Ford is Recalling 4,247 2020-2022 Ford Explorers Because the Driveshafts Can Disconnect

Ford is recalling more than 4200 Explorers that the company thought had been fixed. The Ford Explorers can develop a serious problem because of a rear axle bolt. If the bolt breaks, the Explorer’s driveshaft can separate. If the vehicle is driving, it can stop moving. If the vehicle is parked, the same issue can allow it to roll away. The vehicles were recalled previously, but in some cases, the software wasn’t updated correctly. The recall affects certain 2020-2022 Ford Explorers.

What is Causing the Issue

According to paperwork filed with the National Highway Traffic Safety Administration, too much torque can put too much pressure on a rear axle bolt, causing it to bend or even break. If it breaks while the vehicle is moving, it can bring the Explorer to a sudden stop. The NHTSA Safety Recall Report says “If the rear axle bolt breaks, the driveshaft or halfshafts may become disconnected, resulting in loss of the vehicle’s forward power and loss of transmission torque to the rear wheels. Loss of the vehicle’s forward power increases the risk of crash and injury.”

Conversely, if the Explorer is stopped, a broken bolt can allow it to roll away. “Transmission torque is necessary to hold the vehicle in park. If the parking brake is not applied, the loss of the primary park torque will allow the vehicle to roll in park increasing the risk of crash and injury. Inability to achieve or hold park can result in unintended vehicle movement if the parking brake is not applied, increasing the risk of a crash.”

How Ford Will Fix the Problem

Owners will be notified to take their vehicle to a Ford or Lincoln dealer to have the Power Control Module software updated. Then Ford will closely monitor the recalls to make sure that the modules were correctly updated. Owners who have paid to have these repairs completed at their own expense may be eligible for reimbursement.

While there is no warning or sign that the bolt is about to break, drivers say that when the axle housing moves out of its position, there is a loud grinding or clunking noise. Ford says no injuries have been reported because of this.

Recall Information

Ford will notify owners by mail between Apr 24, 2025 - May 01, 2025. The NHTSA number for this recall is 25V-166. Ford’s number for the recall is 25S22. The same Explorers were previously recalled under NHTSA’s recall numbers 23V-199 and/or 22V-255. The previous Ford recall numbers were 22S27 and 23S16.

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Mary Conway is a professional automotive journalist and has decades of experience specializing in automotive news analysis. She covered the Detroit Three for more than twenty years for the ABC affiliate, in Detroit. Her affection for the Motor City comes naturally. Her father ran a gas station while Mary was growing up, in Wisconsin.

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