2016-2019 Ford Explorer Safety Recall 21S22 Roof Rail Covers

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May 5, 2021 NHTSA CAMPAIGN NUMBER: 21V316000

Roof Rail Covers May Detach

A detached roof rail cover can create a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V316

Manufacturer Ford Motor Company

Components STRUCTURE

Potential Number of Units Affected 616,967

 

Summary

Ford Motor Company (Ford) is recalling certain 2016-2019 Explorer vehicles. The retention pins could loosen and allow the roof rail covers to detach from the vehicle.

 

Remedy

Dealers will install push-pins and replace any damaged rail clips and roof rail covers, as necessary, free of charge. The interim owner notification letter was mailed on June 22, 2021. Owner notification letters (remedy available) were mailed on October 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S22.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Explorer 2016-2019 Chicago September 19, 2014 through March 3, 2019

 

Certain 2016 – 2019 model year Explorer vehicles equipped with painted roof rail covers were removed from the 20N11 customer satisfaction program when 21S22 was published.

  • Vehicles equipped with satin or chrome plated roof rail covers will remain in 20N11.
  • Vehicles previously repaired under 20N11 will not be moved to 21S22.

 

REASON FOR THIS SAFETY RECALL

On some of the affected vehicles, the roof rail covers may become detached from the vehicle. A detached roof rail cover can create a road hazard for other road users, increasing the risk of crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect and secure both sides of the roof rail covers as described in the technical instructions. This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE: Both roof rail covers should be serviced at time of repair.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of August 30, 2021. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with roof rail cover detachment.

 

RENTAL VEHICLES

Rental vehicles are not approved for this program.

Part shortages do not qualify for rental vehicles.

 

PARTS REQUIREMENTS / ORDERING INFORMATION
 

Video Instruction:

Review the following video clips before ordering parts or attempting to repair a vehicle:

Roof Rack Cover Inspection with 2mm Feeler Gauge

YouTube video

 

Roof Rack Cover Removal

YouTube video

 

Roof Rack Cover Inspection – Checking Interior of Cover for Damage

YouTube video

 

Retaining Clips Inspection

YouTube video

 

Roof Rack Base Inspection

YouTube video

 

TSB Previously Performed, Removing Retaining Clips With Epoxy

YouTube video

 

Incorrect Drilling Method

YouTube video

 

Correct Procedure to Measure Drill and Install Push Pins

YouTube video

 

NOTE: Both roof rail covers should be inspected/serviced at time of repair.

Part Number  Description   Order Quantity
-78551A46- RH Roof Rail Cover

(part number varies by vehicle – use Ford ECat to identify the specific part number by VIN)

As Needed
-78551A47- LH Roof Rail Cover

(part number varies by vehicle – use Ford ECat to identify the specific part number by VIN)

As Needed

 

Part Number  Description Order Quantity Claim Quantity
FB5Z-7851050-A Retaining Clips (inserted in Base Rail)

(1 per package, 7 each side, 14 possible)

Note:  Replacing all 14 clips is not required unless they are broken and is considered over repairing a vehicle.

 

As Required

0 to 14

 


CERTAIN 2016-2019 MODEL YEAR EXPLORER VEHICLES — ROOF RACK REPAIR

Table Of Contents

Inspection 4
Pass / Fail 6
Cleaning 11
Drilling and securing 12
Appendix A – Picture Requirement 17

 

OVERVIEW

Most customers can be serviced in one dealer visit by completing the following:

  • Inspection procedure, all parts are reusable.
  • Clean Off Adhesive from prior repair.
  • Drilling and Push Pin installation.
  • No SSSC contact necessary.
  • No photos required.

 

Review the videos below before starting this repair procedure:

Inspection with Feeler Gauges

YouTube video

 

Roof Rack Cover Removal

YouTube video

 

Roof Rack Cover Inspection

YouTube video

 

Retaining Clips Inspection

YouTube video

 

Roof Rack Base Inspection

YouTube video

 

Removing Retaining Clips with Epoxy

YouTube video

 

Wrong Drilling Method

YouTube video

 

Correct Procedure to Measure, Drill and Install Push Pins

YouTube video

 

 

Materials List

2mm Feeler Gauge Sharp 15/64 Drill Bit Painters Tape
Paint Stick or Marker Tape Measure Cardboard

 

SERVICE PROCEDURE

NOTE: Perform this repair on both sides of the vehicle.

 

NOTE: Most customers should be serviced in one visit with the push pin retainers and do not require parts or photos.

 

Identify all the parts that require replacement, and take digital images.

 

Part orders can be expedited by successfully completing the following:

 

a. Complete each step of this inspection procedure.

b. Identify and clearly highlight location of damage.

c.  Obtain digital images, label RH or LH side.

 

A loose or lifted roof rail cover in the front or rear does not indicate the need for parts to be replaced, the root cause needs to be identified in the inspection procedure. See Figures 1, 2 and 3.

 

NOTE: The roof rail base front end caps do not need to be replaced if the roof rail passes inspection. Only replace the roof rail base front end caps if damage has occurred during transfer of parts.

 

NOTE: The roof rail base rear gutter molding does not need to be replaced if the roof rail passes inspection. Only replace the roof rail base rear gutter molding if damage has occurred during transfer of parts.

 

Inspection Procedure

 

NOTE: This inspection is to be performed on both sides.

 

1. Using a 2 mm feeler gauge, check the spacing on the front and rear of both the RH and LH roof rail covers. See Figure 4. If the feeler gauge fits between the roof rail cover and the roof rail base then it fails inspection. Does the roof rail covers pass or fail?

 

NOTE: A failing roof rail cover does not require replacement at this time, further investigation is required.

 

If FAIL – For RH roof rail cover, take a picture of the feeler gauge in position of the failing roof rail cover, then Proceed to Step 2.

– For LH roof rail cover, take a picture of the feeler gauge in position of the failing roof rail cover, Proceed to Step 2.

 

If PASS – For RH roof rail cover, Proceed to Drilling and Securing procedure on Page 12.

– For LH roof rail cover, Proceed to Drilling and Securing procedure on Page 12.

 

2. Inspect the affected roof rail cover(s), roof rail base, retaining clips (seven each side), and roof rail retaining towers (seven each side).

a. Remove the affected roof rail cover(s). See Figure 5.

 

NOTE: Roof rail base removed from vehicle for clarity.

 

NOTE: A broken roof rail base hook does not need to be replaced.

 

b. Inspect the affected roof rail base. See Figure 6.

i. If broken, take photos of roof rail base for both the RH and LH.

1. Photos must be clearly labeled RH or LH.

2. Damaged roof rail bases must be clearly identified with a bright highlighter or similar.

 

c. Inspect the retaining clips (7 per side) on the affected side without removing them from the roof rail base. See Figures 7, 8 and 9.

i. Clips that are reusable:

      • Different colors.
      • Different styles.
      • No major damage identified.

ii. Clips that cannot be reused:

      • Missing.
      • All or partial of the top missing from the clip base.
      • Broken retaining tang.
      • Covered in epoxy from a previous repair.

 

d. Inspect the retaining towers (7 each side) on the interior or underside of the affected roof rail cover(s). See Figure 9.

i. Broken tangs do not require replacement.

ii. If broken, take photos of retaining towers on the roof rail covers.

1. Photos must be clearly labeled RH or LH.

2. Broken retaining towers must be clearly identified with a bright highlighter or similar.

 

e. Inspect for any other damage preventing the roof rail cover from being fully seated on the roof rail base.

i. Take photos of any other damage for both the RH and LH.

1. Photos must be clearly labeled RH or LH.

2. Damage must be clearly identified with a bright highlighter or similar.

ii. Take photo showing vehicle mileage. See Figure 10.

 

3. In steps a through e – if no damage identified then proceed to the cleaning procedure on Page 11.

 

4. In steps a through e – if damage is identified on the roof rail covers, roof rail base, retaining clips (seven each side), and roof rail retaining towers (7 each side) – then proceed to photo requirements on Page 18.

 

Cleaning

1. If Technical Service bulletin (TSB) 19-2364 or 20-2154 was performed, evidence of RTV or expoxy will be seen on the roof rack cover and or roof rail contact patch. Inspect the roof rack cover retaining tower and roof rail contact patch for signs of RTV or epoxy adhesive. See Figure 11. Was evidence of RTV or epoxy found?

 

If YES – Replace all the roof rail clips on the affected side, then proceed to Step 2 on Page 11.

If NO – Proceed to Step 2 on Page 11.

 

2. Reinstall the roof rail cover by reversing the removal procedure. See Figure 5 on Page 5.

 

Drilling and Securing

1. At the rear of the vehicle, apply painters tape to the inboard end of the roof rail cover. See Figure 12.

 

2. From the first screw from the rear, measure 150 mm (6 in) from the screw towards the rear of the vehicle and up 20 mm (.75 in) from the top of the roof rail base. Mark the measurement on the tape. See Figure 13.

 

3. From the first mark, measure 100 mm (4 in) towards the rear of the vehicle and up 18 mm (.70 in) from the top of the roof rail base. Mark the measurement on the tape. See Figure 14.

 

4. Set a depth gauge on the 15/64 drill bit at 25 mm (1 in). Having a second person apply downward pressure, drill out both marks. See Figure 15.

 

5. Remove the painters tape and install the push pin retainers. See Figure 16.

 

6. At the front of the vehicle, apply painters tape to the inboard end of the roof rail cover. See Figure 17.

 

7. From the first screw from the front, measure 348 mm (13.75 in) from the screw towards the front of the vehicle and up 13 mm (.5 in) from the top of the roof rail base. Mark the measurement on the tape. See Figure 18.

 

8. From the first mark, measure 63 mm (2.5 in) towards the front of the vehicle and up 9 mm (.25 in) from the top of the roof rail base. Mark the measurement on the tape. See Figure 19.

 

9. Having a second person apply downward pressure, drill out both marks. See Figure 20.

 

10. Remove the painters tape and install the push pin retainers. See Figure 21.

 

Appendix A – Photo requirements

1. Digital images are now required to be attached to each roof rail cover part order. Before submitting VIN-specific part order to SSSC, review new digital image submission requirements on page 2 of Attachment II in the Dealer Bulletin. See Figures 22 through 25 for examples.

 


21S22 – CERTAIN 2016-19 FORD EXPLORER VEHICLES – ROOF RAIL COVER DETACHMENT

 

Provide the chronology of events leading up to the defect decision.

 

April 2020 – NHTSA inquired into 11 VOQs related to roof rail cover detachment while driving.  Ford reviewed warranty claims related to the affected component.

 

May – August 2020 – The issue was brought to Ford’s Critical Concerns Review Group (CCRG) for review on May 12, 2020.  The CCRG considered the rates of detachment, severity, and detectability of a loose or rattling cover.  The CCRG determined this issue did not present an unreasonable risk to motor vehicle safety due to the low projected probability of detachment, low mass of the component, and high detectability of a loose roof rail cover through visual and audible means.

 

September 2020 – Ford shared the CCRG’s analysis with NHTSA and made the agency aware of its recommendation to address the concern with a customer satisfaction program that would provide customers who experience the condition outside of warranty with a one-time repair.

 

November 2020 – Ford’s Field Review Committee reviewed the concern and approved a onetime repair extended coverage action for 10 years/150,000 miles.

 

December 2020 – March 2021 – Post-launch of the extended coverage program, Ford continued to monitor field data. Ford believed that the extended coverage program, in combination with the high detectability of this concern, would result in the proactive repair of vehicles prior to progression of the issue to a potential detachment.

 

April 2021 – Ford met with NHTSA to review the updated data. NHTSA requested that Ford conduct a safety recall for this concern.

Ford discussed with NHTSA the rationale for excluding vehicles with plated roof rail covers from a safety recall. Warranty analysis shows a significantly lower rate of detachment and loose/rattling claims on vehicles with plated roof rail covers. Projections indicate no trend of increasing rate for plated variants. Pull force data confirms plated variants have increased retention strength and are less susceptible to solar loading, which is a contributing factor to this condition.

 

On April 30, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action.

 

Ford is not aware of any reports of accident or injury related to this condition.

 

May 5, 2021

 


FORD MOTOR COMPANY ISSUES SAFETY RECALL

MAY 10, 2021 | DEARBORN, MICH.

DEARBORN, Mich., May 10, 2021 – Ford Motor Company is issuing a safety recall for select 2016-19 Ford Explorer vehicles for roof rail covers that may become detached from the vehicle while driving and create a hazard for others on the road. Affected Explorer series vehicles include base and XLT trim levels, as well as Police Interceptor and Explorer Sport models with roof rail covers that are painted Silver, Black or Absolute Black.

This action affects 620,483 vehicles in the U.S. and federal territories, 36,419 in Canada and 4,260 in Mexico.

Ford is not aware of any reports of accidents or injuries related to this condition.

Dealers will secure the roof rails with plastic push pins. Customer notifications will begin the week of June 28. The Ford reference number for this recall is 21S22.

 


 


4 Affected Products

Vehicle

MAKE MODEL YEAR
FORD EXPLORER 2016-2019

 


10 Associated Documents

Manufacturer Notices(to Dealers,etc) – Advance notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice Safety Recall 21S22 Certain 2016 – 2019 Model Year Explorer Vehicles equipped with Painted Roof Rails Roof Rail Cover Detachment

RCMN-21V316-7487.pdf 162.598KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V316-5725.pdf 49.356KB

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Miscellaneous Document – Media Release re Ford Motor Company is issuing a safety recall for select 2016-19 Ford Explorer vehicles for roof rail covers that may become detached from the vehicle while driving and create a hazard for others on the road.

RMISC-21V316-3414.pdf 74.246KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 21S22 Certain 2016 – 2019 Model Year Explorer Vehicles equipped with Painted Roof Rail Covers Roof Rail Cover Detachment

RCMN-21V316-3980.pdf 4580.855KB

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Recall Acknowledgement

RCAK-21V316-3461.pdf 644.938KB

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Defect Notice 573 Report

RCLRPT-21V316-2352.PDF 215.116KB

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Miscellaneous Document – Chronology re 21S22 CERTAIN 2016-19 FORD EXPLORER VEHICLES ROOF RAIL COVER DETACHMENT

RMISC-21V316-0418.pdf 97.408KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V316-6124.pdf 53.122KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V316-4477.pdf 52.809KB

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ISSUED Renotification Notice

RCRN-21V316-3373.pdf 556.401KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V316&docType=RCL

 


 

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