U.S. auto safety regulators have launched a preliminary evaluation affecting more than 1.2 million Ford Explorer SUVs, this following reports that seat-mounted side airbags deployed during collisions caused severe second- and third-degree burn injuries to front-seat occupants.
The investigation, opened last Friday, November 6, by the National Highway Traffic Safety Administration (NHTSA), covers an estimated 1,236,155 Ford Explorer SUVs from the 2021-2026 model-years. The probe includes both civilian trim levels and specialized Ford Explorer Police Interceptor variants widely used by law enforcement agencies across North America.
Incidents involve severe burns
According to NHTSA documentation, the agency has received 11 separate reports — comprising eight consumer complaints (Vehicle Owner Questionnaires) and four Early Warning Reporting injury logs — detailing 10 incidents that resulted in burn injuries requiring medical treatment.
The reports indicate that while the side-impact airbags deployed as intended during crashes to protect occupants' torsos, the physical deployment mechanism itself inflicted serious secondary burn injuries on drivers and front passengers.
Several filings highlight specific complications involving law enforcement equipment and seating positions. In one notable complaint dated February 2025 and involving a Police Interceptor, an officer’s tactical vest and three layers of clothing caught fire when a side airbag deployed after a collision with a delivery truck, causing third-degree burns that required skin graft surgery. Other filings detail melted utility belts and direct hot gas exposure where side airbag vents faced occupants.
Probe status and manufacturer response
A preliminary evaluation is an initial data-gathering phase and does not constitute an official product recall. NHTSA opened the inquiry to evaluate the scope, frequency, and safety implications of the issue before deciding whether to request a manufacturer recall or close the file.
Ford spokesperson Michael Albano stated that the Dearborn automaker is cooperating fully with the federal investigation.
Industry analysts note that while side airbags rely on rapid pyrotechnic inflation to protect passengers within tight door clearances, secondary burn risks remain an area of ongoing technical scrutiny across the sector.
Canadian owners can check Transport Canada’s online database with their 17-digit Vehicle Identification Number (VIN) to track any future safety bulletins or related recall notices.