine fire risks

Ford Motor Co. is recalling more than 90,000 Explorer police vehicles in North America because of engine complications that could increase the risk of an under-the-hood fire.

The engine failure is expected to produce loud, clunking noises and result in a loss of torque. This recall covers the 2020-22 Ford Explorer large police crossovers.

Following three reports of fires caused by engine block breaches — which can occur when oil and fuel vapors build up under the hood — Ford's critical concern review group began investigating 3.3L Explorer Police Interceptor Utility vehicles in July 2023. Analysis at the Lima Engine Plant in Ohio suggested connecting rod fractures might be the issue, but no specific root cause was identified, according to NHTSA documents.

The service remedy is being developed. In the meantime, Ford advises customers to park and shut off the engine if they hear unexpected engine noises, experience torque reduction or see smoke from the engine compartment.

"Our goal is to prevent quality issues from happening in the first place. When they do occur, our focus is on responding quickly with a recall or service action to prevent our customers from experiencing issues," a Ford spokesperson told Automotive News.

Affected vehicles are equipped with the Police Interceptor Utility package and 3.3L Hybrid and Gas engines. Ford anticipates dealers will update the powertrain control module software, which will include diagnostics for connecting rod bearing failure and an inspection for engine noise.

Parts and software remedies are expected to be available in the second quarter of 2025.

Ford is not aware of any injuries or deaths related to the defects, and the automaker expects less than 1 percent of vehicles to be affected.

"We are committed to improving our launch quality and long-term quality," the Ford spokesperson said.

Ford had the most recalls of any U.S. automaker in 2023 and has held this position for the last three years, according to partial NHTSA data.

Notifications began Aug. 12, and mailed owner notification letters are expected starting Aug. 19. Owners will be contacted when further information is available.