2020-2023 Explorer non-hybrid vehicles equipped with a 3.0L EcoBoost or 3.3L Duratec engine and 2020-2023 Aviator non-hybrid vehicles equipped with a 3.0L EcoBoost engine may exhibit an exhaust rattle requiring replacement of the left or right exhaust flexible pipe (5G203). The updated part locates the flexible joint portion of the pipe closer toward the catalytic converter than the originally equipped part. This is due to a design change with these replacement components which will not cause any functional issues with the vehicle.
full bulletin at NHTSA ↗2021 Ford Explorer fuel system problems
moderate Owners of the 2021 Ford Explorer have filed 8 NHTSA complaints about the fuel system at roughly $1,200 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See fuel system across all vehicles →
Complaints
8
Recalls
0
Avg fix
$1,200
| Model year | fuel system complaints |
|---|---|
| 2017 Explorer | 5 |
| 2018 Explorer | 4 |
| 2021 Explorer (this page) | 8 |
| 2022 Explorer | 12 |
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system 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 22-2176 to increase the labor operation allowance and update the part list. Some 2020-2022 Escape/Corsair vehicles built on or before 3-Jan-2022, 2020-2022 Explorer vehicles built on or before 14-Feb-2022, 2020-2022 Aviator vehicles built on or before 07-Feb-2022 and 2021-2022 Bronco Sport vehicles built on or before 3-Dec-2021 may exhibit a slow fuel fill and/or spit back condition during refueling. This may be due to the design of the fuel tank filler pipe. To correct the condition, follow the Service Procedure to replace the fuel tank filler pipe.
full bulletin at NHTSA ↗Some 2020-2022 Escape/Corsair vehicles built on or before 3-Jan-2022, 2020-2022 Explorer vehicles built on or before 14-Feb-2022, 2020-2022 Aviator vehicles built on or before 07-Feb-2022 and 2021-2022 Bronco Sport vehicles built on or before 3-Dec-2021 may exhibit a slow fuel fill and/or spit back condition during refueling. This may be due to the design of the fuel tank filler pipe. To correct the condition, follow the Service Procedure to replace the fuel tank filler pipe.
full bulletin at NHTSA ↗Some 2020 - 2022 Explorer/Aviator/Police Interceptor Utility vehicles may display a distance to empty value in the instrument panel cluster (IPC) that does not correctly represent the actual fuel level of the vehicle. This may be due to excessive idling and/or a learned value in the powertrain control module (PCM) that is incorrect. To correct the condition, perform the PCM - Reset the Keep Alive Memory (KAM) application in the appropriate Ford diagnostic scan tool. For claiming, use Causal Part 12A650 and applicable labor times from Section 10 in the Service Labor Time Standards (SLTS) Manual.
full bulletin at NHTSA ↗Some 2020-2021 Escape/Corsair vehicles built on or before 30-Mar-2021 and Explorer/Aviator vehicles built on or before 09-Apr-2021 may exhibit a slow fuel fill and/or spit back condition during refueling. This may be due to the design of the fuel tank filler pipe. To correct the condition, follow the Service Procedure to replace the fuel tank filler pipe.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 0 most recent
Had fuel system trouble with your 2021 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 fuel system problem on the 2021 Ford Explorer?
It's a documented issue but not catastrophic. 8 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 8 complaints filed, fuel system issues most often appear around 54,286 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 $1,200 for fuel system 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 fuel system?
No active recalls currently cover fuel system 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/2021/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.