Some 2020-2023 Explorer vehicles may exhibit a condition of intermittent headlamp operation while the vehicle is OFF and have diagnostic trouble code (DTC) B1533 stored in the body control module (BCM). This may be due to the internal logic within the headlamp switch. To correct this condition, replace the headlamp switch (service base PN: 11654). Refer Workshop Manual, Section 417-01.
full bulletin at NHTSA ↗2020 Ford Explorer lighting problems
moderate Owners of the 2020 Ford Explorer have filed 42 NHTSA complaints about the lighting at roughly $250 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See lighting across all vehicles →
Complaints
42
Recalls
0
Avg fix
$250
| Model year | lighting complaints |
|---|---|
| 2016 Explorer | 4 |
| 2017 Explorer | 5 |
| 2018 Explorer | 4 |
| 2020 Explorer (this page) | 42 |
| 2021 Explorer | 8 |
| 2022 Explorer | 3 |
1crash
What stands out
Of the 12 model years of Ford Explorer we track for lighting problems, this one carries the most owner complaints on file — 42.
Owners have filed 42 lighting 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 lighting 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.
Some 2020-2023 Explorer vehicles may exhibit a condition of intermittent headlamp operation while the vehicle is OFF and have diagnostic trouble code (DTC) B1533 stored in the body control module (BCM). This may be due to the internal logic within the headlamp switch. Switch and/or module replacement will not resolve this condition. Headlamp operation is not affected while the vehicle is ON. A new headlamp switch is currently under development to correct this condition. The customer can continue to drive the vehicle until parts become available. Monitor OASIS for updated repair information.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2020 Ford Explorers report widespread issues with the LED headlamp assemblies on both driver and passenger sides. The most common complaint is low-beam failure accompanied by a "Check Headlamp System" dashboard warning. Failures occur across the ownership timeline—some reported under the 3-year warranty, others well after expiration—and mileage varies from under 46,000 to 120,000 miles.
Failures manifest as total loss of function or intermittent operation; lights will go out mid-drive and spontaneously restore hours or days later. Owners describe condensation buildup inside assemblies, and in one case, micro-fractures in the headlamp lens itself diffusing light output. When addressed, dealers report problems with LED control modules and the headlamp assembly itself, but replacement of either component often does not resolve the warning message or prevent recurrence.
Repair costs are substantial. A single headlamp assembly replacement runs $1,500–$2,500 including labor and calibration. Some owners report replacing modules or entire assemblies multiple times within a few years. Daytime running lights and turn signals occasionally fail alongside or separate from low-beam issues. Owners cite this as a safety problem—legally required equipment that they cannot repair affordably—and note numerous online complaints suggesting a systemic defect rather than isolated failures.
Failure modes owners describe
LED low-beam failure with intermittent operation
Driver and passenger side low beams go out, sometimes intermittently, with 'Check Headlamp System' warning on dash. Failures resolve temporarily only to recur hours or days later. Some failures are persistent.
When: Reported from under 46,000 miles to 120,000+ miles; some failures occur within months of purchase, others after 4+ years of ownership.
Symptoms owners cite: Low beam inoperative; Intermittent on/off cycling; Dashboard warning: 'Check Headlamp System See Owner's Manual'; High beam and daytime running lights may still function; Turn signals unaffected in most cases
Codes mentioned: B155A:96 (LED control module failure)
Repairs/costs cited: Dealers recommend replacement of entire headlamp assembly at $1,500–$2,500 per side including labor and calibration. Some owners report replacement of LED control module alone (part #JX7Z-13C788-L, ~$1,112 or replacement headlamp asset part #MB5Z-13008-AG, ~$1,750) providing temporary fix before recurrence. Replacement of low-beam bulb alone not possible—full assembly replacement required.
Recalls/TSBs owners mention: Ford has not issued a recall. Warranty coverage varies; some early failures covered under 3/36 warranty, others denied post-warranty. Ford service advisors state LED headlamps are designed to last the life of the vehicle. When contact made, manufacturer states no recalls exist and directs owners to pay full repair cost.
Headlamp lens micro-fractures and condensation
Micro-fractures appear in headlamp lens plastic, some in front of light source diffusing output; condensation buildup observed inside assemblies. One owner's right headlamp developed fractures at lower inside corner within months of left assembly replacement.
When: Reported within 4 years of ownership at under 45,000 miles; condensation failure reported at 120,000 miles.
Symptoms owners cite: Visible micro-fractures in lens; Light diffusion reducing output visibility; Condensation accumulation inside assembly; Low beam dysfunction; Dashboard warning message
Repairs/costs cited: Entire assembly replacement required. Cost approximately $1,800 per assembly. First failure replaced under 3/36 warranty; subsequent failure on same vehicle denied warranty coverage.
Recalls/TSBs owners mention: Ford replaced first affected assembly under warranty but refused to cover a second assembly failure on same vehicle, citing warranty expiration. No TSB or extended coverage program mentioned.
Persistent 'Check Headlamp System' warning despite repair
Warning message remains on dashboard after replacement of headlamp module, LED control module, or entire headlamp assembly. Warning recurs days or weeks after part replacement, sometimes alternating between driver and passenger side.
When: Recurring throughout ownership; warning can reappear within hours of repair completion.
Symptoms owners cite: Persistent dashboard warning; Warning reappears after module or assembly replacement; Lights may function normally despite warning; Dealers unable to isolate root cause
Repairs/costs cited: Multiple replacements of control modules and headlamp assemblies reported ($2,000+ per replacement in some cases); owners report warning returns within 24 hours of repair. One owner replaced both modules for approximately $2,000 total with no lasting resolution.
Recalls/TSBs owners mention: Dealers and manufacturer unable to diagnose cause. Dealers suggest continued module or assembly replacement; no permanent fix identified in complaints. Manufacturer directed owners to pay for repairs; no recall issued.
Turn signal failure
Turn signal, typically driver side, fails or goes out intermittently after headlamp module replacement. One owner reports turn signal 'continuously goes out every month or so' following module replacement.
When: Reported months after vehicle purchase and following headlamp repair.
Symptoms owners cite: Turn signal inoperative or intermittent; Recurring monthly outages
Repairs/costs cited: No repair cost cited; associated with prior module replacement.
Recalls/TSBs owners mention: Dealership replaced driver side headlight module under warranty; turn signal issue emerged afterward with no clear resolution provided.
Daytime running light malfunction
Driver side daytime running light not functioning.
When: Timing not specified.
Symptoms owners cite: Daytime running light inoperative
Repairs/costs cited: No repair details provided.
Synthesized from 42 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Adaptive headlamp assembly on my 2020 Ford Explorer Platinum AWD has failed twice in 2-years. First, upon receiving the vehicle, the passenger side had to be replaced (dealer was unable to fix the problem, so had to replace the whole headlamp assembly which requires a complete removal of the front bumper). Now the driver side headlamp has failed - and I haven't even had the car 2-years yet (will…
Passenger side Headlight low beam went out. Dealer says it’s $1500 because whole headlight assembly must be replaced instead of a bulb. We live off of social security, so of course we don’t have the money for this. Now we can’t drive at night and we both have medical problems. This is both worrisome and dangerous. After some research, this is a recurring issue, especially for Platinums.
Low beam headlights have both went out in our second year of ownership. At 1600.00 each and 600.00 labor to replace.
Had lighting 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 lighting problem on the 2020 Ford Explorer?
It's a documented issue but not catastrophic. 42 complaints have been filed. Repairs average $250 and most owners catch it before it causes a breakdown.
At what mileage does the lighting typically fail?
Based on the 42 complaints filed, lighting issues most often appear around 88,500 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $250 for lighting 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 lighting?
No active recalls currently cover lighting 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.