Head-to-head reliability
FORD Explorer vs FORD Fusion
How the FORD Explorer and FORD Fusion compare on NHTSA complaints, recalls and crash reports — and which is the lower-risk used buy.
Based on NHTSA owner-complaint & recall records
FORD Explorer vs FORD Fusion: The Explorer averages 475.8 complaints per year, while the Fusion averages 1,356.1. Explorer has more structure issues, Fusion more steering and engine problems. Fusion has 7 deaths reported, Explorer none. Source: NHTSA owner complaints.
The picture
Is the FORD Explorer or FORD Fusion more reliable?
A plain-English read on what the NHTSA record says about living with each vehicle.
FORD Explorer
The Ford Explorer, over the past decade, has accumulated a high volume of complaints, averaging nearly 476 per year, with structure and powertrain issues dominating. Owners report cracked stabilizer arms, trim pieces blowing off, and serious transmission and engine problems, including complete replacements. This suggests that while the Explorer offers utility, it may come with significant reliability headaches, especially as it ages.
FORD Fusion
The Ford Fusion shows an even higher complaint rate, averaging over 1,356 per year, with steering and engine issues being the most frequent. Reports of lower control arms snapping and engine failures leading to fires highlight potential safety concerns. The Fusion's reliability record is concerning, with a higher incidence of serious failures that could affect safety and ownership costs.
The numbers
Side-by-side NHTSA record
Lower is better in every category. The highlighted cell is the stronger result.
| Category | FORD Explorer | FORD Fusion |
|---|---|---|
| Total complaintsAll model years combined | 4,758 Better | 13,561 |
| Safety recallsFederal recall campaigns | 165 | 91 Better |
| Crash reportsCrash-related complaints | 129 Better | 468 |
| Complaints per yearAveraged across model years | 475.8 Better | 1356.1 |
| Reported injuriesTied to owner complaints | 160 Better | 306 |
| Reported deathsTied to owner complaints | 0 Better | 7 |
Source: NHTSA owner complaints & recall records.
What actually goes wrong
The problems owners report
The most-complained-about systems on each vehicle — what fails, and what owners say in their own words.
FORD Explorer
- 01STRUCTURE1,169
- 02UNKNOWN OR OTHER956
- 03POWER TRAIN868
- 04ENGINE552
- 05ELECTRICAL SYSTEM465
Owners report cracked stabilizer arms and trim pieces (A-pillar moldings) blowing off, which can crack the windshield and create hazards. This indicates potential weakness in body and chassis components.
Transmission and engine defects are common, with some owners requiring complete engine and transmission replacements. Symptoms include hesitation, misfiring, and the vehicle stopping unexpectedly, which can be dangerous in traffic.
Some owners report the vehicle rolling while parked on slopes despite being in Park with the parking brake engaged, suggesting potential issues with the parking brake or transmission park mechanism.
“Around 20,000 miles, I took my vehicle to the dealer due to rattling and knocking in the front right wheel well and it was discovered the stabilizer arm was cracked. Received the vehicle back, and approximately 1000 miles later, there is rattling at the front…”
“The A piller molding on BOTH sides of the windshield has been blown off. When blown off it cracked the windshield. This resulting in a hazard to drivers around but also the fuel economy of the car.”
FORD Fusion
- 01STEERING4,144
- 02ENGINE2,535
- 03POWER TRAIN2,016
- 04ELECTRICAL SYSTEM1,285
- 05UNKNOWN OR OTHER1,144
The most common issue is failure of the lower control arm, which can snap while turning, leading to loss of control. Also, the horn may stop working, which is a safety concern.
Engine failures are reported, including sudden shutdowns and fires, particularly in the PHEV model. Owners also describe loud knocking and vibration after routine maintenance, indicating potential internal damage.
Transmission cooling line failures cause fluid leaks, leading to transmission damage without warning lights. This can result in costly repairs and unexpected breakdowns.
“I’ve learned a while ago that the vehicle doesn’t have a working horn, I’ve replaced the fuse at least five times and it’s still not working. Yes the car was sold to me this way. Also I’ve been getting this warning to my ford app: “The Blind Spot Information…”
“The front left lower control arm (driver's side) snapped off (broke) while turning a corner. There was no reason for the breakage other than turning. It was repaired through insurance. The driver's safety as well as the safety of pedestrians were put at risk…”
Official recalls
Safety recalls on record
Federal recall campaigns — the defect, the risk, and the fix. Confirm any open recall was completed before you buy.
FORD Explorer — 165 recalls
The defect: Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
The risk: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The fix: Dealers will update the image processing module (IPMB) software, free of charge. Interim owner notification letters informing owners of the safety risk were mailed April 25, 2023. Owner notification letters were mailed February 13, 2023. O…
The defect: Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement…
The risk: Without a label that shows the proper restraint usage guidelines, the occupants may have an increased risk of injury in the event of a crash.
The fix: Ford will mail owners the warning labels, free of charge. Owner notification letters were mailed December 19, 2024. Owners may call Ford customer service at 1-866-436-7332. Ford's number for this recall is 24C39.
The defect: Ford Motor Company (Ford) is recalling certain 2023 Explorer vehicles. The right-front lower fastener connecting the steering knuckle and strut may be loose or missing.
The risk: A loose or missing connection between the knuckle and strut can cause improper tire alignment, resulting in a steering pull or require increased steering effort. Additionally, the brake hose may contact the tire and become damaged, resulti…
The fix: Dealers will inspect the fasteners, and tighten or install them as necessary, free of charge. Owner notification letters were mailed March 08, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall…
The defect: Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
The risk: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The fix: Dealers will replace the 360-degree camera, free of charge. Owner notification letters were mailed November 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S23. This recall expands a…
FORD Fusion — 91 recalls
The defect: Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
The risk: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash or injury.
The fix: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Fo…
The defect: Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2…
The risk: A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations ca…
The fix: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
The defect: Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it…
The risk: An electrical short circuit can increase the risk of a fire.
The fix: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded bl…
The defect: Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
The risk: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash or injury.
The fix: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Fo…
Buyer analysis
FORD Explorer or FORD Fusion: which should you buy?
The Ford Explorer has fewer complaints per year (475.8) compared to the Ford Fusion (1,356.1), indicating a lower frequency of reported issues. However, both have serious reliability concerns, with the Fusion showing a higher rate of safety-related failures like steering and engine fires.
Key differences
- Explorer has more structure-related complaints (1169) vs Fusion's steering (4144), indicating different problem areas.
- Fusion has a much higher total complaint count (13,561) and more crash-related complaints (468) than Explorer (129).
- Explorer has more recalls (165) than Fusion (91), but Fusion has more deaths (7) vs Explorer (0).
- Explorer owners report issues with trim and stabilizer arms, while Fusion owners report control arm failures and engine fires.
- Inspect the front suspension for cracked stabilizer arms and check for loose or missing A-pillar moldings.
- Test the transmission for smooth shifting and check for any warning lights, as owners report complete failures.
- Check the steering and suspension components, especially the lower control arms, for any signs of wear or damage.
- Look for any fluid leaks under the car, particularly transmission fluid, and verify the engine runs smoothly without unusual noises.
Before you buy
- Have a mechanic inspect the suspension and steering components on both vehicles.
- Check for any open recalls and ensure they have been addressed.
- Test drive at various speeds and on slopes to check for transmission and parking brake issues.
- Review maintenance history for any major repairs like engine or transmission replacements.
- For the Fusion, specifically check the high-voltage battery system if it's a PHEV.
Year by year
Which model years to avoid
Complaints per model year for both vehicles — lower is better. The spikes are the years to scrutinize.
| Year | FORD Explorer | FORD Fusion |
|---|---|---|
| 2020 | 1184 | 177 |
| 2019 | 287 | 370 |
| 2018 | 715 | 432 |
| 2017 | 1678 | 1100 |
Check the actual car
Comparing models is smart. Checking the VIN is essential.
Brand averages tell you the trend. A VIN check tells you what's wrong with the specific FORD Explorer or FORD Fusion in front of you — accident history, open recalls and title records.
Go deeper
Full reliability reports
- Comparison
- FORD Explorer vs FORD Fusion
- FORD Explorer total complaints
- 4,758
- FORD Fusion total complaints
- 13,561
- FORD Explorer total recalls
- 165
- FORD Fusion total recalls
- 91
- FORD Explorer avg complaints/year
- 475.8
- FORD Fusion avg complaints/year
- 1356.1
- More reliable overall
- FORD Explorer
- FORD Explorer top complaint area
- STRUCTURE
- FORD Fusion top complaint area
- STEERING