Ford recalls 410,000 Explorer SUVs over risky suspension defect

Ford has announced a major recall affecting over 410,000 Explorer SUVs from the 2017–2019 model years. The issue involves faulty rear suspension toe links, which can fracture and lead to a loss of steering control. Owners will receive notification letters starting on 9 March, with repairs offered at no cost.

The problem was first flagged in 2018 when Ford received reports of rear toe link failures causing loss of directional control. An internal investigation began in 2021, focusing on corrosion and metal fatigue in the components. Two accidents potentially linked to the defect have been recorded, though no injuries were reported.

In October 2024, the US National Highway Traffic Safety Administration (NHTSA) approved Ford's recall plan (24S53). The fix involves replacing the defective parts with reinforced toe links made from high-strength steel, increasing thickness from 5.5 mm to 7.5 mm. Additional welds and improved mounting brackets will also be installed to prevent future failures.

Despite the large number of vehicles involved, Ford estimates that only around 1% of the recalled models actually have the defect. Dealers will carry out the replacements free of charge. Owners with questions can contact Ford Customer Service at 1-866-436-7332.

This recall is part of a broader trend, as Ford issued 103 safety recalls in 2025—more than any previous year.

The recall covers Explorer models built between 2017 and 2019, with repairs set to begin after notification letters are sent. Ford's solution involves upgraded components designed to eliminate the risk of suspension failure. Owners are advised to check their vehicles and schedule repairs promptly once notified.