The National Highway Traffic Safety Administration (NHTSA) has opened an investigation into more than 1.2 million Ford Explorer SUVs following reports that defective side airbags could cause serious burns during deployment.
The investigation covers 1,236,155 Ford Explorer vehicles from the 2021 through 2026 model years, including police-operated versions. The agency is examining complaints involving injuries allegedly caused by side airbag deployment during crashes.
According to NHTSA, the investigation follows eight Vehicle Owner Questionnaires and four Early Warning Reporting death and injury reports. These complaints describe incidents involving drivers and front-seat passengers who allegedly suffered serious burns.
Some reported injuries include second- and third-degree burns that required medical attention. The complaints suggest that airbag deployment may release hot chemical substances or unreacted propellant capable of causing significant skin injuries.
NHTSA has identified 11 reported crashes or fires and 10 injury reports connected to the alleged problem. No fatalities have been reported to the safety agency in connection with these incidents.
The Ford Recall 2026 situation remains under investigation, and the agency has not announced an official recall covering these vehicles. The preliminary evaluation will determine the potential defect’s scope, frequency and safety consequences.
One complaint involved a 2022 Ford Explorer owner from Reseda, California. The owner reported that the driver’s-side airbag deployed during an August 25, 2025, crash and allegedly released airbag propellant that caused a severe chemical burn.
Another complaint, submitted by a 2023 Ford Explorer owner in December 2023, described burns suffered by a front-seat passenger after a side-impact collision triggered the airbags. The passenger reportedly experienced first- and second-degree burns.
A separate complaint filed in July 2024 by a Missouri resident described a hot chemical substance allegedly released by the side airbag. The individual reported that the substance melted clothing and caused chemical burns.
The Ford Recall 2026 investigation comes as the automaker continues efforts to address vehicle quality and reliability concerns. Ford has already faced several major safety recalls, including an earlier campaign affecting more than 13 million Explorer and Lincoln Aviator vehicles.
NHTSA will use the preliminary evaluation to establish whether the reported airbag behavior represents a safety-related defect. If investigators confirm a defect, the agency could move forward with a formal recall.
