Ford Explorer Roof Rails Flying Off Triggers New Recall for Nearly 300,000 SUVs

Ford is calling back roughly 288,000 Explorers from the 2016 to 2019 model years because the trim covering the roof rails can simply fly off while driving. It’s one of the more bizarre safety issues to hit the SUV that essentially invented the segment, and it’s actually a repeat problem: the same thing happened in 2021.

Back then, more than 615,000 Explorers were recalled for the exact same loose trim caps. Now. Ford says the fix it used last time might not have worked for everyone.

The problem centers on two-piece roof rails. The main rail bolts to the roof and holds cargo, but the long plastic trim cap covering it can detach. ” Heat from the sun is making it worse, causing the clips to soften and fail. The 2021 recall only covered painted caps, black or silver, because plated caps on higher trims were thought to have better retention.

But now, even those plated rails are failing.

Worse, some of the original repairs didn’t hold. While many SUVs got four push-pins to secure the caps, others received a two-part epoxy adhesive that can loosen over time. The National Highway Traffic Safety Administration opened an investigation after 46 owner complaints, including from vehicles that had already been fixed.

This time, dealers will inspect every recalled vehicle and install new push-pins, replacing any broken clips or damaged covers. Ford will start mailing recall notices in late August, but the actual repair parts won’t be ready until late September. Owners will get a second letter when the fix is available.

Anyone with questions can contact their dealer or Ford customer care.