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 ↗2019 Ford Explorer electrical problems
moderate Owners of the 2019 Ford Explorer have filed 17 NHTSA complaints about the electrical, typically surfacing around 45,600 miles at roughly $850 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See electrical across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$850
| Model year | electrical complaints |
|---|---|
| 2015 Explorer | 71 |
| 2016 Explorer | 93 |
| 2017 Explorer | 81 |
| 2018 Explorer | 45 |
| 2019 Explorer (this page) | 17 |
| 2020 Explorer | 136 |
| 2021 Explorer | 34 |
| 2022 Explorer | 28 |
| 2023 Explorer | 9 |
When does it fail?
Of the 17 electrical complaints filed for the 2019 Ford Explorer, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 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
No new NHTSA electrical complaint has been filed on this vehicle in over 5 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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.
This article supersedes TSB 24-2165 to update the TSB Service Procedure. Some vehicles listed in the Model statement above may exhibit various SYNC performance related concerns including but not limited to: Display operation concerns Navigation inoperative Voice recognition concerns Phone connection issues Dropped phone connections Applink related performance Travel Link not present or showing incorrect traffic Slow system response NOTE: Ford has found some of the APIMs replaced and returned for inspection contained an outdated software level and the APIM did not require replacement. The customer concern may have been resolved by updating the APIM with latest level of softwar
full bulletin at NHTSA ↗Some 2015-2021 Ford and Lincoln vehicles may exhibit an illuminated MIL with diagnostic trouble codes (DTCs) P0011, P0012, P0014, P0015, P0016, P0017, P0018, P0019, P0021, P0022, P0024 and/or P0025. Pinpoint test HK in the Powertrain Control and Emissions Diagnosis (PC/ED) or in Section 303-14 of the Workshop Manual (WSM) has been updated to address this concern.
full bulletin at NHTSA ↗In various 2017-2023 Ford and Lincoln vehicles, customers may receive a message in the FordPass or LincolnWay App stating Feature Unavailable. Since this is a fleet vehicle, it cannot access the (SYNC Connect) FordPass or LincolnWay app through the TCU Embedded Modem. If this message appears, the vehicle may be equipped with a fleet telematics module. Replacement of the TCU or TCU related repairs will not prevent this message from appearing. Refer the customer to in app FordPass Guides or LincolnWay Concierge Teams to aid with fleet telematics removal. Open app, select Account > Help > CHAT or CALL option.
full bulletin at NHTSA ↗Some 2018-2023 F-150, Expedition, Navigator, Transit, Aviator and Explorer vehicles may exhibit an illuminated MIL with diagnostic trouble codes (DTCs) P0627, P025A, P025B, P00C6, P008A and/or U0109 stored in the powertrain control module (PCM). This may be due to an intermittent or partial disconnect of the harness to the fuel pump control module (FPCM) connector, connector pin push-outs, damaged pins/terminals, or loose/corroded grounds. Inspect FPCM connector, applicable grounds (F-150 - G401, Expedition/Navigator - G403, Transit - G401, 2018-2019 Explorer G302, 2020-2022 Explorer/Aviator - G407) and confirm FPCM connector (F-150 - C4336, Expedition/Navigator - C433, Transit - C433, 201
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2019 Explorer's electrical system shows patterns of failure across multiple subsystems. Most prevalent: horn problems. Several owners report total horn inoperability—no sound when pressed, fuse and relay tested good. Others found a single horn installed instead of dual, making the stock horn nearly inaudible from inside the vehicle; one owner retrofitted dual horns to restore adequate warning volume. Three separate complaints detail inadequate horn sound as a design choice.
The Sync 3 touchscreen fails intermittently, then becomes completely non-functional, disabling maps, Bluetooth, and climate controls. One owner paid over $1,200 for replacement; the 2020 model has documented recalls for the same defect.
B-pillar trim detachment at highway speeds pulled door wiring and caused electrical shorts, forcing battery disconnect to prevent fire. A second owner reported the same B-pillar issue. Related: roof rail covers repeatedly loosen and detach despite TSB-20-2154 repair, and wiring harness failure at 75,000 miles produced burning smell and backup camera blackout.
Battery failures included swelling, explosion, and acid leakage at 42,000 miles; a second failure recurred despite replacement. Charging system faults appear above 80°F ambient temperature, persisting after battery and terminal replacement. One owner experienced a no-start condition after parking; fuel pump module was replaced but the problem returned within four months. Excessive cabin fumes from the ignition area, strong during acceleration, went undiagnosed through three dealer visits.
Same Ford Explorer electrical reports on nearby years: 2016 · 2017 · 2018 · 2020 · 2021
Failure modes owners describe
B-pillar exterior trim detachment
B-pillar exterior trim (door panel) detaches at highway speeds due to defective clips and adhesive, becoming a projectile hazard. The detachment pulls on keypad wiring, causing the trim to flail and creating immediate road safety risk.
When: Highway speeds; one report at unspecified mileage
Symptoms owners cite: Exterior trim flailing in wind; Keypad wiring tethering detached trim; False 'Liftgate Open' warning triggered simultaneously; Door keypad becomes inoperable; Electrical short in door harness from damaged wiring
Repairs/costs cited: Manual disconnection of battery required to prevent fire risk from short circuit. Dealers acknowledge failure but note current recalls (25S53) only cover 2016–2017 models; 2019 model uses same defective clips and adhesive.
Recalls/TSBs owners mention: Recall 25S53 applies to 2016–2017 models only; Recall 24S02 addresses similar A-pillar detachment. No expansion to 2019 model year confirmed in narratives.
Battery failure and acid leakage
Battery becomes swollen, explodes, and leaks battery acid inside the vehicle. Failure occurred twice within approximately one year, with dealer replacing the first battery and then identifying active acid leakage on second occurrence around 42,000 miles.
When: First failure at unknown mileage (October 2020); recurrence by May 2021 at approximately 42,000 miles
Symptoms owners cite: Odor detected under hood; Swollen, exploded battery; Battery actively leaking and covered in battery acid; Water leaking into headliner and sunroof (occurred during same complaint)
Repairs/costs cited: First battery replaced by dealer with consumer-purchased Walmart battery; second failure left unrepaired at dealer.
Recalls/TSBs owners mention: Initially stated no recall associated with VIN; later agreed to lemon law buyback of vehicle under Florida law.
Inadequate horn sound output
Vehicle equipped with single horn instead of dual horns, resulting in significantly reduced sound output that is nearly inaudible from inside the vehicle and fails to meet safety expectations. This appears to be a manufacturing cost-reduction choice affecting multiple 2019 model year vehicles.
When: Present from new; affects 2019 model year
Symptoms owners cite: Single horn installed instead of dual horns; Horn barely audible from inside vehicle; Inadequate volume for emergency warning purposes; Sound output insufficient for safe distance warning; Muffled or muted horn tone
Repairs/costs cited: Owner retrofit using Ford part GB5Z-13832-A (dual horns from other model years) to restore adequate horn sound.
Recalls/TSBs owners mention: No manufacturer recall or TSB documented in narratives for horn adequacy issue.
Horn inoperability
Horn fails completely and does not sound when activated. Multiple complaints report total loss of horn function with no warning lights present, indicating intermittent or electrical circuit failure independent of fuse and relay.
When: Various mileages ranging from 45,600 to 74,000 miles
Symptoms owners cite: Horn does not sound when depressed; No warning lights illuminated; Complete loss of audible horn response; Horn fuse and relay confirmed functional in at least one case
Repairs/costs cited: No repairs documented; one scheduled diagnostic was not completed.
Recalls/TSBs owners mention: No manufacturer response documented in narratives.
Wiring harness failure with burning odor
Rear wiring harness fails while vehicle is parked, producing a burning odor and causing multiple electrical system failures including backup camera display malfunction and unknown warning light illumination.
When: Approximately 75,000 miles
Symptoms owners cite: Burning odor while parked; Backup camera display goes black; Multiple unknown warning lights illuminated; Loss of backup camera function
Repairs/costs cited: Rear wiring harness replaced by dealer.
Recalls/TSBs owners mention: Manufacturer notified; case filed with them.
Sync 3 infotainment system failure
Ford Sync 3 touchscreen becomes intermittently unresponsive, then completely non-functional, affecting navigation, climate controls, and Bluetooth connectivity. Complaint notes that 2020 Explorer models have documented recalls for the same issue, suggesting the 2019 model year shares the defect.
When: Began intermittently, progressed to total failure near/after warranty expiration
Symptoms owners cite: Intermittent screen blackout; Screen freezes in reverse camera mode; Touchscreen becomes unresponsive; Bluetooth connection failure; Complete loss of infotainment functions; No access to maps or on-screen controls
Repairs/costs cited: Estimated repair cost over $1,200 for screen replacement at Ford dealership.
Recalls/TSBs owners mention: Recalls documented on 2020 model Explorer for this exact issue; no recall mention for 2019 model in narrative.
Excessive cabin fumes from ignition area
Strong chemical fumes enter the cabin from the ignition area, particularly during acceleration and long-distance driving. Fumes are powerful enough to require sunroof opened for ventilation. Failure persists despite three dealer diagnostic visits with no reproducible diagnosis.
When: From 1,100 miles onward; persists through multiple service visits over extended period
Symptoms owners cite: Strong fumes from ignition system area; Fumes intensify during acceleration; Fumes worse on long drives; Odor strong enough to require active ventilation; Failure intermittent and not reproducible at dealer
Repairs/costs cited: No repairs completed despite three dealer visits; failure remains undiagnosed.
Recalls/TSBs owners mention: Manufacturer notified; no resolution or recall documented.
Charging system fault warning in high temperatures
Battery indicator light appears on dash with accompanying Ford Pass app message indicating charging system fault when ambient temperature exceeds approximately 80 degrees. Persists after battery replacement and terminal cleaning, suggesting deeper electrical system issue.
When: Recurring during temperatures above ~80°F; reported over three-year period from April 2019 through May 2023
Symptoms owners cite: Battery indicator light illuminates on dash; Ford Pass app shows 'Charge System Fault' message; Warning only appears in high ambient temperatures; Intermittent recurrence (reported 12+ times over lease and purchase period)
Repairs/costs cited: Battery and terminals replaced without resolving warning; no other repairs documented.
Recalls/TSBs owners mention: Dealer unable to duplicate failure during service; no recall or TSB documented.
Roof rail cover loosening
Roof rail covers on both left and right sides come loose after dealership repair of TSB-20-2154, continue to loosen, and can detach and become projectiles. Complaint also notes electrical wires coated with soy-based coating that attracts rodents.
When: After dealership completion of TSB-20-2154 repair
Symptoms owners cite: Roof rail covers detach after repair; Covers continue to come loose despite repair; Covers can fly off and create accident hazard; Soy-based wire coating attracts squirrels and rodents; Rodent activity can cause engine fire risk
Repairs/costs cited: TSB-20-2154 repair completed but problem recurs; no permanent fix documented.
Recalls/TSBs owners mention: TSB-20-2154 exists but appears ineffective in preventing ongoing detachment.
No-start condition after extended parking
Vehicle will not start after being turned off and left for a period of time. Engine cranks but will not fire. Battery checks out as functional. Fuel pump module identified as faulty and replaced, but failure recurred within four months.
When: After extended vehicle parking; recurrence within 4 months of repair
Symptoms owners cite: Engine cranks but will not start; Failure occurs after vehicle left parked for period of time; Battery functional when tested; Fuel pump module failure identified
Repairs/costs cited: Fuel pump module replaced at dealership; failure recurred.
Recalls/TSBs owners mention: No manufacturer response documented.
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Roof rail covers on left and right sides of 2019 Ford explorer come loose after dealership repaired Ford tsb-20-2154, still coming loose, they can fly off vehicle and cause an accident electrical wires are coded with soy causing squirrels / rodents etc.to eat engine wires and trying to build a nest in engine can creat a fire
Had electrical trouble with your 2019 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 electrical problem on the 2019 Ford Explorer?
It's a documented issue but not catastrophic. 17 complaints have been filed. Repairs average $850 and most owners catch it before it causes a breakdown.
At what mileage does the electrical typically fail?
Across the 8 complaints that reported odometer mileage, most electrical failures cluster between 19,000 and 74,000 miles, with the median around 45,600. A quarter of owners report trouble before 19,000; a quarter make it past 74,000. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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/2019/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.