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Ford Authority

All 2025 Ford Explorer Models Have One Rear Axle Bolt

Back in April 2022, The Blue Oval issued a recall for select 2020-2023 Ford Explorer models due to an issue with the rear axle mounting bolt after it discovered that this part could fracture under hard acceleration. The automaker instructed dealers to replace these defective rear axle mounting bolts – and later – subframe bushings with new parts, though some customers found that fix to be inadequate, arguing that two bolts were necessary for strength purposes. Regardless, it seems as if all refreshed 2025 Ford Explorer models that began shipping out in August now come equipped with one bolt, though that piece has received some improvements.

“At launch [2020 model year], we had one bolt on everything except for ST and Platinum, those were two-bolt,” the Ford Explorer engineering team explained to Ford Authority. “Then we made a change to make it all the same, with all models going to one bolt. That’s when a lot of the quality stuff staring coming back and some units started breaking. As a response to that, we upgraded the bolting and fastening mechanism, like bushings, things like that…since that initial to one-bolt. It’s still one bolt, but that bushing and connecting interface has been upgraded. So, it still looks the same, but it’s a different setup. The upgraded one bolt took place for mid-2022 MY.”

This is an interesting revelation after Ford has faced its fair share of issues pertaining to the previous rear axle mounting bolt design, which has since prompted not just one, or two, or three, but four different lawsuits, as well as an investigation by the National Highway Traffic Safety Administration (NHTSA).

Regardless, the NHTSA ultimately chose to close its investigation into this matter back in February after it concluded that that Ford’s actions aimed at correcting the problem are adequate, citing the automaker’s assertion that its repairs have resulted in “lower current and projected failure rates.” However, the agency also retains the right to reopen the investigation if things change at any point in the future.

Brett's lost track of all the Fords he's owned over the years and how much he's spent modifying them, but his current money pits include an S550 Mustang and 13th gen F-150.

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Comments

  1. The term, “single point of failure” comes to mind. How much money could Ford have possibly saved by reducing one bolt? How much money did they lose from the single bolt failure? How much are they paying in legal costs?

    Reply
  2. One bolt vs two bolts to prevent a major component failure. That’s the trouble when accountants are in charge of engineers. The engineers designed axle for the higher output ST engine because of the stress and the bean counters used one.
    What would Porsche do?

    Reply
    1. Use an Audi part?

      Reply
  3. This is why toyota sell more vehicles then ford. Toyota would fix this problem. How about jim, is ford ready to start building vehicles with better quality? 🤔

    Reply
  4. I see no hope for this company until a leadership change takes place.
    AND that includes Bill Ford

    Reply
  5. And reducing Blue Cruise subscription costs after a large bunch of us have already taken delivery of 25 Explorer at the considerably higher fee. And appears FMC is not going to adjust or do anything for us. Pretty bad for us long time Ford fan boys. Agree with above nothing is really going to change until Farly and the Ford family hands off.

    Reply
  6. shame on Farley of all people you should know better .you have allowed the quality and marksmanship to go by the way side you are on your way to distroying Ford Motor Company records show since you have taken command of Ford there has been more recalls than ever in the history of Ford Motor Company step down and do not take Ford with you .

    Reply
  7. Another piece of junk from Ford thanks to Failure Farley, yet Failure Farley gets to keep his job.

    Reply
  8. One more reason why I’ll never buy a brand new vehicle. Bought my 2020 Explorer ST in August. I got lucky and have the two bolt version. One of the rear muffler brackets/hangers broke two weeks ago. Cheap mold injected metal part. We will see how many other parts fail or break. Hate to admit it, but I may be moving to Toyota if they ever make a good looking vehicle.

    Reply
  9. I just finished 9 years working in the Ford world as a parts advisor the only thing I can say is that Ford is certainly going downhill in quality. The recalls are insane, and over stupid stuff.

    Reply
  10. The article about trying to shave another few hundred off the cost of the new EV pickup says it all. There are 2 kinds of customers, loyalists and conquest. Charge another $500 or whatever to MSRP, get your dealers under control, and design and build it right. Both customers will be happier.

    Reply
  11. Wow – so many people who think they are engineers. Going from 2 points of failure to only one will actually cut the probability of failure in half. It’s not as if Ford is using the same bolt, they will use an upgraded bolt with (likely) twice the strength as the two bolt design.

    Reply
    1. …what?

      That’s some incredibly misleading statistics usage. While yes, in theory the probability of a bolt breaking goes down because you only have one bolt, the probability of total failure goes up. A two bolt solution requires failure of both bolts for a total failure, vs a single bolt with the cost reduced design.

      The correct design choice is two bolts, both of which are stronger. Though truth but told, even heavily modded STa weren’t breaking the two bolt setup.

      Reply

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