Ford is recalling 288,314 Explorer SUVs because the roof rail covers can come loose and fly off while driving, posing a danger to other road users.
One accident has already been reported.
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The recall affects certain 2016-2019 Explorers equipped with roof rail covers that may loosen over time.
Owners may notice a visible gap between components or hear a rattle while driving.
Previous Fixes Fell Short
Ford initially launched a customer satisfaction campaign in 2020 to address the issue, using a two-part epoxy to secure the covers.
In 2021, the company issued a recall for vehicles with painted covers, replacing damaged parts and securing them with plastic push-pins.
However, vehicles with satin/chrome-plated covers were excluded at that time due to a lower rate of complaints.
In March 2026, the NHTSA's Office of Defects Investigation contacted Ford about 46 reports of loose or detached roof rail covers, including vehicles previously repaired.
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Ford determined that vehicles with unrepaired satin/chrome covers and those repaired with epoxy continued to experience problems.
Vehicles fixed with push-pin fasteners performed as intended.
The root cause remains unclear, but heat cycles and wear may loosen retention clips.
The epoxy repair process is also technician-sensitive, and improper application or curing may have contributed to failures.
A remedy is not yet available.
Owners will receive an initial notification in August, with a second notice when repairs are ready, likely in September.
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Dealers will inspect and repair or replace the necessary components.
