Ford just announced its 58th recall this year. It is massive. Specifically, 288,316 2016-to-2019 Ford Explorer SUVs are on the chopping block. Why? Their roof rails might literally come off while you are driving.
This is the second time around. Ford already issued a fix. It failed. Now, the National Highway Traffic Safety Administration (NHTSA) wants Ford to do it again. But correctly this time.
Why Do 2016-2319 Explorer Roof Rails Detach?
You might have fixed these yourself, or at a dealership. Or maybe you haven’t. If your roof is noisy, rattling, or looks slightly misaligned, listen up. That is a bad sign. A detached cover is an even worse one. Ford admits to one accident already caused by this.
The root cause isn’t just age. It is poor previous repairs. Technicians were instructed to use a specific two-part epoxy to hold the covers down. Many did not apply enough adhesive. Or they used it in the wrong spot. Some skipped curing times entirely. In some cases, they didn’t even replace broken clips before gluing it back.
Ford calls this a “technician-sensitive” repair issue. That is corporate speak for “our mechanics messed up.”
Which Explorers Are Affected By The Loose Roof Rail Recall?
Not every Explorer. This recall targets specific years and cover types.
- 2016 through 2019 model years.
- Vehicles with satin, chrome-plated, or painted roof rail covers.
- Previously, Ford thought plated covers were safer. They had higher retention strength. The data changed.
If you have a vehicle that was previously fixed with just epoxy, it is still at risk. The NHTSA sent questionnaires to owners in early 2022. 46 people complained about rattling or detaching rails. Many had already been “repaired” under Ford’s voluntary campaign or the first safety recall.
Ford investigated. They found the epoxy fails over time. The heat expands the materials. The glue dries out. The clip snaps. Crack. And there goes your roof rack cover, probably flying off on the highway.
How Is Ford Fixing The Explorer Roof Rail Recall Now?
No more glue as a primary solution.
Ford is now instructing dealers to use push-pin fasteners. Specifically, four of them per rail.
The new fix procedure is straightforward. Inspect the cover. If the clips are broken, replace them. If the cover itself is damaged, swap it out. Then, secure the whole assembly with plastic push-pins.
These pins stay put. Epoxy does not. Vehicles already repaired with the pins are fine. If your dealer just used glue during the previous recall, you are not done. You need the pins.
The Timeline Of Failure
This has been building since 2020.
- 2020: Ford notices an uptick in loose rails. They offer a one-time extended warranty repair. The fix? Epoxy.
- April 2021: The first official safety recall for painted covers only. Ford excluded chrome/satin ones. They believed the plated ones were stronger. Data said otherwise later.
- Early 2022: NHTSA pushes Ford. Owner complaints mount. Ford digs into the data.
- Now: A new safety recall includes all cover types. The old epoxy fix is officially a bust for many.
Ford knew this was an issue years ago. They tried to band-aid it with warranty repairs. That band-aid slipped off. Now, regulators are forcing a real fix.
Do You Need To Visit Your Dealer?
Check your year. If you drove a 2016 to 2019 Explorer, look at your roof.
- Do you hear wind noise when cruising?
- Do the covers look crooked?
- Have they fallen off?
If yes, you are in trouble. Even if you had “service” in the past, that service might not have lasted. The new fix adds physical retention that glue never could.
Dealers are told to inspect everything. If the pins aren’t there, they must add them. It is a tedious process but necessary. Leaving a roof rack unsecured turns a family hauler into a projectile hazard.
Ford’s recent recalls feel different. They target older models. Cars from six or seven years ago. It suggests they are catching up on quality control issues that were ignored back in the day. Or maybe they are just afraid of more lawsuits. Either way, get it fixed. Don’t wait until a cover shatters your windshield on the I-95.
It is annoying to go back to the dealer. The last one didn’t stick. This one should. Hopefully.
