Certain 2011-2017 Model Year Explorer Vehicles Rear Wheel Knuckle Replacement REASON FOR THIS SUPPLEMENT Program Terms: added 21R01 and 21R02 REASON FOR PROVIDING A NO-COST, ONE-TIME REPAIR: added 21R01 and 21R02 OWNER NOTIFICATION MAILING SCHEDULE: added mailing schedule for 21R01 and 21R02 OASIS ACTIVATION: added 21R01 and 21R02
full bulletin at NHTSA ↗2016 Ford Explorer suspension problems
severe Owners of the 2016 Ford Explorer have filed 46 NHTSA complaints about the suspension, typically surfacing around 84,400 miles at roughly $900 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See suspension across all vehicles →
Failure mileage
Complaints
46
Recalls
0
Avg fix
$900
| Model year | suspension complaints |
|---|---|
| 2012 Explorer | 14 |
| 2013 Explorer | 55 |
| 2014 Explorer | 82 |
| 2015 Explorer | 63 |
| 2016 Explorer (this page) | 46 |
| 2017 Explorer | 43 |
| 2018 Explorer | 18 |
| 2019 Explorer | 8 |
| 2020 Explorer | 29 |
6crashes
2injuries
What stands out
Owners have filed 46 suspension 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.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering suspension 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.
Certain 2011-2017 Model Year Explorer Vehicles Rear Toe Link Replacement Under Safety Recall 21S32, some of the affected vehicles exposed to a highly corrosive environment where road salt is used extensively during winter months, have experienced a seized toe link ball joint resulting in a fracture of the outboard section of the rear suspension toe link.
full bulletin at NHTSA ↗This program provides a no-cost, one-time repair (if needed) to the rear wheel knuckles for six (6) months from the Repair Order (RO) opening date for field service actions 21S32 or 21S43 provided that the RO opening date occurs on or before July 31, 2023. This is a one time repair. In some of the affected vehicles exposed to a corrosive environment where road salt is used during winter months, the rear toe link ball joint located in the rear knuckle could seize. A seized toe link ball joint could wear out and develop a knocking noise after installation of the updated toe links in the FSAs 21S32 or 21S43
full bulletin at NHTSA ↗Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in Certain States/Provinces; Rear Toe Link Ball Joint Inspection This program is a proactive investigation by Ford Motor Company to obtain field data and parts for testing. Ford is voluntarily conducting this program to inspect the toe link ball joint and, if necessary, replace both rear toe links and wheel knuckles on vehicles always registered and always residing in the Nashville, Houston, Miami, Dallas, Atlanta, Phoenix, Winnipeg, and Calgary areas. The replacement toe links and knuckles being installed contain no enhancements and are identical to the parts being removed. It i
full bulletin at NHTSA ↗Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in Certain States/Provinces Rear Toe Link Ball Joint Inspection This program is a proactive investigation by Ford Motor Company to obtain field data and parts for testing. Ford is voluntarily conducting this program to inspect the toe link ball joint and, if necessary, replace both rear toe links and wheel knuckles on vehicles always registered and always residing in the Nashville (and Calgary) area. The replacement toe links and knuckles being installed contain no enhancements and are identical to the parts being removed. It is very important that any parts obtained from this pr
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report a cascade of suspension failures on the 2016 Ford Explorer, with the rear toe link as the most dangerous. The link breaks—often at the weld—during normal driving at highway speeds (55–70 mph), causing the rear wheel to lose alignment and the vehicle to fishtail or veer off the road into embankments or barriers. Multiple owners have crashed and some were hospitalized. Critically, this failure happens to owners repeatedly even after Ford's recall repair (Campaigns 19V435000, 20V675000, 21V537000), with at least one owner experiencing three prior toe link replacements before a fourth failure. The replacement parts themselves are failing within months.
Complicating everything is a parts shortage that has persisted for years. Dealers tell owners parts are "4–6 weeks out" but then months go by with no resolution. Ford won't confirm when parts will arrive, and dealers won't certify vehicles as safe to drive while waiting. Owners also report confusion: they receive recall notices but dealers then claim their VIN is not covered—even when the vehicle matches the recall's stated build dates and assembly plant.
Beyond suspension, owners describe transmission casings cracking open (visible gears inside), transmission hard shifts losing gears at highway speed ($10,000 repair at 74,000 miles), coolant mysteriously disappearing from new vehicles, and burning-coolant smells that dealers dismiss as normal. One owner had both a $10,000 transmission failure and a $12,000 engine failure within 10,000 miles. Dealers consistently resist warranty help and sometimes refuse to document complaints in writing.
Same Ford Explorer suspension reports on nearby years: 2013 · 2014 · 2015 · 2017 · 2018
Failure modes owners describe
Rear toe link fracture
The rear suspension toe link cracks or breaks during normal driving, often at the weld, causing sudden loss of rear wheel alignment and vehicle control. Multiple owners report this occurring on previously recalled parts, suggesting recurring defects.
When: 20,000–143,000 miles; some failures within months of recall repair
Symptoms owners cite: Pop or loud noise from rear suspension; Vehicle fishtailing or drifting during turns, braking, or on wet/uneven roads; Rear wheel turns sideways or loses attachment to wheel hub; Loss of steering control at highway speeds (55–70 mph); Vehicle veers off road or into embankment
Repairs/costs cited: Toe link replacement; some owners report the replacement part also broke within months. Independent mechanics have found aftermarket adjustable toe links can be installed if recalled non-adjustable parts create handling issues. Labor and part costs not consistently cited; some dealers charge for alignment only.
Recalls/TSBs owners mention: NHTSA Campaigns 19V435000, 20V675000, 21V537000 issued for toe link cracks. Many parts unavailable for extended periods (4–6 weeks minimum, some dealers indefinitely). Some VINs reported as not included in recall eligibility despite vehicle matching recall build dates. Dealer states it was completed, then later failures denied as not under recall coverage.
Rear toe link alignment issue post-recall
Recall replacement of adjustable toe links with non-adjustable solid toe links prevents rear wheel alignment adjustment, leaving vehicle with misaligned rear suspension and dangerous handling characteristics.
When: Post-recall (2019–2020 timeframe)
Symptoms owners cite: Rear end feels like it is 'dancing' when hitting road imperfections; Excessive sway, especially in rain or on uneven roads; Cannot be driven safely over 40 mph; Vehicle pulled from road or into embankment due to loss of control
Repairs/costs cited: Recall work (20S62) replaced adjustable toe links with non-adjustable versions. Owners report needing to pay for aftermarket adjustable toe link installation and full rear alignment at independent shops ($500–$1,000+ estimated). Dealers state recall procedure is correct and no adjustment is possible.
Recalls/TSBs owners mention: NHTSA Campaign 20S62 and 20V675000. Dealer states recall performed as specified by Ford; Ford customer service states no updates to recall at this time. Owners directed back to dealers for further action.
Rear control arm/upper suspension link failure
Rear upper control arms or suspension links display abnormal movement and fail to maintain proper wheel alignment, rendering rear suspension unserviceable.
When: 70,000–143,000 miles
Symptoms owners cite: Abnormal movement in upper control arms detected during alignment check; Suspension cannot be properly aligned; No warning lights illuminated
Repairs/costs cited: Parts not yet repaired in reported cases. Owners directed to dealers for recall-related work (21V537000) but VINs not included in recall coverage.
Recalls/TSBs owners mention: NHTSA Campaign 21V537000. VIN not included in recall; owners referred to NHTSA Hotline.
Front tie rod breakage
Front tie rod fails catastrophically, often while backing out of garage or at low speed, causing front wheel to turn 90 degrees or more and rendering vehicle immobile.
When: No mileage specified in complaints; at least one at low mileage
Symptoms owners cite: Loud clunk or noise from front suspension; Front wheel turns completely sideways; Vehicle immobile; requires flatbed towing; Rubber boot torn on tie rod shows heavy rust and corrosion on failed part
Repairs/costs cited: Right front tie rod replaced; dealer declined to replace both sides despite rubber boot failure on at least one side. Part showed extreme rust and deterioration.
Recalls/TSBs owners mention: None reported; owner states dealership had never heard of this failure mode before.
Barrier/strut noise and failure
Rear barrier struts or suspension struts fail, producing abnormal noise at highway speeds and requiring replacement.
When: 70,000 miles
Symptoms owners cite: Abnormal noise from rear suspension at 60 mph; No warning lights; Independent mechanic and dealer both confirm struts need replacement
Repairs/costs cited: Barrier struts require replacement. Recall parts unavailable; one dealer waited over one year to complete recall (19V435000) without resolution.
Recalls/TSBs owners mention: NHTSA Campaign 19V435000. VIN initially reported as not included in recall despite notification being received. Parts distribution disconnect; dealer stated parts not available.
Rear suspension rattling noise and water leak
Rattling noise from rear suspension combined with water entry from roof rack area; related to multiple suspension and structure recalls.
When: 70,000 miles
Symptoms owners cite: Rattling noise underneath vehicle at various speeds; Water entering vehicle from roof rack area; No warning lights initially; airbag warning light later illuminated
Repairs/costs cited: Recall repairs (20V675000, 21V537000, 21V316000) attempted but mechanics unavailable; vehicle rescheduled twice and left unrepaired.
Recalls/TSBs owners mention: NHTSA Campaigns 20V675000, 21V537000, 21V316000. Parts distribution disconnect; no mechanics available to complete repairs.
Front axle separation
Front wheel axle assembly separates from vehicle while driving, rendering vehicle undrivable and requiring towing.
When: 220,000 miles
Symptoms owners cite: Front wheel axle comes apart while driving at 55 mph; No warning lights illuminated; Vehicle can barely be driven to residence after failure
Repairs/costs cited: Owner removed shocks but did not repair full axle. Vehicle not repaired.
Recalls/TSBs owners mention: Recall 17E048000 related to Wheels and Suspension. Local dealer confirmed no associated recalls for this vehicle.
B-pillar trim detachment
B-pillar (center vertical frame member) interior trim panel detaches from vehicle body during normal driving.
When: 100,500 miles
Symptoms owners cite: Driver's side B-pillar trim detaches while driving 30–35 mph; No warning lights
Repairs/costs cited: Recall part not available at dealer; vehicle not repaired.
Recalls/TSBs owners mention: NHTSA Campaigns 21V316000, 24V031000, 25V347000 (Structure). Repair parts not available.
Transmission casing fracture and hard shifts
Transmission casing cracks internally, visible through fractured casing. Vehicle experiences hard shifts after braking and acceleration cycles, culminating in loss of gears and sudden power loss at highway speed.
When: 74,000 miles (failure event); hard shifts reported previously during year prior
Symptoms owners cite: Hard shifts when accelerating after braking; Loud clunk from transmission area while exiting highway; Engine revs high before moving; no warning lights initially; Loss of gears; sudden loss of propulsive power while merging onto busy highway; Oil leak; smoking from under hood; burning oil smell
Repairs/costs cited: Full transmission replacement, approximately $10,000. Owner reports casing visibly cracked and gears visible inside casing.
Recalls/TSBs owners mention: Owner claims Customer Satisfaction Program #20B27 or #20N07 should apply; Ford refused assistance.
Coolant loss and engine misfire
Persistent coolant loss from undetermined cause, combined with cylinder misfire and exhaust gas recirculation into coolant system, indicating internal engine failure.
When: 84,000 miles
Symptoms owners cite: Low coolant level repeatedly after refilling; Coolant level does not hold; continues to drop; Burning coolant smell; Engine overheating warning light
Repairs/costs cited: Dealer diagnosed cylinder 3 misfiring and exhaust recycling into coolant system; full engine replacement estimated at $12,000. Owner reports coolant loss and related issues began at much lower mileage.
Recalls/TSBs owners mention: Ford refused assistance or information on expected failure rates; owner spent over one hour on phone with Ford customer service.
Coolant loss with oil seal leaks and dealer service failures
Chronic coolant loss from early ownership (10 miles on new vehicle) unresolved despite multiple dealer visits and seal replacements. Accompanied by burning coolant smell, oil leaks, and rotten egg/sulfur smell on acceleration that dealer attributes to fuel rather than investigating.
When: New vehicle (10 miles initially); persisting to 14,900 miles
Symptoms owners cite: Coolant loss immediately after delivery; no coolant in overflow reservoir; Burning coolant smell after long drives; Oil leak from oil seal area; Rotten egg/sulfur smell during acceleration (dealer refused to document in work order); Exhaust smell inside cabin; Foul smell from vents
Repairs/costs cited: Oil seal replaced; coolant loss persists. Dealer states coolant loss and burning smell are normal. Steering wheel peeled and ordered for replacement. No repairs completed for coolant issue.
Recalls/TSBs owners mention: Dealer stated owner responsible for diagnosis cost if mechanic finds nothing wrong; owner told to cover technician time. No factory technical support offered despite new vehicle.
Turbo oil leak onto catalytic converter
Oil leaks from turbocharger booster assembly onto catalytic converter, causing both components to fail and triggering check engine warning.
When: 85,000 miles
Symptoms owners cite: Check engine warning light illuminated; Vehicle fails to accelerate properly when pressing accelerator pedal; Oil leak from turbo visible on catalytic converter
Repairs/costs cited: Turbo booster and catalytic converter both need replacement. Vehicle not yet repaired at time of complaint.
Recalls/TSBs owners mention: Owner notified manufacturer and local dealer; no assistance offered. Also reported prior power transfer unit fault and prior front control arm/ball joint replacement.
Steering rack/electric power steering failure
Electric steering rack and pinion fails during turns, causing wheels to continue turning without driver input or excessive resistance to steering input.
When: 70,000 miles
Symptoms owners cite: During left or right turns at various speeds, wheels continue to turn without driver input; Power steering effectively fails during cornering
Repairs/costs cited: Electric steering rack and pinion requires replacement; not yet repaired.
Recalls/TSBs owners mention: Manufacturer notified; NHTSA Campaign 21V537000 referenced but vehicle reportedly not covered.
Transmission shudder
Transmission exhibits shudder or vibration during acceleration, worsening as vehicle ages.
When: 100,000 miles
Symptoms owners cite: Transmission shudder during acceleration; Shudder described as not severe but present
Repairs/costs cited: No repairs documented; owner questions why this is occurring at 100k miles.
Recalls/TSBs owners mention: No response documented.
Axle noise and CV joint issues
Knocking or marble-like rattling noise when turning; CV axles replaced but noise persists, suggesting either incorrect repair or additional joint/suspension component failure.
When: Mileage not specified
Symptoms owners cite: Knocking noise when turning (curving); Sound described as like 'jar of marbles'; Noise continues after CV axle replacement
Repairs/costs cited: CV axles replaced; noise persists, suggesting diagnosis incomplete or additional components failed.
Recalls/TSBs owners mention: No response documented.
Recall parts availability delays
Multiple suspension and structure recalls issued for the 2016 Ford Explorer, but repair parts remain unavailable for extended periods (4 weeks to indefinitely), leaving owners unable to have safety-critical repairs completed and unsafe to drive.
When: Recall notifications issued 2019–2025; parts delays ongoing
Symptoms owners cite: Dealer informs owner parts on backorder 4–6 weeks; After months, dealer still unable to confirm parts arrival date; Months pass with no resolution (e.g., 5+ months for recall 20S62/20V675); Manufacturer cannot provide parts availability timeline
Repairs/costs cited: Owners unable to complete recall work; asked to either wait indefinitely or have unsafe vehicles. Dealers will not confirm vehicle is safe to drive while parts unavailable. Owners request rental vehicle coverage; Ford denies.
Recalls/TSBs owners mention: NHTSA Campaigns 19V435000, 20V675000, 20S62, 21V537000, 21V316000, 24V031000, 25V347000. Ford manufactures states parts not available and cannot confirm delivery dates. Manufacturers referred owners to NHTSA Hotline.
Recall VIN eligibility confusion and denial
Owners receive recall notifications but are later told their VIN is not included in recall coverage, despite the vehicle meeting stated recall build-date and plant criteria. Some failures occur on previously recalled parts that were installed under an earlier recall, creating uncertainty about warranty and coverage.
When: Recall notification issued; denial at service appointment
Symptoms owners cite: Recall notice received for vehicle; Dealer states VIN not in recall database or not covered; Vehicle falls within recall build date and plant criteria per owner research; Failure of previously replaced recall part denied as non-warranty
Repairs/costs cited: Vehicle not repaired; owners told to contact NHTSA Hotline for clarification.
Recalls/TSBs owners mention: Dealers and manufacturer state VIN not included in recall; owners directed to NHTSA.
Recall completion documentation and retest failures
Dealers document recall completion but vehicle either does not have failure corrected or fails inspection after recall work, requiring repeat repair attempts.
When: Post-recall completion; months later or immediately after
Symptoms owners cite: Dealer document states recall completed; Vehicle inspection detects same condition requiring replacement; Vehicle fails inspection and is labeled as unsafe to drive; Recall work later found to have incomplete fastening (bolts not tightened)
Repairs/costs cited: Repeat recalls required; bolts found loose from initial recall work. Parts quoted 4–6 weeks for replacement. Dealers state rental coverage not available.
Recalls/TSBs owners mention: Recall inspection finds failure; new parts ordered (4–6 week delay). No rental or loaner vehicle coverage provided.
Airbag warning light and system faults
Airbag warning light illuminates during suspension failures or independently, raising concern that airbag deployment logic or electrical safety systems are compromised.
When: Post-suspension failure; during rear suspension work
Symptoms owners cite: Airbag warning light illuminates; Owner concerns about unintended airbag deployment or failure to deploy; Seat belt warning light also illuminated in at least one case
Repairs/costs cited: Owner concerned about safety but repair not completed; VIN not in recall.
Recalls/TSBs owners mention: Dealer states VIN not in recall; vehicle not diagnosed or repaired. Manufacturer stated owner may have to pay for repairs.
Steering wheel material degradation
Steering wheel covering peels or degrades prematurely, requiring replacement even on new vehicle.
When: Under 15,000 miles (new vehicle at delivery)
Symptoms owners cite: Steering wheel covering peels
Repairs/costs cited: New steering wheel ordered and replaced.
Recalls/TSBs owners mention: Replacement wheel ordered; treated as warranty repair on new vehicle.
Synthesized from 46 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had suspension 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 suspension problem on the 2016 Ford Explorer?
It's a meaningful issue. 46 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $900.
At what mileage does the suspension typically fail?
Across the 22 complaints that reported odometer mileage, most suspension failures cluster between 49,000 and 105,000 miles, with the median around 84,400. A quarter of owners report trouble before 49,000; a quarter make it past 105,000. 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 $900 for suspension 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 suspension?
No active recalls currently cover suspension 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.