The 2013 Ford Explorer shows a pattern of body and structural defects across this complaint cluster. The most frequent and immediate safety issue is detachment of windshield A-pillar trim pieces while driving at highway speeds; owners describe trim breaking loose, flying into traffic, or causing drivers to lose visibility when loose trim fouls wiper blades. This failure has repeated even after dealer replacement because recall parts (Campaign 24V031000) remain unavailable as of late 2024, leaving vehicles unrepaired for extended periods.
Hood paint regularly bubbles, peels, and chips starting around 36,000–61,000 miles despite careful maintenance. Owners and dealerships acknowledge this as a known manufacturing defect (aluminum hood with failed factory sealer), yet Ford denies warranty coverage based on mileage thresholds and refuses recall despite widespread complaints across multiple model years.
Water intrusion affects the cabin and trunk through failed windshield seams, tailgate seals, and sunroof drains. Moisture pools in floorboards, corrodes electrical systems, and spawns mold. Dealership repairs (drain clearing, seal replacement) often fail to stop the leaks. Windshield trim molding also breaks and detaches, sometimes catching wipers and obscuring visibility with sticky residue.
Exhaust gas enters the cabin during acceleration or hill climbing, and owners have measured carbon monoxide up to 15 PPM. TSB 16-0166 exists, but Ford's outreach to affected owners remains incomplete and inconsistent. One owner reported their VIN marked as unaffected despite clear symptoms.
A driver-side door latch failure leaves the door unable to close securely, creating safety hazards that Ford refuses to repair beyond an expired recall window.
Failure modes owners describe
A-pillar trim detachment
Exterior windshield A-pillar trim clips and trim pieces detach or become loose from the vehicle while driving or parked. Detached trim can fly into traffic, strike windshields, damage adjacent components, or leave exposed areas where moisture enters.
When: Starting around 40,000 miles; many reports at 60,000-120,000 miles; some early as 23,000 miles
Symptoms owners cite: Flapping or rattling noise from windshield area; Visible looseness of trim around windshield A-pillars; Trim detaching and falling off vehicle; Trim striking windshield and causing cracks; Trim flying into traffic
Repairs/costs cited: Requires replacement of A-pillar trim clips and/or entire trim pieces. Multiple reports cite $300–$506 range for professional replacement. Many owners ordered parts from junkyards or online retailers (Amazon). Some interim repairs used tape, glue, or Velcro but failures recurred.
Recalls/TSBs owners mention: NHTSA Campaign Number 24V031000 (Structure) issued; however, Ford stated replacement parts were not yet available as of late 2024. Multiple dealers confirmed parts unavailable and on backorder. Some dealers applied temporary tape as interim measure. Ford has not provided timeline for part availability.
Hood paint bubbling and peeling
Paint on aluminum hood bubbles, blisters, chips, and peels, typically starting at the perimeter or front edge. Occurs early in ownership despite normal maintenance and care. Factory seam sealer or paint application appears defective.
When: Starts between 36,000–61,000 miles; often evident within 1–2 years of ownership
Symptoms owners cite: Paint bubbling and blistering on hood edge; Paint flaking and peeling; Discoloration and corrosion visible under failed paint; Progressive deterioration over time
Repairs/costs cited: Preliminary repair estimates cited $738 for paint work, though extent of sealer failure may require more extensive body shop work. Owners report dealership refusal to cover under warranty after 36,000 miles, despite problem originating earlier. Some owners obtained partial reimbursement from Ford only after escalating complaints.
Recalls/TSBs owners mention: Ford has refused recall despite widespread complaints across 2013–2014 Explorer owners. Dealerships blame owner maintenance or aluminum hood material vibration. Ford acknowledges the issue exists but denies warranty coverage based on mileage cutoff. Extended warranties sold by Ford exclude body sealer failures.
Water intrusion into cabin and trunk
Water leaks into vehicle interior from multiple entry points including windshield seams, door seals, sunroof drains, tailgate body seams, and roof-to-windshield junction. Water pools in floorboards, soaks carpeting, fills wheel wells, and creates mold/mildew hazard.
When: Early in ownership; some reports within 6 months of purchase; recurring after attempted repairs
Symptoms owners cite: Water in front passenger footwell and floor mats; Water in rear seat and spare tire wheel well; Water intrusion through sunroof area; Standing water in trunk and floorboards; Water entering through windshield-to-roof junction; Water from tailgate body seams; Mold, mildew, and sickening odor; Fogged windshield from interior moisture
Repairs/costs cited: Dealership diagnostics identified failed factory seam sealer at tailgate and windshield seams. Some repairs included clearing clogged sunroof drains, replacing sunroof, and replacing door seals, but leaks persisted. One preliminary estimate for full seam repair: $738. Repairs sometimes required body shop work.
Recalls/TSBs owners mention: Extended warranties sold by Ford exclude body sealer and water intrusion issues. Dealerships attributed issues to clogged drains rather than manufacturing defects. Some repairs attempted but failures recurred. No recall issued despite acknowledged widespread pattern.
Windshield molding (trim) detachment
Windshield trim molding breaks, cracks, or detaches from the vehicle. Molding may fly off into traffic or flap against windshield, fouling wiper blades and obscuring visibility. Associated rubber weather stripping can become exposed and catch on wipers.
When: Occurs at various mileages in normal driving conditions, some at highway speeds
Symptoms owners cite: Loud noise or pop when molding breaks; Visible cracks in molding; Molding flapping or partially detached; Weather stripping exposed and flapping; Molding flying off into traffic; Sticky glue residue from weather stripping on windshield; Wiper blades fouled or rendered inoperable; Visibility obscured by glue or flapping trim
Repairs/costs cited: Owners report purchasing replacement molding pieces themselves; one estimate referenced $506.54 for replacement labor. Interim repairs used glue, tape, or Velcro but failures recurred. Some pieces purchased from junkyards.
Recalls/TSBs owners mention: No recalls issued at time of early complaints; later complaints reference Campaign 24V031000 as potentially related but note parts unavailability. Some dealers confirmed previous observations of this issue on model but denied warranty coverage.
Exhaust gas intrusion into cabin
Exhaust fumes enter passenger compartment through air conditioning vents during acceleration, climbing hills, or highway driving at higher RPMs. Owners report carbon monoxide detected in cabin; symptoms include headaches, dizziness, eye irritation, and nausea.
When: Present from new ownership or early in ownership; triggered at RPM ≥3,500
Symptoms owners cite: Exhaust odor in cabin during acceleration or hill climbing; Odor stronger in warmer weather; Headaches, dizziness, eye irritation; Carbon monoxide readings up to 15 PPM measured by owners; Nausea and general malaise; Wipers rendered inoperable by loose weather stripping getting caught
Repairs/costs cited: Ford dealership technicians contacted Ford Engineering but reported fix did not resolve issue. One owner recorded CO measurements up to 15 PPM. A/C line replacements recommended in one case at cost of $2,100. TSB 16-0166 exists for this issue.
Recalls/TSBs owners mention: TSB 16-0166 issued for exhaust odor in cabin; Ford offered free repair for some owners but not all VINs included. NHTSA and Center for Auto Safety investigated; Ford notified owners of 'potentially affected vehicles' but not universally. One owner reported VIN marked as 'not affected' despite symptoms. Dealer advised using cabin air recirculation mode, which only trapped odor inside. Multiple owners report Ford customer service stonewalling.
Driver door latch failure
Driver-side door latch breaks, preventing door from closing securely. Door flies open during turns and motion. Owner must hold door shut while driving or enter through passenger seat.
When: At undisclosed mileage; related to prior recall 15V171 (Interior Door Handle Spring)
Symptoms owners cite: Door does not close properly; Door flies open on turns and acceleration; Constant 'door ajar' warning light; Door handle inoperable; Cannot enter or exit vehicle safely
Repairs/costs cited: Latch replacement required. One owner charged $106.94 for diagnostic plus $2.55 for handle parts without prior authorization. Repairs not covered due to expired recall window.
Recalls/TSBs owners mention: Related recall 15V171 expired in July 2020; Ford refuses to cover latch repair beyond recall expiration. Dealership performed recall work in 2015 but issue persisted or recurred.
Frame corrosion from inadequate recall repair
Rear suspension toe link/ball joint recall (20S62/20S32) performed multiple times at same dealership, but corrosion and structural frame damage developed despite repairs. Documentation irregularities raised concerns about repair completeness.
When: Apparent by 2022 after third recall service; frame corrosion documented at service
Symptoms owners cite: Severe frame corrosion and structural damage; Vehicle unsafe and unusable; Unusual mileage documentation (exact values like 87,600 and 95,000 miles on separate service entries)
Repairs/costs cited: Ewald Ford technicians photographed and documented significant corrosion and submitted to Ford corporate requesting frame replacement. Repair estimate not provided in narrative.
Recalls/TSBs owners mention: Recall 20S62 (also 20S32) issued for rear suspension toe link/ball joint corrosion risk. Three recall repairs performed; however, Ford refused to reopen recall or authorize frame replacement despite documented corrosion and technician concerns about repair adequacy.
Synthesized from 386 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.