This article supersedes 25-2302. Reason for update: update the labor time allowance for F-150 vehicles, update the Parts list to replace the part number W716979-S439 with W721084-S439, and add a note for LV fluids XT-10-QLVC and CXT-10-LV6 "Transfer Case Fluid". Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: Harsh engagement Delayed engagement Harsh shift Delayed shift Illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC)s P0751, P0752, P0756, P0757, P0761, P0762, P0766, P0767, P0771, P0772, P2700, P2701, P2702, P2703, P2704, P2705, P2707, P2708, P0729, P0731, P0732, P0733, P0734, P0735, P073
full bulletin at NHTSA ↗2021 Ford Explorer powertrain problems
moderate Owners of the 2021 Ford Explorer have filed 104 NHTSA complaints about the powertrain, typically surfacing around 39,000 miles at roughly $2,500 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See powertrain across all vehicles →
Failure mileage
Complaints
104
Recalls
0
Avg fix
$2,500
| Model year | powertrain complaints |
|---|---|
| 2017 Explorer | 112 |
| 2018 Explorer | 43 |
| 2019 Explorer | 32 |
| 2020 Explorer | 440 |
| 2021 Explorer (this page) | 104 |
| 2022 Explorer | 53 |
| 2023 Explorer | 10 |
| 2025 Explorer | 13 |
2crashes
1injury
When does it fail?
Of the 104 powertrain complaints filed for the 2021 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
Owners have filed 104 powertrain 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.
Powertrain accounts for 26% of all owner complaints filed against this vehicle, across 12 categories tracked.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering powertrain 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.
For 20202026 vehicles equipped with the 10R60 transmission, a new Transmission Clutch Circuit Leak Test has been introduced in the Ford Diagnosis and Repair System (FDRS). This test utilizes the pressure and vacuum transducer (PVT) when available. Workshop Manual (WSM) updates related to this diagnostic procedure are planned for release in Q4 2026. The new test improves the accuracy of detecting leaks within transmission fluid circuits and replaces the previous air check method. The previous air check procedure has been shown to produce a high rate of false positives, which may lead to unnecessary repairs when no actual leak is present. Accordingly, the air check procedure is not to be us
full bulletin at NHTSA ↗Some 2020-2026 Explorer/Police Interceptor Utility/Aviator vehicles may require replacement of the front drive halfshaft inner/outer CV joint boot for various reasons. If Workshop Manual (WSM), Section 205-04 > Diagnosis and Testing leads to CV joint boot replacement, L1MZ-3A331-G (Explorer/Police Interceptor Utility front inner/outer CV joint boot kit), L1MZ-3A331-H (Aviator front inner/outer CV joint boot kit), L1MZ-3A331-F (Explorer/Police Interceptor Utility front inner CV joint boot kit) and L1MZ-3A331-E (Aviator front inner CV joint boot kit) have been released for service. Refer to WSM, Section 205-04 for Removal and Installation procedures.
full bulletin at NHTSA ↗This bulletin supersedes 26-2046. Reason For Update: update the parts list to change the claim quantity of the C clutch friction plates (HL3Z-7B164-A), C clutch steel plates (HL3Z-7B442-F), D clutch steel plates (HL3Z-7B442-D), add the rear driveshaft flange CV joint-to-pinion flange cup bolts and retaining straps (LK4Z-4B496-B) for Transit, and update the parts description for the transfer case fluids applicable for each vehicle line. Some of the vehicles listed in the Model statement above may exhibit all of the following conditions: * Harsh engagement * Delayed engagement * Harsh shift * Delayed shift * Illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC) P0751
full bulletin at NHTSA ↗Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine and 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable to enter electric-only drive modes as expected during normal drive cycles. This may be due to the software within the belt integrated starter generator (BISG). For vehicles with this condition, follow Pinpoint Test I: Battery Isolation/Voltage Stabilization Control Circuit Carry Outance located in the Workshop Manual (WSM), Section 303-06D and repair the vehicle as necessary. No
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2021 Ford Explorers describe recurring powertrain failures across multiple categories. The most prominent issue is rear axle bolt fracture (NHTSA 22V255/23V675, Ford 22S27, Program 22N06). Owners report loud banging, grinding, and metal-on-metal noises followed by loss of motive power, vibration, and uncontrolled vehicle rollaway in park—one owner's vehicle rolled into a utility pole. The root cause: Ford installed a single-bolt rear subframe designed for lower-powered engines on ST and high-performance models requiring two bolts; some 2020 models and Lincoln Aviators received the correct two-bolt design. Ford's recall fix—PCM reprogramming to auto-engage the parking brake—is a workaround, not a repair. One owner reported that after the PCM update, the vehicle randomly slammed to complete stops at highway speeds with no warning, eventually rolling downhill after losing drivetrain engagement.
Transmission failures are widespread. Owners report harsh shifting with high RPM surges (7–8k rpm), delayed engagement when shifting from park to reverse (1–3 seconds), loss of power mid-acceleration, jerking and lurching, fluid leaks from transfer case seals, and burnt clutches at low mileage (6,900–25,000 miles). Multiple owners experienced complete transmission failure requiring replacement. Several incidents occurred on busy streets or highways, creating serious collision risks. One owner's transmission failed mid-merge, forcing repeated accelerator presses over 10–20 seconds to move the vehicle.
Other powertrain failures include engine stalling at highway speed with wrench-light warnings, engine power loss forcing vehicles into limp mode, and a catastrophic internal engine failure at 11,000 miles despite proper maintenance. One owner reported blue-gray smoke on startup from defective turbos leaking oil into the exhaust. Coolant intrusion into the transmission has been documented.
Warranty and repair delays are endemic. Owners report waiting 6–7 weeks for parts, dealers lacking required recall-repair tools despite parts availability, and Ford refusing to include vehicles that meet recall criteria. One owner waited 30 days for diagnostics with no work performed. Dealer loaner denials and contradictory safety clearances add to owner frustration. One owner's vehicle was cleared as safe by Ford's field engineer and customer service despite multiple unresolved incidents, only to later cause a crash.
Same Ford Explorer powertrain reports on nearby years: 2018 · 2019 · 2020 · 2022
Failure modes owners describe
Rear Axle Bolt Fracture
Single rear axle mounting bolt fractures during normal driving or acceleration, allowing rear axle housing to shift out of position. This disconnects the driveshaft/half-shafts from the differential, causing loss of drive torque to rear wheels and uncontrolled vehicle rollaway when parked.
When: Occurs during highway driving, acceleration, or trailer towing; some owners report mileage 25,000–113,000 miles; others experience failure shortly after recall repair
Symptoms owners cite: Loud bang or grinding noise (metal on metal); Sudden loss of motive power; Severe vibration and clunking from rear; Vehicle rolls downhill uncontrolled when placed in park; Rear end shifts suddenly during turns
Codes mentioned: Transmission not in park warning, Emergency brake apply warnings
Repairs/costs cited: Rear differential replacement found large metal chunks in fluid; cost ~$6,000 reported by one owner. One owner's vehicle was repaired by dealer only after crash occurred.
Recalls/TSBs owners mention: NHTSA 22V255, 23V675; Ford 22S27, Program 22N06. PCM reprogramming applied as recall fix, but this only auto-engages parking brake—does not fix underlying single-bolt design flaw. Some owners report vehicle excluded from recall despite meeting all criteria. Lincoln Aviator received two-bolt design; police interceptor models receiving correct subframe replacement while consumer models do not.
Transmission Shifting Failures and Power Loss
Transmission exhibits harsh, delayed, or missed shifts; lurches forward unexpectedly; or loses all power during acceleration. Issues include high RPM surges, slipping, grinding noises, and complete loss of motive power on roadways.
When: Occurs from 6,900 miles onward; some failures at very low mileage (under 15,000 miles); failures often happen when accelerating from stop or merging into traffic
Symptoms owners cite: Jerking, lurching, or hard forward surge; 1–3 second lag when shifting from park to reverse; RPM spikes to 7–8k rpm followed by sudden jerk; Loss of power while accelerating; Rough transitions from park to drive; Grinding or ringing noise during shifts; Vehicle unable to shift out of first gear; Transmission drops into neutral unexpectedly; Burnt smell from transmission fluid
Codes mentioned: See manual prompt on dashboard, Drive modes not available warning, Transmission failure diagnostic, Coolant intrusion into transmission (found on some vehicles)
Repairs/costs cited: Complete transmission replacement required on multiple vehicles; low-mileage transmissions found to have low/discolored fluid with burnt clutches; one replacement failed again 7,000 miles later; another failure occurred immediately after recall PCM service (same vehicle as axle bolt issue). Transfer case seal leaks reported on transmission output; 6–7 week parts wait times; one vehicle waited 30 days for dealer diagnostics before transmission removal begun.
Recalls/TSBs owners mention: Multiple owners advised transmission would adapt after 500–1,000 miles of driving; claim did not resolve issue. Dealers initially diagnosed as software update needed, then escalated to full replacement. One vehicle received replacement transmission while recall PCM update was being applied—replacement failed immediately. Warranty coverage disputed on at least one vehicle at 46,000 miles.
Engine Power Loss and Stalling
Engine loses power or stalls without warning during highway driving, forcing vehicle into limp mode or complete stop. Wrench-light warning may appear or may not appear before failure.
When: Occurs on highway at 60–80 mph; one vehicle at 13,000 miles, another at 80,000 miles
Symptoms owners cite: Powertrain warning light illumination; Immediate speed reduction from highway speed; Complete engine stall/loss of all power; Vehicle enters limp mode after power loss; No ability to accelerate after restart until vehicle cools/is restarted; Recurring failures after restart
Codes mentioned: Powertrain warning light (wrench symbol), Service engine light, Possible valve failure code (one case)
Repairs/costs cited: One case: defective valve required engine disassembly for diagnostics; parts not available at dealership time of report. Another case: excessive metal shavings found in oil filter indicating internal engine component failure; engine block replaced.
Recalls/TSBs owners mention: Manufacturer referred complainants to NHTSA hotline; one case linked to possible Ford Campaign 24S55 (engine valve issue). No proactive recall initiated for stalling events at time of complaints.
Defective Engine Turbos
Both turbos leak oil into hot exhaust system, generating blue-gray smoke on startup. Risk of fire and engine damage.
When: At 13,000 miles on new vehicle
Symptoms owners cite: Blue-gray smoke on startup (documented with video); Turbos leaking oil into exhaust; Potential fire risk
Repairs/costs cited: Dealer removed engine and transmission; broke numerous bolts during removal and replaced with inferior quality parts. After repair, hoses left loose, antifreeze short, turbo boost hose fell off; antifreeze burning smell and rough idle resulted.
Recalls/TSBs owners mention: Ford denied lemon law buyback claim after vehicle spent 2 months at dealer for repeated failed repairs.
PCM Recall Reprogramming—Unintended Consequences
After PCM update applied to prevent rollaway (automatic parking brake engagement), vehicle randomly slams to complete stop while driving at highway speeds, followed by drivetrain disengagement and vehicle rollaway downhill.
When: Occurred multiple times within days of PCM recall service; incidents at 30–50 mph
Symptoms owners cite: Random complete stop while driving (slamming brakes); Audible clicking sound preceding stop (sometimes); Drivetrain disengagement after slamming; Uncontrolled rollaway downhill after disengagement; No ability to accelerate during rollaway; Occurs with multiple drivers in same vehicle
Codes mentioned: Hill Start Assist failure warning
Repairs/costs cited: Dealership unable to reproduce issue despite multiple visits and different drivers; vehicle was repeatedly returned to owner with no repairs; one crash resulted into utility pole.
Recalls/TSBs owners mention: Ford customer service and legal department refused continued loaner vehicle, stated no similar complaints received (later proven false), field engineer cleared vehicle as safe without supply of service records. Ford eventually repurchased vehicle after crash. Owner notes a subsequent PCM recall was later issued for same issue but after repurchase completed.
Transmission Engaging Delay / Shift Lag
Significant delay (1–3 seconds) between shifting commands and actual transmission engagement, particularly when shifting from park or drive to reverse. Vehicle continues to roll forward during lag, creating collision hazard.
When: Occurs during routine low-speed maneuvers and three-point turns
Symptoms owners cite: 1–3 second lag between shift command and engagement; Vehicle continues rolling forward while waiting for reverse to engage; Near-collision incidents during three-point turns; Near-miss scenarios when trying to reverse to avoid traffic hazard
Repairs/costs cited: Dealership test drive determined shifting was smooth; owner concern about lag (not smoothness) was not addressed. Owner suspects software reprogramming needed.
Recalls/TSBs owners mention: No action taken; dealership cleared vehicle without addressing lag concern.
Vehicle Rollaway from Park
Vehicle unexpectedly rolls away while parked or while in park with engine running, despite brake pedal and/or parking brake engagement.
When: Occurs at low mileage (10,000 miles reported); one incident at 30,500 miles after recovery from limp mode
Symptoms owners cite: Vehicle lurches forward when in park with engine running; Vehicle unable to remain stationary in park; Vehicle rolls away even with brake pedal depressed; Automatic transmission shifts into park on its own (sometimes without owner input)
Codes mentioned: Automatic Emergency Braking Unavailable message, Transmission unable to shift out of park, Traction control warning light, Hill start assist warning light, Start-to-stop warning light
Repairs/costs cited: One incident caused garage wall damage; vehicle not diagnosed or repaired by dealer.
Recalls/TSBs owners mention: Linked to rear axle bolt fracture recall (22V255) and PCM programming logic. One case reported dealership unable to duplicate failure.
Brake System Failure Post-Recall Service
After PCM recall repair, brake pedal becomes hard and unresponsive; vehicle fails to stop adequately. Warning lights indicate parking brake fault, ABS failure, and uphill assist failure.
When: Immediately after recall service completion
Symptoms owners cite: Brake pedal depressed to floorboard without stopping vehicle; Hardened brake pedal at various speeds; Vehicle unable to stop as needed; Brake pedal goes soft then hard unpredictably
Codes mentioned: Parking brake fault light, Uphill assist warning light, ABS warning light
Repairs/costs cited: Dealership confirmed 5 other vehicles experienced same failure post-recall service; vehicle not repaired.
Recalls/TSBs owners mention: No response documented; owner unable to reach manufacturer.
Multiple Electrical and Electronic Malfunctions
Scattered electrical system faults including camera/display failures, electronics shutdowns, autonomous activation of lights and wipers, and loss of power steering and brake assist.
When: Occurs at low to mid mileage; one case at 36,000 miles
Symptoms owners cite: Front camera image black, gray, or blank; Navigation system inoperable; Wipers activate spontaneously without rain; Lights turn on autonomously when vehicle parked and off; Radio turns on autonomously; Persistent blue screen during backup camera use; Power steering unavailable; Brake assist unavailable; Blind spot monitoring unavailable; Traction control unavailable; Vehicle electronic shutdown while driving (twice in three weeks); All-wheel drive malfunction warnings; Electrical components intermittently unavailable
Codes mentioned: Pre-collision assist not available, Powertrain malfunction / reduced power light, AWD mode warning
Repairs/costs cited: Dealership tightened battery cables and cleared vehicle as safe; battery jump-start temporarily restored function but problem recurred. One case reported smell of fire from inside vehicle cabin during power malfunction.
Recalls/TSBs owners mention: No meaningful response documented; dealership cleared vehicle without addressing root cause.
Rear Differential Component Failures
Secondary rear axle/differential component failures including wheel hub assembly failure and drive axle spline failure, sometimes occurring on vehicles previously serviced under recall.
When: At 113,000 miles on vehicle previously serviced under rear axle bolt recall
Symptoms owners cite: Abnormal clunking from rear differential while reversing; Vehicle vibration during reverse maneuver
Repairs/costs cited: Drive axle, wheel hub assembly, and hub splines required replacement; vehicle had received previous rear axle bolt recall repair.
Recalls/TSBs owners mention: Dealership noted vehicle was previously included in NHTSA 22V255 and repaired; vehicle not yet repaired for new failure.
Rear Subframe Bushing Failure
Rear subframe bushing fails, requiring replacement. Occurs on vehicles with single-bolt rear differential design; may be related to inadequate subframe for performance engine.
When: One owner reported bushing replaced under warranty, then failed again; another reported failure in fall, replacement occurred, then failure repeated
Symptoms owners cite: Bushing failure detected during routine maintenance or after component inspection
Repairs/costs cited: Replaced under warranty on first occurrence; second failure on same vehicle suggests underlying design issue not addressed by PCM-only recall.
Recalls/TSBs owners mention: Warranty coverage applied for replacement; owner notes incorrect subframe (single-bolt design) continues to be installed on 2021–2022 models despite known issue, and only some 2023 models receiving corrected two-bolt design.
Synthesized from 104 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
When given gas to move from a complete stop, vehicle lost all power. After vehicle lost all power to rear wheels, warning lights flashed on cluster. Manually moved vehicle to side of road and checked under SUV to see rear axle was at a unusual angle and later discovered rear axle bolt on road. Vehicle was towed to dealership, which originally completed recall repair in July of this year, for this…
The contact owns a 2021 Ford Explorer. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 23V675000 (Power Train); however, the repair failed to prevent a failure shortly after the vehicle was serviced. The contact stated that after shifting from reverse(R) to drive(D), there was an abnormal grinding sound coming from the vehicle before the vehicle lost automotive…
The contact owns a 2021 Ford Explorer. The contact stated that while reversing, the vehicle suddenly shifted into park, after which the vehicle went into LIMP mode. After restarting the vehicle, the vehicle was unable to shift out of park and displayed the "Automatic Emergency Braking Unavailable" message. The traction control, start-to-stop, and hill start assist warning lights were illuminated.…
The contact leased a 2021 Ford Explorer. The contact stated while driving approximately 25 MPH, the vehicle accelerated independently. The contact stated that five minutes later the vehicle went into safety mode and the vehicle failed to move. The low battery message was displayed. The vehicle was towed to the residence. The contact called the local dealer but, the vehicle was not diagnosed or…
While driving on the freeway, the customer experienced a power train failure, which resulted in the vehicle stopping. Though the vehicle was able to continue driving, it would unpredictably jump gears and eventually became immobile. The "service engine" wrench light first appeared on [XXX], signaling the issue. The vehicle was inspected by Curt Service in Oak Park, Michigan, and no additional…
Had powertrain 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 powertrain problem on the 2021 Ford Explorer?
It's a documented issue but not catastrophic. 104 complaints have been filed. Repairs average $2,500 and most owners catch it before it causes a breakdown.
At what mileage does the powertrain typically fail?
Across the 23 complaints that reported odometer mileage, most powertrain failures cluster between 11,100 and 75,000 miles, with the median around 39,000. A quarter of owners report trouble before 11,100; a quarter make it past 75,000. 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 $2,500 for powertrain 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 powertrain?
No active recalls currently cover powertrain 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.