Ford Recalls: Ford has launched another major safety recall affecting 288,314 Ford Explorer SUVs after discovering that roof rail covers on certain vehicles could loosen and detach while driving. The latest action includes some SUVs that had already undergone earlier repairs, raising fresh concerns about the effectiveness of previous fixes.
The recall follows a renewed investigation prompted by reports submitted to the National Highway Traffic Safety Administration (NHTSA) and applies to selected 2016-2019 Ford Explorer models.
Ford Recalls More Than 288,000 Explorer SUVs
Ford has issued a new recall covering 288,314 Explorer SUVs because roof rail covers may not remain securely attached.
The recall affects certain 2016-2019 Ford Explorer vehicles fitted with painted, satin-plated and chrome-plated roof rail covers.
According to the NHTSA recall report, the roof rail covers could become loose over time and eventually separate from the vehicle, creating a potential road hazard.
Ford said some of the affected SUVs had already received repairs under previous service campaigns.
Ford Recalls: Why Are Previously Repaired Vehicles Being Recalled Again?
Ford’s latest investigation found that some earlier repair methods did not permanently resolve the issue.
According to the recall report, some repairs depended heavily on proper technician installation.
Investigators found that in certain cases:
- Damaged retention clips may not have been replaced.
- Incorrect amounts of adhesive or epoxy may have been applied.
- Adhesive may not have cured properly before vehicles are returned to service.
As a result, roof rail covers on some previously repaired vehicles continued to lose their holding strength over time.
Ford Recalls: Warning Signs Owners Should Watch For
Ford said drivers may notice several warning signs before a roof rail cover detaches.
Possible symptoms include:
- Increased wind noise while driving
- Squeaking or rattling sounds from the roof area
- A visible gap between the roof rail cover and the roofline
- Misaligned roof rail trim
The automaker said it is aware of one reported accident linked to a detached roof rail cover.
Ford Recalls: What Ford Will Do to Fix the Problem
Ford dealers will inspect affected vehicles free of charge.
If technicians find broken clips or damaged roof rail covers, they will replace the necessary parts.
Dealers will also install plastic push-pin fasteners on vehicles where they are missing, as the company believes this repair method provides a more durable solution than the earlier adhesive-based approach.
Owners of affected vehicles will receive recall notifications with instructions for scheduling repairs.
Ford Recalls: How the Investigation Led to the New Recall
Ford first became aware of roof rail cover complaints in 2020 and initially addressed the problem through an extended warranty program using adhesive-based repairs.
In 2021, the company launched a safety recall after discussions with the National Highway Traffic Safety Administration (NHTSA). That campaign mainly focused on painted roof rail covers because available warranty data suggested satin- and chrome-plated versions were less likely to detach.
However, in March 2026, NHTSA’s Office of Defects Investigation notified Ford about 46 owner complaints involving loose or detached roof rail covers on vehicles that included both previously repaired and unrepaired Explorers.
Ford reopened its investigation and found that vehicles repaired only with adhesive, as well as those never repaired, could still develop the problem. By contrast, Explorers repaired using push-pin fasteners have not shown the same issue.
Ford Recalls: What Owners Should Do Next
Owners of affected 2016-2019 Ford Explorer SUVs should wait for Ford’s official recall notification or contact their local dealership to determine whether their vehicle is included.
Until repairs are completed, drivers should pay attention to any unusual roof noise or visible gaps around the roof rail covers and arrange an inspection if they notice signs of loosening.
