Some 2020-2024 Explorer/Police Interceptor Utility hybrid vehicles may exhibit a "Refuel Error See Manual" message in the instrument panel cluster (IPC) after installing a replacement fuel filler door assembly (7827936). This may be due to a concern with the replacement fuel filler door assembly. If diagnostics in the Workshop Manual (WSM), Section 501-14 Body > Handles, Locks, Latches and Entry Systems > lead to fuel filler door switch replacement, install a new fuel filler door assembly ordered from depot stock to correct this condition. Suspect parts have been cleared from parts depot inventory.
full bulletin at NHTSA ↗2020 Ford Explorer body problems
severe Owners of the 2020 Ford Explorer have filed 32 NHTSA complaints about the body, typically surfacing around 62,000 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
32
Recalls
0
Avg fix
$1,500
| Model year | body complaints |
|---|---|
| 2016 Explorer | 545 |
| 2017 Explorer | 618 |
| 2018 Explorer | 269 |
| 2019 Explorer | 141 |
| 2020 Explorer (this page) | 32 |
| 2021 Explorer | 21 |
| 2022 Explorer | 8 |
| 2023 Explorer | 8 |
1crash
1fire
4injuries
What stands out
Owners have filed 32 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.
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.
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 ↗2020-2026 Police Interceptor Utility vehicles may require level III ballistic panels to be replaced due to broken mounting tabs. Individual level III ballistic panel mounting tab service parts are now available: right-hand (78201B68) and left-hand (78201B69). Replacement of the level III ballistic panel assembly is not required for this condition. Level IV ballistic panels do not have removable mounting tabs and still require complete panel replacement. Level III vs level IV ballistic panels can be identified by a large roman numeral label on the panel or by the vehicle window sticker if equipped.
full bulletin at NHTSA ↗Some 2020-2023 Explorer vehicles may exhibit various issues with the roof rack side. If there is an issue with the roof rack side that requires replacement, a lower level service part is now available separately (7855114 and 7855115). It is no longer necessary to replace the entire roof rack assembly.
full bulletin at NHTSA ↗This article supersedes TSB 23-2181 to add 2024 vehicle model year. Some 2020-2024 Explorer/Aviator vehicles may exhibit a lack of audio and/or a water leak in the rear liftgate area and/or water in the spare tire area. The customer may indicate that this concern is more noticeable after a car wash or rainfall. To correct the condition, follow the Service Procedure to identify the leak path.
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 constellation of structural and trim-related failures on the 2020 Ford Explorer. Hood alignment defects appear early: one owner at 68K miles had a missing hood adjuster that couldn't be corrected even after replacement, leaving a misaligned hood with quarter-inch gaps. Another owner's hood detached at highway speed, smashing the windshield and scattering glass into the cabin.
Chrome and plastic trim components deteriorate prematurely. Door handles (both exterior and interior) develop peeling or fractured chrome plating at mileages as low as 17K miles, creating sharp edges that have cut owners' hands. A-pillar trim pulls away from the body, windshield trim detaches at 40K miles, and rear window trim comes loose. One owner reports a prior-generation recall for A-pillar trim on earlier Explorers.
Sunroof and panoramic roof components fail regularly. Shade mechanisms sag due to failed clips, interior sunshade covers detach and fall into the cabin at highway speed, and one sunroof exploded without apparent cause while the vehicle was running with AC on.
Water intrusion is widespread. Multiple owners report water pooling in the spare tire well (one with 3 inches accumulated), rear-seat wetness from weld joint breakdown, cabin leaks near the dead pedal with mold development, and windshield seal failures allowing water entry. Owners smell mold and report allergic reactions.
Glass failures occur spontaneously. Rear windows shatter without impact while parked or at low speed; quarter-panel windows crack. One owner reports both driver and passenger A-pillar glass blowing off in separate incidents. A sunroof exploded while running.
Same Ford Explorer body reports on nearby years: 2017 · 2018 · 2019 · 2021
Failure modes owners describe
Hood misalignment and detachment
Hood adjuster missing or failed causing misalignment; one hood detached completely at highway speed and struck windshield
When: 68K miles for adjuster failure; highway speeds for detachment
Symptoms owners cite: Hood lower than normal on one side; Uneven gaps between hood and fender; Hood completely detached and impacted windshield
Repairs/costs cited: Dealer replaced hood adjuster but did not resolve misalignment; second incident required windshield replacement ($886.85) and hood repair
Recalls/TSBs owners mention: Dealer confirmed no collision damage; manufacturer referred owner to NHTSA
Door handle chrome deterioration and sharp edges
Chrome plating on interior and exterior door handles peels or fractures, creating sharp edges that have cut owners' hands
When: 17K to 62K miles
Symptoms owners cite: Chrome paint peeling from door handles; Chrome plating fractured exposing sharp metal; Lacerations to hands when opening doors
Repairs/costs cited: No repairs completed; owners declined to pursue after being informed handles not covered by CSP 22N17
Recalls/TSBs owners mention: CSP 22N17 covered power window switch chrome tips only; door handles not included; referred to NHTSA; no recalls available
Windshield and trim trim separation
Windshield molding and trim pieces detach from vehicle while driving; owner notes prior-generation recall for same issue on 2017-2019 models
When: 40K to 76K miles
Symptoms owners cite: Windshield trim detached at 70 MPH; Driver-side and passenger-side windshield trim both detached; A-pillar trim pulling away from body with wind noise; Rear window trim coming loose and becoming projectiles
Repairs/costs cited: Vehicle out of warranty; not repaired
Recalls/TSBs owners mention: Out-of-warranty vehicles declined assistance; no recalls for 2020 model noted despite prior recalls on 2017-2019
Panoramic sunroof shade malfunction and interior sunshade detachment
Sunroof roller clips fail causing shade to sag; interior sunshade covers detach and fall into cabin during operation
When: 66K to 78K miles
Symptoms owners cite: Panoramic shade sagging; Interior sunshade cover detaches and falls inside cabin; Obstruction of rear window affecting driver visibility
Repairs/costs cited: One owner awaiting replacement of sunshade cover; clip failure documented by dealer
Recalls/TSBs owners mention: Manufacturer notified; no assistance offered
Spontaneous glass failure (rear window and sunroof)
Rear windows shatter without impact while parked or at low speed; sunroof exploded while vehicle was running with AC on
When: Highway speeds and while parked; one incident while running stationary with AC activated
Symptoms owners cite: Rear window shattered at 30 MPH without impact; Rear window shattered while vehicle parked overnight; Sunroof exploded while running with AC on, headliner closed; Quarter-panel side windows cracking spontaneously; A-pillar glass panels shattering underneath both sides
Repairs/costs cited: One owner paid insurance deductible; no dealer repairs documented
Recalls/TSBs owners mention: No warnings or recalls issued; owners contacted NHTSA
Water intrusion and interior flooding
Multiple water leaks including spare tire well pooling, rear-seat seepage, and cabin flooding near dead pedal; weld joints break down allowing water entry
When: Early ownership; documented at various mileages
Symptoms owners cite: Water accumulating in spare tire well (3+ inches reported); Wet rear seats and mold smell; Water entering cabin near dead pedal when sunroof drains used; Water entering through windshield seal; Musty mold smell causing allergic reactions; Rusted spare tire mechanism from prolonged water exposure
Repairs/costs cited: One owner had spare tire well drained; dealer replaced parts but did not resolve leak; windshield seal replacement attempted; mold remediation pending
Recalls/TSBs owners mention: Dealers inspected and attempted repairs; weld joint breakdown suspected on at least one vehicle
Panoramic liftgate unexpected closure
Hands-free liftgate system closes unexpectedly without button activation; foot-sensor activation closes door when standing near bumper with cargo
When: Over two-year ownership period; repeated incidents
Symptoms owners cite: Liftgate closes 20+ times without actuation; No closing chime sounding in many instances; Foot-sensor activation triggered by proximity while loading cargo; Unsafe closure on people including children and grandchildren
Repairs/costs cited: Software update performed; condition persisted; dealer stated foot function cannot be deactivated
Recalls/TSBs owners mention: Software update attempted; no further assistance offered
Interior trim and components detachment
Upper center console detached from housing causing crash; interior trim pieces becoming loose
When: 48K miles for center console
Symptoms owners cite: Upper center console detached while driving at 30 MPH; Detachment caused driver to crash into another vehicle
Repairs/costs cited: Not repaired; police report filed
Recalls/TSBs owners mention: Manufacturer contacted and case filed
Driver's side door lock malfunction
Driver's door locks and prevents entry or exit at random, posing safety risk especially for disabled occupants
When: Intermittent throughout ownership
Symptoms owners cite: Driver's door locks and will not unlock; Cannot enter or exit vehicle through driver's door
Repairs/costs cited: Not specified
Side mirror wind noise
Exterior rear-view side mirrors produce loud whistling noise while driving
When: During highway operation
Symptoms owners cite: Loud whistle noise when driving
Vehicle fire
Vehicle spontaneously caught fire while being driven, destroying entire front end; no warnings before flames appeared
When: While actively being driven
Symptoms owners cite: Flames coming from under hood; Complete front-end destruction
Repairs/costs cited: Vehicle declared total loss by insurance; salvage company took possession
Recalls/TSBs owners mention: No warnings or pre-incident alerts
Synthesized from 32 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had body trouble with your 2020 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 2020 Ford Explorer?
It's a meaningful issue. 32 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Across the 10 complaints that reported odometer mileage, most body failures cluster between 40,000 and 68,000 miles, with the median around 62,000. A quarter of owners report trouble before 40,000; a quarter make it past 68,000. 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/2020/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.