The Ford Explorer, one of America’s most popular SUVs, has faced scrutiny in recent years due to a growing number of reports involving defective rear axle bolts and axle separation issues in models from 2020 through 2025.
These defects have led to safety recalls, warranty repairs, and in some cases, serious safety risks on the road.
Owners of Ford Explorers are finding that it takes an extended amount of time to complete the repairs. California’s lemon law requires warranty repairs to be completed within thirty (30) days. Ford is also required to make parts available to its dealerships in order to timely complete warranty repairs.
What’s the Issue with the Defective Rear Axle?
Many owners of newer Ford Explorer have reported problems related to the rear axle bolt and rear subframe assembly. In some cases, the bolt can fracture, causing the axle to disconnect and resulting in a loss of power or vehicle control.
This defect affects both rear-wheel drive (RWD) and all-wheel drive (AWD) Explorers and has led to Ford issuing multiple technical service bulletins (TSBs) and recalls over the years.
Warranty repairs identify the following:
Affected Model Years: 2020, 2021, 2022, 2023, 2024 and 2025
Though some units have been addressed through recalls, many owners continue to report axle bolt problems even after repairs.
However, it will be better for you to inform your Ford dealer that your Ford Explorer has a vibration or shuddering while driving, or that there is a clunking or popping noise from the rear axle. This way your Ford dealership will be repairing an actual defect, and not simply performing a recall procedure.
Ford Recalls and TSBs
Ford has issued multiple recalls tied to potential rear axle bolt failure, including:
- NHTSA Recall No. 23V-230 – Rear axle bolt may fracture (2020–2022 models)
- TSBs instructing dealerships to replace the rear axle bolt and/or install a new subframe bracket to prevent separation
Some owners report that repairs don’t always resolve the problem permanently, raising further concerns about design flaws.
Safety and Legal Concerns
A fractured axle bolt is a serious defect. In severe cases, the vehicle can lose power or control, increasing the risk of an accident. For families and commuters relying on the Explorer for daily transportation, this issue is more than an inconvenience — it’s a potential hazard.
Lemon Law Protection in California
If you’re a California resident and your Ford Explorer has been in for repeated axle-related repairs, you may qualify for relief under the California Lemon Law (Song-Beverly Consumer Warranty Act).
You may qualify if:
- Your vehicle is under the manufacturer’s warranty when the issue is first reported
- Ford has made multiple repair attempts for the same axle defect (usually 2 or more for serious safety issues)
- Or, your Explorer has been out of service for 30 or more total days due to warranty repairs
- The axle defect substantially impairs the vehicle’s use, value, or safety
The axle bolt defect in 2020–2025 Ford Explorers is more than a minor flaw — it has real safety implications and continues to affect a growing number of owners. While Ford has taken steps to address the issue through recalls and service updates, many vehicles remain vulnerable. If your Ford vehicle has unrepaired defects, recalls and lengthy delays in the shop, contact the Attorneys at the RV Auto Legal Team for a FREE CONSULTATION and personalized assistance with your lemon law claim.
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