Ford Motor Co. has issued a new safety recall covering 288,314 model-year 2016-2019 Explorer SUVs after determining that roof rail covers can loosen and detach while vehicles are in motion, creating a potential road hazard for surrounding traffic. The latest action also affects some vehicles that were previously repaired under earlier Ford campaigns, prompting owners to verify whether their SUVs have been recalled again.
The recall, filed with the National Highway Traffic Safety Administration (NHTSA) under campaign number 26V448 and Ford recall number 26S54, follows an investigation into reports that certain previous repairs failed to prevent the trim pieces from separating at highway speeds. According to Ford, one crash has been alleged to have resulted from a roof rail cover detaching from a vehicle that had already undergone an earlier repair.
The recall applies to Ford Explorer SUVs built between Sept. 19, 2014, and March 3, 2019, covering all 2016 through 2019 model years. Because the affected vehicles were not manufactured in sequential VIN order, Ford said owners should verify eligibility by checking their 17-digit Vehicle Identification Number rather than relying solely on the model year or trim level.
According to the NHTSA safety report, the affected roof rail covers were supplied by JAC Products of Saline, Michigan. Ford estimates that approximately 1% of the recalled vehicles currently exhibit the defect.
The issue centers on roof rail covers that can gradually lose retention and separate from the vehicle while driving, increasing the risk of a collision for motorists traveling behind the affected SUV.
This marks the third major effort by Ford to address the problem.
The company's previous actions included:
- November 2020: A customer satisfaction program that used a two-part epoxy adhesive to secure loose roof rail covers.
- May 2021: Safety Recall 21V316 (Ford 21S22) covering more than 620,000 U.S. Explorers, introducing four plastic push-pin fasteners for painted roof rail covers instead of adhesive.
Chrome and satin-plated roof rail covers were excluded from the 2021 recall because available data at the time suggested they posed a lower long-term risk.
Ford's latest investigation began after NHTSA's Office of Defects Investigation presented the automaker in March 2026 with 46 owner questionnaires describing continued loosening or detachment of roof rail covers, including vehicles that had already been repaired through earlier programs.
The company's review, conducted between April and June, concluded that the earlier epoxy repair was not consistently effective. According to Ford's filing with NHTSA, the adhesive-based procedure proved to be "repair technician-sensitive," meaning the outcome could vary depending on whether damaged clips were replaced and whether adhesive was applied correctly and in sufficient quantity.
Ford also determined that plated roof rail covers that had never been repaired could gradually loosen after repeated exposure to heat and sunlight over time. By comparison, vehicles repaired with the plastic push-pin fastening system introduced during the 2021 recall have continued to perform as intended.
Owners do not have to wait for official notification letters before determining whether their vehicles are affected. Ford said customers can immediately check their VIN through the NHTSA recall database or Ford's online recall lookup system. Dealers were notified of the campaign on July 16 and are prepared to begin inspections.
Ford's notification schedule includes:
- Aug. 24-28, 2026: Interim owner notification letters.
- Sept. 21-25, 2026: Remedy notification letters once repairs are fully available.
The automaker said owners should pay attention to several warning signs that may appear before a roof rail cover separates completely.
Potential symptoms include:
- Increased wind noise at highway speeds.
- Squeaking or rattling sounds from the roof area.
- Visible gaps or misalignment between the roof rail cover and the roofline.
Owners experiencing any of these conditions are encouraged to arrange a dealer inspection immediately rather than waiting for mailed notifications.
Under the recall, Ford and Lincoln dealers will inspect the roof rail covers free of charge. If the vehicle already has the plastic push-pin fasteners installed, no additional repairs will be necessary. Otherwise, technicians will replace damaged clips or roof rail covers as needed and install four plastic push-pin fasteners on each side of the vehicle.
The campaign represents Ford's 57th recall of 2026 and underscores the company's continuing efforts to resolve a defect that has remained under regulatory scrutiny for several years.
