Ford has issued its smallest recall of the year, but the problem affects a critical component. According to an August 13 announcement from the National Highway Traffic Safety Administration, exactly six 2026 Ford Explorer SUVs equipped with the base 2.3-liter EcoBoost four-cylinder engine are at risk of total engine failure.
Ford Traces Explorer Engine Problem to Production Process
The issue emerged after Ford’s internal quality team identified 10 2026 Explorers that required warranty engine replacements. The automaker found that all 10 vehicles were equipped with inline-four engines built at the Dearborn Engine Plant during the same 30-minute production window.
Each of those 10 vehicles experienced at least one faulty engine rod bearing. Ford later traced the problem to a polishing shoe used during the manufacturing process.
After the polishing shoe was replaced on the assembly line, some crankshafts were produced with inaccurate measurements for the second crank pin. That condition could lead to excessive rod bearing wear.
By the time the recall was issued, Ford had identified one additional Explorer requiring an engine replacement. The automaker also found six more vehicles built during the affected 30-minute window that need to return for replacement of the engine’s long block.
Ford will cover the cost of parts and installation for affected customers and dealers as part of the recall.
Only 17 Explorers Are Affected
Although the engine problem is potentially serious, the number of affected vehicles is extremely small. More than 126,000 Explorers had been sold by the end of June, while the total affected population identified in connection with the issue stands at 17 vehicles.
The affected owners may have experienced signs including engine knocking and power loss despite their SUVs being nearly brand-new.
Ford’s Quality Controls Under Scrutiny
Ford’s recent recall activity suggests the automaker continues to face quality challenges, an issue CEO Jim Farley has said could take years to resolve.
At the same time, the Explorer campaign demonstrates how closely modern vehicle production is monitored. Ford was able to identify the specific 30-minute period during which the affected four-cylinder engines were built and determine which production component was responsible for the problem.
However, problems affecting current-year Ford products conflict with the automaker’s contention that its quality issues are primarily associated with older products.
Ford’s 2026 Quality Ranking Improves
Ford’s quality results have shown improvement in at least one measure. According to JD Power’s Initial Quality Survey, Ford moved from 14th place to third place in 2026, indicating that its customers experienced fewer issues during their first 90 days of ownership than in previous years.
Ford has also issued warnings to its suppliers, tightened internal quality controls and strengthened its internal review process. The automaker has identified problems dating from the previous decade that likely should have been recalled already.
Despite those efforts, Ford is on track to record its second-worst year for recalls in history, with 2025 remaining its worst. The latest Explorer campaign adds another quality issue to the automaker’s ongoing recall challenges.
