The federal government has opened a preliminary evaluation into an estimated 1,236,155 Ford Explorers from the 2021 through 2026 model years following reports that seat-mounted side airbags can cause burn injuries when they deploy.
NHTSA Investigates Side Airbag Burns in Ford Explorer Models
The National Highway Traffic Safety Administration’s Office of Defects Investigation opened Preliminary Evaluation PE26008 on November 6, 2026. The regulatory inquiry encompasses 1,236,155 Ford Explorer sport utility vehicles spanning the 2021 to 2026 model years, including specialized police variants.
Federal regulators launched the probe after occupants reported second- and third-degree burns stemming from the deployment of seat-mounted side airbags during traffic collisions. Regulators noted that the investigation aims to evaluate the scope, frequency, and potential safety-related consequences of the alleged defect.
Depending on regulatory findings, this initial assessment by the agency may trigger deeper reviews, potentially culminating in a recall. NHTSA noted that a preliminary evaluation is an investigative step and does not establish a defect or mean that a recall will follow. NHTSA stated that there is no set number of complaints needed to open an investigation.
Injuries and Vehicle Owner Questionnaires Behind the Probe
The agency’s docket includes eight Vehicle Owner Questionnaires and four Early Warning Reporting injury notices, combining for 11 total incident reports and 10 reported injuries without any fatalities. Authorities have documented 11 incident reports involving the alleged defect, resulting in 10 reported injuries and no fatalities. Documented cases linked to this probe generally involved medical intervention for injuries classified as second- or third-degree burns.
Affected motorists and passengers have required professional medical intervention for severe skin damage. Burn injuries have been reported for both drivers and front passengers and were typically diagnosed as second or third-degree burns requiring medical treatment,
regulators said. Consumers have described that during a crash involving deployment of the seat-mounted side airbag, they sustained burn injuries,
the NHTSA said.
Among the documented incidents are injuries sustained by law enforcement personnel operating Explorer Police Interceptors. One filing described a February 20, 2025, collision involving a UPS delivery truck that struck the right-front side of a police cruiser, triggering the deployment of the side airbag.
POLICE VEHICLE WAS CLEARING INTERSECTIO WHEN A UPS TRUCK COLLIDED WITH IT’S RIGHT SIDE FORWARD. THE COLLISION CAUSED THE SIDE AIRBAG TO DEPLOY. THE OFFICER’S VEST, SWEATER, UNDERSHIRT, T-SHIRT AND THE OFFICER’S RIGHT SIDE SUFFERED THERMAL BURNS FROM THE EXHAUST PORT. THE OFFICER SUFFERED 3RD DEGREE BURNS AND HAD TO HAVE SURGERY AND SKIN GRAFT.
Vehicle Owner Questionnaire 11647596, via Torquenews
Complainant Allegations Concerning Airbag Exhaust Vents
Several vehicle owners have pointed directly to the design of the airbag’s exhaust mechanism as the source of thermal injuries. Out of the initial public complaints submitted to regulators, multiple files state that hot gases vented directly toward the occupant rather than away from the cabin seat.
Side seat airbag has exhaust port facing inwards, instead of outward, towards the door of the vehicle, that caused the hot chemical from the airbag to push out all the gas at the left side of my body, melting my clothes and causing chemical burns to my side when it deployed upon a wreck.
Vehicle Owner Questionnaire 11602427, via Torquenews
Another motorist filing a separate complaint regarding a 2026 Police Interceptor crash reported similar directional issues with the safety equipment. During a traffic accident the driver side seat airbag deployed. The airbag vent faces towards the driver when it deploys,
the report stated. Three of the eight complaints say it faced toward the occupant, though that remains a complainant allegation rather than an agency finding.
Federal Inquiry Could Lead to Recalls or Engineering Analysis
A preliminary evaluation represents an initial investigative phase by federal authorities and does not automatically result in an official recall or mandate for repairs. Depending on what evidence regulators uncover during their review, the inquiry could escalate into an engineering analysis or a formal recall campaign.
Corporate representatives have acknowledged the federal inquiry and confirmed ongoing cooperation with safety officials. Safety is a top priority at Ford. We are working with NHTSA to support its investigation,
a Ford spokesperson said.
