2015 Ford Explorer steering problems

The steering rack/pinion assembly fails, causing partial or complete loss of power steering assist. Failures range from intermittent lockup to total steering loss. Some owners report the steering wheel becomes extremely difficult to turn (requiring manual effort) or locks completely. Owners describe sudden onset with no advance warning, sometimes occurring at highway speeds, creating severe safety hazards.

When: Typically 25,000–103,000 miles; failures occur within 6 years of ownership, often shortly after warranty expiration (36 months or 100,000 miles)

Symptoms owners cite: Sudden loss of power steering assist or intermittent failure; Steering wheel locks up or becomes extremely difficult to turn; Popping, grinding, crunching, or clunking noises when turning steering wheel; Dashboard warnings: 'Steering Assist Fault', 'Service Steering Assist Soon', 'Steering Fault – Service Required', 'Steering Fault – Contact Dealer'; Associated warnings: 'Service AdvanceTrac', 'Terrain Management Failure', 'Power Steering Assist Fault'; Failure may reset temporarily after turning engine off and restarting; Clicking, ticking, or humming sounds at low speeds

Codes mentioned: P0022 (Cam Timing Over Retarded), P052D (Cold Start Cam Timing Over Retarded), P193E (A/C Clutch Request Signal), U0121 (Lost Communication with ABS Control Module), C1B00 (Steering Angle Sensor), U2011:49 (Steering Gear Issue)

Repairs/costs cited: Replacement of entire steering rack/pinion assembly (called 'steering gear' or 'electronic steering rack'). Owners cite costs ranging from $1,731 to $3,600; most repairs fall between $1,800–$2,600. Some owners report Ford dealers had parts in stock, suggesting frequency. One owner reported Ford's own diagnostic stated 'URGENT SERVICE REQUIRED.' Recall kit available for some failures but has proven ineffective for some owners.

Recalls/TSBs owners mention: 2011–2014 Explorers recalled for steering failure (NHTSA Campaign 14V286000), but 2015 model year excluded despite identical failure mode. Several owners cite Ford's response: dealers initially unable to diagnose when problem cannot be replicated; some dealerships offered 'financial assistance' or covered partial cost (50% in one case); Ford hotline unwilling to authorize repairs unless problem can be reproduced while vehicle is in possession; most denials cite warranty expiration or lack of recall applicability to VIN.

The rear tow link (also called rear toe link) snaps or fractures while vehicle is in motion, typically at highway speeds. When the link breaks, the vehicle loses rear suspension control, causing severe fishtailing and loss of control across multiple traffic lanes. This failure has occurred multiple times on some vehicles even after dealer repairs and after recall kit installation.

When: Documented at 41,339 miles and during repeated instances within 400 miles of driving after repairs

Symptoms owners cite: Sudden loss of vehicle control and fishtailing across traffic lanes; Vehicle fishtails at 65–75 mph and may cross into oncoming traffic; Loud clunking or snapping noise preceding or during loss of control; Vehicle may strike barriers, reflector posts, or other vehicles as a result

Repairs/costs cited: Rear tow link replacement; one failure also required replacement of rear tie rods (found to be severely worn). Despite recall kit installation and multiple dealer repairs, the link has snapped repeatedly on the same vehicle (3 times within 400 miles of driving). Dealer personnel expressed concern about vehicle safety, stating it was 'unsafe to drive.'

Recalls/TSBs owners mention: First instance covered under recall and repaired free of charge. Subsequent failures were NOT covered; owner was told tie rods were severely worn and vehicle was unsafe. Recall kit installed but has failed to prevent additional breakage on at least one vehicle.

The electronic power steering (EPAS) system experiences intermittent electrical faults that cause temporary loss of power steering assist, often resetting after restarting the engine. Some owners report corrosion in steering control module terminal contacts. Failures typically occur at low to moderate speeds but are extremely dangerous at highway speeds. Multiple warning lights and messages appear, sometimes clearing on their own.

When: Failures reported between 10,300 and 160,000 miles; can occur repeatedly within short timeframes (multiple times per week to multiple times per month)

Symptoms owners cite: Intermittent 'Steering Assist Fault – Service Required' or 'Power Steering Assist Fault' warning; Sudden loss of power steering assist, requiring manual steering effort; Associated warnings: 'Service AdvanceTrac', 'Terrain Management Failure', 'Steering Fault – Contact Dealer'; Steering difficulty or lockup for a few seconds to several minutes; Warning lights may disappear after engine restart or after a few minutes of driving; No visible damage or component failure initially detected; Terrain management mode selector may also become unresponsive during failures

Codes mentioned: Power Steering Assist Fault, Terrain Management System Fault, Service AdvanceTrac Fault

Repairs/costs cited: One dealer diagnosis: corrosion in power steering control module terminal contacts; grease applied at cost of $323. Owner was warned that if failure recurred, steering control module replacement would cost $2,300. Replacement of entire EPAS rack and pinion (electronic steering gear) in other cases, costing $1,916–$2,000. Steering control module replacement also performed in some cases.

Recalls/TSBs owners mention: Dealers often unable to diagnose intermittent faults because failures do not occur while vehicle is in their possession. Ford hotline has refused to authorize repairs unless the problem can be duplicated during dealership inspection. In some cases, dealerships have stated they cannot fix the problem without a diagnosis code and have offered only 1 week of rental coverage while vehicle remains at service location unable to be repaired. Some owners contacted Ford directly and were told they need a new steering rack but were offered no recall or coverage.

In at least one documented case, the power steering system failed as part of a broader electrical system failure affecting instrument cluster, entertainment screen, exterior lighting, and windshield wipers simultaneously. The vehicle exhibited intermittent electrical rebooting behavior, with systems failing and then restoring power independently.

When: Failure occurred at 55 mph in steady rain

Symptoms owners cite: Check battery warning message in instrument panel; Sudden loss of power steering; Instrument cluster display goes black; Entertainment/info screen goes black; Headlights and windshield wipers slowed or ceased operation; Squealing sound (similar to slipping belt) heard before systems reset; Multiple systems failing and restoring intermittently over 30-mile stretch

Repairs/costs cited: Battery and alternator were tested and found to be within normal parameters. Belt was visually inspected and appeared normal. No permanent repair documented; issue could not be reproduced in controlled conditions.

Owners report persistent loud popping, creaking, crunching, grinding, or ticking noises from the front end, particularly when turning the steering wheel at low speeds, going over bumps at an angle, or making sharp maneuvers like pulling into parking spaces. These noises often precede steering rack failure. Initial dealer visits frequently report inability to duplicate the noise despite its obvious presence.

When: Noises can begin early in vehicle ownership (as early as 9,000 miles) and progressively worsen over months or years (documented up to 100,000+ miles)

Symptoms owners cite: Loud popping or cracking noise when turning steering wheel left or right; Grinding or crunching sound from front end during turns; Intermittent ticking noise from front hub area at low speeds; Noises worse when turning at low speed (parking, driveway maneuvers); Noises worse when going over bumps or uneven surfaces at an angle; Noises progressively worsen over time

Repairs/costs cited: Initial misdiagnosis included front strut replacement ($1,000 in one case), which did not resolve the popping. Subsequent diagnosis identified the steering rack/pinion as the source. Mechanics and dealerships frequently report inability to 'duplicate' the noise during inspection, delaying diagnosis.