Ford Motor Company has announced a safety recall affecting 4,247 Ford Explorer vehicles from model years 2020 to 2022. The recall, identified as NHTSA Recall No. 25V-166 and Ford Recall No. 25S22, is due to a software error that resulted in the incorrect installation of a safety update intended to address issues covered by prior recalls.
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The defect involves the Powertrain Control Module (PCM) software, which was not correctly installed despite being recorded as successfully updated. As a result, the original defects addressed by recalls 23S16/23V675 and 22S27/22V255 remain unresolved. These defects can lead to fatigue failure of the rear axle mounting bolt, potentially causing the rear axle housing to move out of position. This issue can result in grinding, clunking, or binding noises and may eventually lead to a loss of forward power or the vehicle rolling while in park if the parking brake is not applied.
The affected vehicles were produced between February 7, 2019, and April 1, 2022. Ford reported that the incorrect software installation was due to a failure of the service tool to upload the correct version during the recall repair process.
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To address the issue, Ford will notify owners by mail beginning April 24, 2025, and continuing through May 1, 2025. Owners will be instructed to bring their vehicles to a Ford or Lincoln dealership where the PCM software will be updated, and the software part numbers validated to ensure the correct installation. This service will be provided free of charge. Customers who previously paid for related repairs may be eligible for reimbursement under Ford’s established recall reimbursement plan.
Dealer notifications are scheduled for April 24, 2025. Vehicle owners can also check the recall status by contacting Ford’s toll-free line at 1-866-436-7332 or by visiting a local Ford or Lincoln dealership, where they can verify their vehicle’s status using the Ford Online Automotive Service Information System (OASIS).
Article by multiple RFHC contributors, based upon information from Ford Motor Company and NHTSA.
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