Ford’s Riskiest Explorer Part Isn’t The Engine, It’s A $5 Plastic Clip

It’s not hard to find stories of exploding batteries, machining debris in the main bearings, and defective crankshafts. But, sometimes, it’s not the expensive parts that fail and cost the automaker millions of dollars in recall parts, it’s the little things. Like, for instance, a five dollar clip that just keeps breaking.

Thus far, Ford has issued three recalls for the Ford Explorer for simple plastic retention pins that can detach, allowing various parts to come loose, including A and B pillar trim, and roof rail covers. These pins may be cheap to replace, but their failure has resulted in over two million NHTSA recall notices being issued. Here’s what you need to know.

The Recalls Affect Fifth-Gen Ford Explorers

There are three recalls in play here. There’s an A-pillar recall, a B-pillar recall, and a roof rail cover recall. At a glance, these recalls may seem unrelated, but it’s hard not to notice the recurring theme of loosening and detached “retention pins.”

Let’s go over each recall in brief.

May 5, 2021: Roof Rail Covers May Detach

Credit: Ford

In over half a million late-fifth-gen Explorers, retention pins “could loosen and allow the roof rail covers to detach from the vehicle.” This could lead to pieces falling off the car and creating a road hazard. The fix involved inspection and replacement of the part, with push-pins being installed as necessary.

January 19, 2024: Exterior A-Pillar May Detach

Credit: Ford

The A-pillar recall covers nearly two million Explorers with retention clips which “may not be properly engaged,” meaning that the exterior A-pillar panel could pop loose and go flying down the freeway. Ford’s fix in this instance involved a simple inspection and replacement of the part.

May 23, 2025: Driver And Passenger Door Trim May Detach

Credit: Ford

The B-pillar recall sees around half a million mid-fifth-gen models losing their exterior door trim while driving, just like we saw in the A-pillar recall. The fix is “currently under development,” with an anticipated final remedy expected in November 2026. We’d bet dollars to donuts it’s gonna involve “inspection and replacement of the part,” though (they oughta put us in charge).

It should be noted that multiple component manufacturers have been named in associated documents, meaning that it’s not a single pin or clip that’s failing. ABC Technologies is named as the supplier in the A and B-pillar pin recalls, while JAC Products is named in the roof rail cover recall. In other words, it’s not just one faulty part, but a broader pattern.

The language of the NHTSA recalls, likewise, suggests that it would be irresponsible to try and pin this on the parts-makers (if you’ll pardon the pun). The retention clips are not referred to as “defective” or “inadequate.” Whether the problem comes down to an issue with the parts, how they were installed, or the simple toll that five or 10 years of use has on a tiny pin, we can’t say.

Read the full article on GameRant

This article originally appeared on GameRant and is republished here with permission.