Operator law enforcement was idling for an extended time in this vehicle. He was found unconscious in the vehicle and diagnosed with acute carbon monoxide poisoning. He was hospitalised for 4 days, and suffers continuing neurological deficits. Post-incident testing by engineer instructed by operator indicated two improper or incomplete welds on exhaust system, allowing exhaust to pool under vehicle and enter passenger compartment through HVAC fresh air intake. Post-incident testing recreated rising CO levels in passenger compartment. Vehicle has also been inspected by manufacturer. There were no warning lamps or messages.

- Austin, TX, USA

When the vehicle is in outside in the direct sunlight, the extreme heat causes the fuel pump driver module to fail. When this module fails, it cause the vehicles fuel pump to stop sending fuel to the motor which causes the vehicle to turn off or run extremely rough, while driving and or stationary. The moduel has been replaced by world ford Pensacola once, and twice by an ASE Certified Master Mechanic, on 3 separate occasions.

- Milton , FL, USA

At 53,000 miles I was driving down the highway and my vehicle sputtered and died leaving me stranded on the side of the road. The vehicle would not start. I took the vehicle to a local repair shop and had to replace the Fuel Pump for the vehicle. That was very low mileage to have an issue with a major part like a fuel pump.

- Winfield, MO, USA

Noticed severe exhaust smell when defrost is on while driving, and more moderately when the recirculated air is on. Looked up the issue online and found that our 2019 Ford Explorer is experiencing the same issues that caused a soft recall from Ford for their 2011-2017 models. Took it to local Ford service center, but they could not replicate the issue. However, the tech at Ford service called their hotline, who stated "rear air vents were loose causing this concern". following this call, Ford service center did the following (all quotes are from service invoice): "removed rear bumper cover and inspect[ed] air extractors. Inspection found both extractors were not connected on the left rear corner of both sides, like they are broken will not properly seat. Inspection also found liftgate drain valve was missing and lr taillamp gromet was not seated to the body. Replaced both extractors and drain valve, reseated lr taillamp body plug, reinstalled rear bumper and test drove." We have not noticed the exhaust smell since the fix one week ago. I am reporting this so that NHTSA and anyone reading this knows that the Ford exhaust issues that caused so many problems are still ongoing through the 2019 model, and also so that consumers who have this model know exactly what to tell their local Ford service centers to do to fix it.

- Pittsboro, NC, USA

Burning smell (presumably exhaust fumes) are leaking into cabin while driving. Happens more often upon hard acceleration and with air conditioning on in air recycle mode.

- Cypress, TX, USA

On March 2nd 2019 Ford Explorer Sport with 1,800 miles was towed to thomassen Ford in charles town wv leaving owner stranded. Complained of strong fuel/gasoline odor inside the vehicle. Fuel/gasoline was leaking badly out of the vehicle onto the exhaust pipe. On March 4th notification was provided from service writer that none of the fuel lines or clamps were attached properly from the factory. Vehicle sat at thomassen Ford until March 27th when repairs were complete. April 9th 2019 some form of fluid leaked out of the parked vehicle for 8 hours after a 7 minute drive. Vehicle was taken to jerry's Ford in leesburg va "unable to duplicate" therefore no action was taken. There are photos of this issue. April 18th 2019 a strange noise coming from the steering column when driving. Vehicle was taken back to jerry's Ford in leesburg va "unable to duplicate" therefore again no action was taken. To this day the vehicle still makes the noise which has gotten progressively worse. There is video of this issue

- Sterling, VA, USA

The contact owns a 2019 Ford Explorer. While driving the vehicle, the contact smelled exhaust fumes and fuel inside the vehicle. The vehicle was taken to advantage Ford (4000 SE federal hwy, stuart, fl 34997, (772) 287-0955) to be diagnosed, but the test was not yet completed. The manufacturer was not contacted. The approximate failure mileage was 4,500.

- Hope Sound, FL, USA