Recall 25V166 affects 4,247 2020-2022 Ford Explorer vehicles for a rear axle bolt fracture. PCM software repair is free at any franchised Ford dealer.
Ford is recalling 4,247 2020-2022 Explorer SUVs because an earlier recall repair left some rear axle horizontal mounting bolts at risk of fracture, which can let the driveshaft disconnect. A disconnected driveshaft can cause rollaway in park without the parking brake or loss of drive power, and Ford dealers will complete the free repair.
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What's wrong?
The Powertrain Control Module (PCM) software on the 2020-2022 Ford Explorer is vehicle programming that helps manage power delivery through the drivetrain. In this recall, that software is tied to the earlier remedy for the rear axle horizontal mounting bolt and driveshaft condition. The correct package is supposed to add the intended protections from recalls 23S16 and 22S27.
Some Explorers were repaired under 23V-199 or 22V-255, but the service tool did not load the correct PCM software. The dealer instructions directed technicians to upload the latest software from Ford, yet affected vehicles left the repair without the intended remedy software. That leaves the prior rear axle bolt issue unresolved. If the bolt fractures, the driveshaft can disconnect.
There is no warning sign before failure. An owner should not expect a light, noise, or driving feel to confirm whether the correct software is installed.
Who's affected?
Each listed year points to the same driveline component and Powertrain Control Module software part family.
| 2021 Ford Explorer | driveline |
|---|---|
| 2022 Ford Explorer | driveline |
| 2020 Ford Explorer | driveline |
| Units affected | 4,247 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific SUV is included.
What's the safety risk?
A disconnected driveshaft can let the Explorer roll away after it is placed in park if the parking brake is not applied. It can also cut drive power, which increases crash risk. There is no warning sign before failure. Use the parking brake every time and schedule the repair soon. Repair is free at any franchised Ford dealer.
What should I do?
- Check your VIN to confirm your 2020-2022 Ford Explorer is included in this recall.
- Contact a franchised Ford dealer to schedule the free PCM software update that addresses the driveshaft-disconnect and rollaway risk.
- Bring the owner letter if Ford mailed one. If not, reference recall number 25V166 when you call.
- Use the parking brake every time you park until the repair is complete.
- Drive cautiously until the repair; a disconnected driveshaft can cause loss of drive power.
What happens at the repair
At the dealer, a Ford technician updates the powertrain control module software for the rear axle and driveline condition covered by this recall. The software update and labor are free under the recall. Ford's standard reimbursement plan covers eligible out-of-pocket repair costs paid before the owner notice. If you already paid for a related repair, contact Ford customer service or bring your repair invoice and payment documentation to the Ford service desk so they can explain the claim process.
| Reimbursement | Reimbursement available |
|---|
Timeline
| March 14, 2025 | NHTSA published the recall |
|---|---|
| April 24, 2025 | Dealer notification began |
| April 24, 2025 | Dealer notification ended |
| April 24, 2025 | Interim owner notification (was planned for this date) |
| April 25, 2025 | Owner notification mailed |
Frequently asked questions
What is recall 25V166?
Recall 25V166 covers 4,247 2020-2022 Ford Explorer vehicles previously repaired incorrectly under recall numbers 23V-199 or 22V-255. The rear axle horizontal mounting bolt can fracture and let the driveshaft disconnect. Ford dealers will update the powertrain control module software for free.
What should I do if my 2020-2022 Ford Explorer is on this recall?
Check your VIN to confirm your specific Explorer is included in recall 25V166. If it is, contact a franchised Ford dealer to schedule the powertrain control module software update. Reference Ford recall number 25S22 when you call. The repair is free.
Is the recall repair free?
Yes. Ford says dealers will update the powertrain control module software free of charge. Use a franchised Ford dealer for the recall repair, and give the service desk recall number 25V166 or Ford recall number 25S22 when you schedule.
What is the safety risk?
The safety risk is vehicle rollaway or loss of drive power. If the driveshaft disconnects and the Explorer is placed in park without the parking brake applied, the vehicle can roll away. A disconnected driveshaft can also remove drive power, increasing crash risk.
What if I bought my Ford Explorer used?
The free recall repair still applies to a used Explorer. Ownership history does not decide recall eligibility. Check your VIN to confirm whether your specific vehicle is included, then contact a franchised Ford dealer and reference recall 25V166 or Ford recall number 25S22.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V166000 |
|---|---|
| Ford customer service | 1-866-436-7332 |
| NHTSA recall # | 25V166 |
| NHTSA recall # (full) | 25V166000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (PDF)
- Download Recall Report (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Misc. Document (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →