NHTSA Probing 1.2 Million Ford Explorer Airbags That Could Burn Passengers

Airbags save lives, but as the Takata debacle showed, faults can make them dangerous. Now, the National Highway Traffic Safety Administration's (NHTSA) Office of Defects Investigation is probing more than 1.2 million Ford Explorers for side airbags that can injure its occupants. While this isn't a recall, NHTSA has received a number of complaints about injuries sustained during crashes.

These include eight Vehicle Owner Questionnaires and four Early Warning Reporting "Death and Injury" reports that claim the side airbags on 2021-2026 Ford Explorer models can cause burns when deployed. The reports state that both drivers and front passengers have been diagnosed with second- and third-degree burns that required medical attention. Ford Explorers used by police are also being investigated.

In total, NHTSA's Preliminary Evaluation is looking at 1,236,155 Ford Explorer models. In the 11 total reports made, there have been 11 crashes or fires, which makes sense due to the airbag deployment, and 10 reports of injuries. Fortunately, the safety agency hasn't been alerted to any fatalities. The probe will evaluate the scope, frequency, and potential consequences of the alleged defect, and, if a fault is confirmed, a recall would then be issued.

One of the customer reports was filed on September 6, 2025, by a 2022 Ford Explorer owner in Reseda, California. The owner says that when the driver's-side airbag deployed in an accident on August 25, 2025, it "deposited unreacted airbag propellant on my skin, causing a severe chemical burn." A separate report was filed by a 2023 Ford Explorer owner on December 12, 2023. In this report, the front-seat passenger claims to have received first- and second-degree burns after a side impact that triggered the airbags to deploy. This person claims "something had burned through 3 layers of clothing." CarScoops also found a related report filed on July 15, 2024, by a Missouri resident who claimed that the side airbag spewed a "hot chemical" onto the left side of their body following a crash, "melting my clothes and causing chemical burns to my side."

Under the leadership of Jim Farley, Ford has been working hard to improve the quality of its vehicles. Not only has Ford issued a concerning amount of recalls this year, including one that affected more than 13 million Explorers and Lincoln Aviators, but in August, Farley revealed that the troubled launch of the fifth-generation F-Series Super Duty in 2023 was "a catalyst for change." Two-thirds of Ford's leaders across its manufacturing, supply chain, engineering, and industrial system departments were given their marching orders and replaced by workers obsessed with improving quality. In June, Ford ranked the highest among mainstream brands in JD Power's initial quality study that analyzes problems experienced by car owners during the first 90 days of ownership. This result suggests that Ford's efforts are bearing fruit.