Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how
full bulletin at NHTSA ↗2016 Ford Explorer body problems
moderate Owners of the 2016 Ford Explorer have filed 545 NHTSA complaints about the body, typically surfacing around 82,500 miles at roughly $1,500 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See body across all vehicles →
Failure mileage
Complaints
545
Recalls
0
Avg fix
$1,500
| Model year | body complaints |
|---|---|
| 2012 Explorer | 128 |
| 2013 Explorer | 386 |
| 2014 Explorer | 256 |
| 2015 Explorer | 371 |
| 2016 Explorer (this page) | 545 |
| 2017 Explorer | 618 |
| 2018 Explorer | 269 |
| 2019 Explorer | 141 |
| 2020 Explorer | 32 |
3crashes
5injuries
When does it fail?
Of the 545 body complaints filed for the 2016 Ford Explorer, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 545 body complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 17 model years of Ford Explorer in our records for body problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using
full bulletin at NHTSA ↗A new 3M adhesive is now available, allowing a longer working time, along with mixing nozzles and applicator. 3M Universal Adhesive Black Part Number 08223, 3M Static Mixing Nozzles Part Number 08193 This program provides a one-time repair for the roof rail covers and retaining clips to 10 years of service or 150,000 miles from the warranty start date of the vehicle, whichever occurs first. This is a one-time repair program. Both roof rail covers should be serviced at time of repair. If a vehicle has already exceeded either the time or mileage limits, this extended warranty coverage will last through June 30, 2021. Coverage is automatically transferred to subsequent owners.
full bulletin at NHTSA ↗On some of the affected vehicles, the roof rail covers can become loose, which can lead to a visible gap between the cover and roof rail base assembly, rattling, and potential detachment.
full bulletin at NHTSA ↗This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2016 Ford Explorers describe a widespread failure where A-pillar and B-pillar exterior trim moldings detach from the vehicle during highway driving, typically at speeds between 50 and 80 mph. The trim pieces fly off without prior warning—owners report no looseness or visible defect beforehand—and become airborne debris that can strike following vehicles or motorcycles. Some owners experience multiple detachments of the same trim piece even after replacement. The detachment often produces a loud noise (tapping, popping, or clicking) and leaves a gap that allows rainwater to pool on the cabin floor, accumulate in cup holders, and short-circuit electrical components like keyless entry keypads and batteries.
Ford issued recalls 24V031 and 25V347 in January 2024, acknowledging the failures. However, many dealerships report parts remain unavailable months later, forcing owners to either drive with missing trim (exposing the windshield gasket to weather damage) or pay $300–$850 out-of-pocket for temporary repairs. Several owners report aftermarket trim is available for purchase online while dealerships claim no stock exists. Some describe seeing other Explorers on the road with missing trim panels, suggesting widespread prevalence.
Separately, owners report hood vibration at highway speeds, roof rack covers detaching and striking other vehicles, and cabin odors linked to exhaust or carbon monoxide exposure. One owner's blood work confirmed CO poisoning after experiencing a sulfur smell while driving.
Same Ford Explorer body reports on nearby years: 2013 · 2014 · 2015 · 2017 · 2018
Failure modes owners describe
A-Pillar and B-Pillar Exterior Trim Detachment
Windshield trim moldings (A-pillar and B-pillar) on both driver and passenger sides detach and fly off the vehicle at highway speeds without warning. The pieces involve clips that fail or become loose. Multiple owners report repeated failures of the same trim piece after replacement. Detachment creates debris hazard and loud noise. Many report seeing other Explorers with missing trim.
When: Highway speeds (50–80 mph); occurs with no prior warning signs; reported from under 36,000 miles through 150,000 miles
Symptoms owners cite: Trim piece detaches and flies off during highway driving; Repeated failures of same piece after replacement; No prior looseness or warning before detachment; Loud noise (tapping, clicking, popping) before or during detachment; Passenger and driver side B-pillar trim held keyless entry keypad, disconnecting when it detaches
Repairs/costs cited: Dealership quotes $300–$851 for trim replacement; owners report parts were glued back, then later replaced with bracket assembly; aftermarket replacements available online; some owners used tape as temporary fix
Recalls/TSBs owners mention: NHTSA Recall 24V031 (A-pillar trim) and 25V347 (B-pillar trim) issued 1/19/2024; parts unavailable for months or longer; dealers report parts backordered or not yet available; some owners told Ford acknowledged design failure and created new part version but cannot fulfill recall; some dealerships closed before completing recalls; one owner had dealer mark recall complete after no parts arrived, then charged $366 out-of-pocket for existing stock trim
Water Intrusion from Detached Trim
After A-pillar and B-pillar trim detachment, water leaks into the vehicle through the gap. Owners report water pooling on floor mats, in cup holders, and leaking from door areas and roof. Rainwater causes musty odor, corroded keyless entry keypads, and dead battery from short-circuiting electrical components.
When: After trim detachment; during and after rain; onset varies with trim failure timing
Symptoms owners cite: Water pooling under floor mats and in rear cup holders; Water leaking from front door area and pillar gasket; Rainwater accumulating on carpet after detachment; Musty odor from moisture; Keyless entry keypad short circuit and failure; Windshield gasket cracking and large pieces coming off after trim removal; Battery drain and vehicle requiring jumpstart after rain
Repairs/costs cited: Owners incurred out-of-pocket replacement of trim to stop water entry; one owner awaiting parts for recall repair while managing water intrusion
Recalls/TSBs owners mention: Related to recall 24V031; no action taken while parts unavailable; one owner received case number but told parts unavailable indefinitely
Hood Vibration at Highway Speeds
Hood vibrates or hums loudly at speeds above 60 mph, particularly in wind. Owners attribute it to thin center panel between two thicker pieces causing resonance. Noise is constant during highway driving and present from around 8,000 miles onward.
When: At speeds above 60 mph; one owner reported issue starting at 8,000 miles; occurs with wind conditions
Symptoms owners cite: Loud buzzing/humming sound from hood at 60+ mph; Vibration of hood center panel; Noise does not stop once triggered
Repairs/costs cited: No repairs documented; owner called it a design flaw; one owner unable to consistently reproduce it for dealer inspection
Recalls/TSBs owners mention: None documented; owner felt this should have been recalled
Roof Rack Cover Panel Detachment
Roof rack covers separate and become airborne at highway speeds. One incident involved a cover striking another vehicle's windshield, causing the other driver to swerve and crash into a third vehicle. Covers separate multiple times despite replacement.
When: Highway speeds (30–65 mph); reported multiple occurrences on same vehicle
Symptoms owners cite: Roof rack cover separates and becomes projectile; Cover strikes windshield of following vehicle; Repeated separations after replacement
Repairs/costs cited: Dealer replaced covers; failure persisted and owner declined further repairs at own cost
Recalls/TSBs owners mention: Related to NHTSA Campaign 21V316000 and 20N11; one owner's VIN not included in recall despite experiencing same failure; dealer referred owner to NHTSA Hotline
Exhaust Fumes and Carbon Monoxide in Cabin
Owner experienced strong sulfur/gas-like smell inside vehicle accompanied by carbon monoxide exposure. Owner developed dizziness, headache, and muscle weakness; blood work confirmed carboxyhemoglobin level at 3.8% (twice normal for non-smoker), indicating CO poisoning. Ford identified failing PTU but claimed CO sensor showed no CO present. Different owner also reported cabin filling with exhaust fumes while accelerating.
When: During normal driving; second owner incident while accelerating
Symptoms owners cite: Strong sulfur or gas-like smell inside cabin; Owner experienced dizziness, headache, muscle weakness; Blood work confirmed carbon monoxide poisoning (COHB 3.8%); Second owner: cabin fills with exhaust fumes while accelerating; black smoke from exhaust pipe
Repairs/costs cited: First owner: Ford identified failing PTU (power transfer unit); second owner had exhaust outlets reset to original position on first visit, but issue recurred on second visit
Recalls/TSBs owners mention: Ford acknowledged smell was from failing PTU but disputed CO poisoning claim despite owner's medical documentation; no recall identified; second owner referenced repair bulletin from 30 days prior but found it applied only to 2011–2015 Explorers, not 2016
Synthesized from 545 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
The contact owns a 2016 Ford Explorer. The contact stated that while the vehicle was parked, the keyless entry pad driver’s side B-pillar detached. The vehicle was taken to a dealer where it was determined that the driver’s side B-pillar needed to be replaced. The vehicle was repaired but the failure reoccurred after two years. The vehicle was taken to a dealer where it was determined that the…
The contact owns a 2016 Ford Explorer. The contact stated while driving at an undisclosed speed, the driver's side windshield trim detached and flew off the vehicle. The contact stated that due to the failure, there was a gap at the base of the windshield, allowing water to enter the engine compartment. Additionally, the contact stated that the passenger's side windshield trim was fractured. The…
The recall has been in place for replacing an exterior A-pillar trim part - we have tried to get it replaced, but there are no parts nationally. Why haven't the parts been created? It has been over a year
The windshield Trim panel flew off at highway speed.
Had body trouble with your 2016 Ford Explorer?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the body problem on the 2016 Ford Explorer?
It's a documented issue but not catastrophic. 545 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Across the 257 complaints that reported odometer mileage, most body failures cluster between 50,000 and 110,000 miles, with the median around 82,500. A quarter of owners report trouble before 50,000; a quarter make it past 110,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,500 for body repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to body?
No active recalls currently cover body issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2016/Ford/Explorer.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.