2020 Ford Explorer forward collision avoidance problems

“Front axle disconnect actuator on my 2020 Ford Explorer 2.3L AWD is failing. The vehicle stores DTC C0631-7E (Actuator Stuck On) and previously stored C0631-7F (Actuator Stuck Off). When the fault is active, the wrench light comes on and the following safety systems are disabled: AdvanceTrac, Pre-Collision Assist, and Hill Start Assist. Ford has issued TSB 25-2373 / 25-2568 for this exact issue requiring replacement of the intermediate shaft with revised part N1MZ-3A329-A and AWD module reprogramming, but there is no recall. Owners must pay for the repair. The problem is intermittent and has been confirmed with a scan tool. This is a known design defect, not normal wear, and it affects safety systems.”

“My 2020 Ford Explorer previously received a safety recall repair under Ford Recall 23S23 for the 360-degree/rearview camera system. Unfortunately, the camera system is malfunctioning again following that repair. The 360-degree display intermittently shows solid blue/teal or black areas instead of properly displaying the vehicle’s surroundings. The camera images also become washed out, distorted, or unusually dark, reducing visibility when reversing. Additionally, my instrument cluster displays the warning “Reverse Brake Assist Not Available – See Manual.” These problems raise serious safety concerns because the vehicle’s camera visibility is compromised while another safety system reports that it is unavailable. This creates potential risks when backing near children, pedestrians, other vehicles, or obstacles. I have photographs documenting the camera malfunctions and dashboard warning. Ford subsequently issued Recall 25S27 after discovering that certain vehicles previously repaired under Recall 23S23 may not have received the correct remedy, even though the repairs were recorded as completed. I have not yet received confirmation whether Recall 25S27 applies to…”

“I own a 2020 Ford Explorer XLT AWD, VIN 1FMSK8DH6LGA35229. While driving, my vehicle displayed “4WD Fault – Service Required” along with the powertrain wrench warning. I then became unable to select/change drive modes. Pre-Collision Assist became unavailable, I experienced Lane Keeping/Lane Assist problems, and additional stability/traction warnings appeared. A professional diagnostic scan found AWD codes C0631:7E-68 and C0631:7F-6C related to the front axle disconnect actuator. The ABS module also stored U0102 (Lost Communication With Transfer Case Control Module) and U0155 (Lost Communication With Instrument Panel Cluster). My mechanic diagnosed failure of the front axle disconnect actuator/intermediate-shaft system. The repair requires removal of the original disconnect system and installation of Ford’s revised intermediate shaft/axle components, replacement of the vent/breather hose, and AWD programming. I was quoted approximately $1,337. The mechanic will then determine whether the transfer case/AWD control module also requires replacement, which would cost approximately $828 additional. Ford has issued TSB 25-2373, superseding TSB 23-2174, for certain…”

“I am writing to formally express serious concerns regarding the safety of a Ford vehicle that continues to carry a 5-star safety rating despite multiple known, safety-critical defects that emerged after relatively low mileage. Two major issues developed between approximately 62,000 and 72,000 miles. Both are documented by Ford Technical Service Bulletins (TSBs), yet neither has been addressed through a formal recall. My vehicle’s warranty expired at 60,000 miles, leaving me responsible for more than $3,000 in out-of-pocket repair costs. Issue 1 – Front axle seal leak (TSB 23-2174) The front axle seal began leaking fluid. According to the TSB, the original affordable seal is no longer available, requiring replacement of the entire axle assemblies at a cost of approximately $2,000. Failure to complete this repair risks axle lock-up and a potential collision. Issue 2 – All-wheel-drive module ground wire omission (TSB 23-2061) Ford failed to install a required ground wire on the AWD module. This caused multiple warning lights to illuminate, including powertrain failure and collision-assist system failure. I refused to allow my wife and children to ride in the…”

“Had recall for parking brake fixed, soon after I’d be on interstate or intersection and it would lose power wrench and check power train system light came on. Took to dealership and they said it was parking pawl sylenuod. Had repaired left the shop didn’t even get home and it did the same: Mechanic said it was gas pedal sensor repaired that and same thing happened it may go real fast or not go . I worked for uber and lyft and have been out of work for a few months. Car setting at dealership and the say I need to pay for a new power train module because my cars lost it brains. So I got recall fixed and my cars went to hell in a hand basket. Now another recall is issued but no resolution. It is a huge safety issue when your gas pedal gets a not responsive to your foot touching the pedal then it accelerating without touching the gas pedal. I’m lucky I didn’t die in it. This year model just needs to be lemoned out. Oh also when it starts messing up airbag not working driver assist not working all the safety features go haywire. I feel sure this is all related to the recall and ford will be hearing from me or a lawyer one.”

“ABS and parking brake. Was confirmed by the dealer & tow truck driver. No warning when I parked it, only after putting it into reverse. There were flashing ABS & Parking Brake lights plus a beeping sound.”