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moderate Owners of the 2022 Ford Explorer have filed 12 NHTSA complaints about the fuel system, typically surfacing around 50,000 miles 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 →
| Model year | fuel system complaints |
|---|---|
| 2018 Explorer | 4 |
| 2021 Explorer | 8 |
| 2022 Explorer (this page) | 12 |
All 2 active fuel system recalls on this vehicle land at critical or severe — none classified moderate.
A detached fuel filler tube can result in a fuel leak, increasing the risk of a fire.
An improperly tightened fuel line connection may result in a fuel leak, increasing the risk of fire.
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.
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 ↗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 2022 Explorer/Aviator vehicles equipped with a 3.0L EcoBoost engine and built on 25-Jan-2022 and through 10-Mar-2022 may exhibit a buzz/vibration/rattle noise at engine idle or low revolutions per minute (RPM) underneath the vehicle near the left rear door. This may be due to the pressurized fuel delivery line contacting the body or the fuel tank creating a buzz/vibration/rattle noise. To correct the condition, follow the Service Procedure to install foam tape.
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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
It's a documented issue but not catastrophic. 12 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
Across the 8 complaints that reported odometer mileage, most fuel system failures cluster between 34,000 and 64,598 miles, with the median around 50,000. A quarter of owners report trouble before 34,000; a quarter make it past 64,598. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
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.
Yes — 2 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.