Ford Police Interceptor Explorers Are Rejecting Their Connecting Rods

Ford has issued a recall affecting 85,238 Ford Explorer vehicles equipped with the Police Interceptor Utility package and 3.3L Hybrid and Gas engines.

The recall follows an investigation into reports of under-hood fires caused by engine failures. In a situation anyone could have imagined, Ford says when one of its engines experiences an "engine block breach" significant quantities of engine oil and/or fuel vapor are released into the engine compartment potentially leading to fires.

For those of you not versed in double speak, an engine block breach is the technical term for shooting a connecting rod through the fender.

Ford says the root issue has been difficult to find. However, the company says it's fairly certain the connecting rods are punching through engine blocks because of connecting rod fractures, which could be linked to bearing seizures. The exact cause of these bearing failures is still undetermined, with potential factors including debris in the bearings, bearing material failures, crankshaft geometry concerns, and issues with lubricant quality. Again, the double-speak: Ford has no idea why this is happening.

Affected vehicles will experience loud noises, such as metal clanking, reduced engine torque, or smoke from the engine compartment—indications that engine failure may be imminent. Ford advises operators to park and turn off their vehicles immediately if they experience any of these warning signs.

The issue appears to be more prevalent in police vehicles, which undergo more frequent high-load driving conditions that could impact engine durability. Ford has noted that there are currently no reports of similar fires occurring in non-police Explorer models.

The recall process began after Ford's Critical Concern Review Group (CCRG) initiated an investigation in July 2023 following three reports of under-hood fires. By July 2024, 13 reports of such fires had been confirmed. Ford has been working to analyze parts returned from the field, including conducting teardown analyses at the Lima Engine Plant, but has not yet identified a singular cause for the failures.

The recall was approved by Ford’s Field Review Committee on August 2, 2024. While no accidents or injuries related to this condition have been reported, Ford is urging affected vehicle owners to seek further information by contacting their local Ford or Lincoln dealer, or by calling Ford’s toll-free line.

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