Ford recalls 492,145 Explorer SUVs from 2016-2017 model years for trim defects.
Manufacturing adhesive failure causes B-pillar door trim to detach while driving.
Additional 63,898 Maverick trucks recalled for loose airbag indicator light issues.
The National Highway Traffic Safety Administration has announced a recall affecting 492,145 Ford Explorer SUVs from the 2016 and 2017 model years due to door trim components that can detach while driving, creating potential road hazards, according to The Associated Press.
The recall addresses a manufacturing defect in the B-pillar door trim, where insufficient adhesive bonding can cause exterior trim pieces to separate from the vehicle at highway speeds. Road & Track reports that Ford identified the root cause as inconsistent use of hand rollers during assembly, which prevented proper adhesive application between the trim and vehicle body.
The affected vehicles were manufactured between June 11, 2015, and April 19, 2017. The safety agency estimates approximately four per cent of the recalled units exhibit the defect, which occurs when a foam component inside the B-pillar exerts outward pressure on inadequately bonded trim pieces.
38 Customer Complaints Trigger Federal Investigation
Ford initially became aware of the trim issue in 2019 and issued a technical service bulletin to dealers, but did not classify it as an unreasonable safety risk at that time. The situation changed in March 2025 when NHTSA received 38 customer complaints about detaching trim components, prompting a federal investigation that led to the mandatory recall designation.
Engineers examined components from salvage yards and reviewed customer photographs to confirm the defect’s scope and identify affected model years. Drivers may notice loose trim when opening or closing front doors, along with increased wind noise or rattling sounds while driving.
The recall is listed under NHTSA number 25V347 and Ford’s internal designation 25S53. No accidents or injuries have been documented in connection with the defect.
Free Repairs Pending Remedy Development
2025 Ford Maverick | Photo: FordFord will begin mailing notification letters to affected vehicle owners starting June 9, 2025. However, a permanent repair solution remains under development, and dealers currently cannot perform the necessary fixes.
Once available, Ford dealers will replace or secure the trim components at no cost to owners. The company has committed to providing free repairs through its authorized dealership network across Canada and the United States.
The Explorer recall coincides with Ford’s announcement of an additional safety recall covering 63,898 model year 2025 Maverick compact pickup trucks, Reuters reports. The Maverick recall addresses potentially loose airbag indicator lights on the dashboard that could prevent occupants from noticing airbag system malfunctions.
Combined, Ford’s latest recall announcements affect more than 555,000 vehicles and add to the manufacturer’s busy 2025 recall schedule, which has already included issues related to control arms, fuel leaks, and electrical systems across multiple model lines.
Canadian Recalls Mirror US Actions
Transport Canada has issued corresponding recalls for Canadian market vehicles affected by the same defects. The Explorer B-pillar trim recall affects 23,060 Canadian units, including both standard Explorer models and Police Interceptor Utility variants, under Transport Canada recall number 2025-282.
The Maverick airbag indicator light issue affects 6,966 Canadian vehicles under recall number 2025-279. Additionally, Transport Canada issued recall number 2025-283 covering 289 Maverick trucks for a separate engine-related safety concern that could potentially cause fires.
Canadian vehicle owners can contact Ford at 1-800-565-3673 or visit www.ford.ca/support/recalls for additional information about scheduling repairs once remedies become available.
