Ford Recalls Over 288,000 Explorers as Roof Rail Covers Risk Flying Off

Ford is pulling more than 288,000 Explorer SUVs from the 2016 to 2019 model years off the road after discovering that roof rail covers can loosen and fly off while driving. The National Highway Traffic Safety Administration says the detached covers become dangerous projectiles, posing a serious crash risk to other drivers.

The problem traces back to a 2020 customer satisfaction program that used epoxy to secure the covers. According to NHTSA, that repair was highly dependent on the technician’s skill, and some damaged clips were never replaced or the adhesive wasn’t applied correctly. Over time, heat and wear caused painted covers to loosen further.

Ford issued a second recall in 2021, switching to plastic push-pin fasteners, but by early 2026, 46 owner complaints showed the epoxy fix still failing.

Owners will need to bring their Explorer to a Ford or Lincoln dealer for a free inspection. If the push-pin fasteners are already in place, no further work is needed. If not, dealers will replace any broken clips or damaged covers and secure everything with the plastic pins. Notification letters will go out in phases starting late August 2026, with a final round in late September.