$165M Penalty Forces Ford To Admit Explorer Suspension Could Snap Mid-Drive
A $165 million federal penalty is already shadowing Ford. Now, 412,774 Explorer SUVs face a recall over a rear suspension part that regulators say could fracture during driving. On November 14, 2024, NHTSA Deputy Administrator Sophie Shulman warned, “Timely and accurate recalls are critical to keeping everyone safe on our roads.” On February 25, 2026, a separate defect involving rear suspension toe links triggered another nationwide recall. The financial hit and the safety risk are converging, and the timeline reveals how this escalated.
A Penalty And A Fracture
Ford Motor Company is operating under a $165 million civil penalty while recalling 412,774 Explorer SUVs for rear suspension toe links that could fracture during driving. The fine ranks as the second-largest in NHTSA’s 54-year history and stems from delayed recalls tied to rearview cameras. Regulators now warn of steering risks in 2017 to 2019 Explorers. Federal attention remains intense.
What Is Breaking Underneath
Recall 26V101 focuses on rear suspension toe links paired with cross-axis ball joints that may seize, bend, and fracture under load. The NHTSA recall report dated February 25, 2026, states that a fracture can cause sudden loss of steering control. Drivers may notice misaligned rear wheels, clunking noises, or unstable handling. The affected parts were produced between May 2017 and March 2019. “The rear toe links may fracture under certain circumstances,” the report states. Ford estimates about 1% of vehicles, roughly 4,128 SUVs, contain the defect.
Federal Inquiry Sparks Recall
This recall began after federal contact. On January 13, 2026, NHTSA reached out to Ford after receiving 5 Vehicle Owner Questionnaires describing steering control failures in Explorers outside earlier recall ranges. Ford’s Critical Concern Review Group opened a new investigation. “When manufacturers fail to prioritize the safety of the American public and meet their obligations under federal law, NHTSA will hold them accountable,” the agency stated November 14, 2024. Ford later identified 2 guardrail collisions and reported zero injuries. Investigators expanded their review.
A Problem Dating To 2016
The Explorer toe link issue traces back to recall 16V-245 in 2016, followed by expansions in 2019, 2020, and 2021. Recall 21V537 covered 644,055 Explorers from model years 2013 to 2017 after 16 crashes and 4 injury allegations, according to NHTSA records. Regulators cited corrosion in salt-belt states as a contributing factor. In 2025, Ford COO Kumar Galhotra said, “The increase in recalls reflects our intensive strategy to quickly find and fix hardware and software issues.” The repeated actions show a continuing mechanical concern.
The $165 Million Order
Ford signed a consent order on November 13, 2024, imposing a $165 million penalty for mishandling a 2020 camera recall affecting 620,246 vehicles. The agreement requires $65 million paid immediately, $55 million deferred, and $45 million tied to performance requirements. Reuters reported on November 14, 2024, that the fine ranks second only to the $1 billion Takata airbag settlement linked to 271 deaths and more than 800 injuries. “The consent order is not an admission of liability by Ford,” the company stated in securities filings.
A Record 153 Recalls
In 2025, Ford issued 153 safety recalls affecting more than 12.93 million vehicles, the highest total recorded by a single automaker in one year. General Motors previously held the record with 77 recalls in 2014, according to Woodard Injury Law on February 2, 2026. Ford exceeded that number by July 2025. Of the 153 campaigns, 42 involved repeat software repairs, about 27% of the total. “The vast majority of recall repairs were successful, with the correct software version installed,” Ford said last year.
Strict Oversight Requirements
The consent order runs for 3 years and may extend to a 4th year. In a November 14, 2024 briefing, NHTSA confirmed Ford must review every recall from the prior 3 years and submit corrections within 5 business days when required. An independent third-party monitor oversees compliance. Ford must invest at least $20 million in upgraded safety analytics and attend mandatory quarterly meetings with regulators. “We appreciate the opportunity to resolve this matter and remain committed to continuously improving safety,” Ford said.
Replacing 412,774 Toe Links
Ford will replace original rear toe links with redesigned versions built for greater strength and corrosion resistance. Car and Driver reported February 25, 2026, that dealers were notified immediately, with owner letters scheduled between March 9 and March 13. Repairs at Ford and Lincoln dealerships will be free of charge. “Ford is asking owners to bring their Explorers into an authorized dealer to replace the old rear toe links with revised versions,” the publication confirmed. Owners can check eligibility through NHTSA’s VIN lookup system.
Industry Recall Comparisons
Woodard Injury Law reported February 2, 2026, that Ford led all manufacturers in U.S. recalls during 2022, 2023, and 2025. In 2025, Chrysler recorded 53 campaigns, General Motors 27, and Volkswagen 25. Toyota recalled 3.22 million vehicles, ranking second by volume. Ford restructured leadership in late 2024 and deployed its AI-powered Mobile Vision System across assembly plants to detect defects earlier. Barclays analysts observed, “The challenges are for investors.” Competitive comparisons frame the broader industry context.
What Owners Should Do Now
Owners of 412,774 Explorers included in recall 26V101 will receive notification letters between March 9 and March 13. Dealers will replace both rear toe links at no cost. Drivers may confirm status by visiting NHTSA’s website or calling 866-436-7332. Ford COO Kumar Galhotra said the surge reflects “our intensive strategy to quickly find and fix hardware and software issues and go the extra mile to help protect customers.” Completed repairs restore proper suspension performance and steering stability.
Sources:
NHTSA Consent Order Press Release: Ford Consent Order; $165 Million Civil Penalty. NHTSA, November 14, 2024
Ford Recalls 412,774 Older Explorers for Faulty Rear Suspension. Car and Driver, February 25, 2026
Ford recalls over 410K vehicles. See affected models. USA Today, February 24, 2026
Ford Motor hit with $165 million US penalty over delayed rearview camera recall. Reuters, November 14, 2024
Ford Recall Statistics 2025–2026. Woodard Injury Law, February 2, 2026
Ford Recalls A Bunch Of Explorers That Could Develop Uncontrollable Rear-Wheel Steering On Their Own. The Autopian, February 24, 2026
