by 
Six vehicles that require full engine replacement
Ford is recalling only six examples of the 2026 Explorer, but this is not a case of a loose trim clip or a slightly glitchy screen. Each of these vehicles will need an entirely new engine assembly. The affected SUVs were built between February 10 and 17, 2026, and under the hood sits Ford’s 2.3-liter four-cylinder engine. As noted in the recall documents, the connecting rod bearing shells in these engines can seize, which can cause sudden engine failure, loss of power, and even a hole in the cylinder block.
None of that bodes well. Ford warns that such a fault could lead to a fire. Owners may hear knocking from the engine before a catastrophic failure occurs, but that is hardly reassuring. Even if a hole in the block doesn’t appear, that sound usually spells a death sentence for the engine. The most interesting part here is how Ford found the problem in the first place.
More: Ford Recalls Over 66,000 Hybrids to Fix a Previous Recall
How the manufacturer discovered the hidden defect
Ford’s engineering quality team found 10 engines replaced under warranty, all with the same issue in the second cylinder. In each one, the connecting rod bearing shells failed, and all of these engines were assembled around the same 30-minute window at the Dearborn engine plant. Tellingly, this happened shortly after replacing the polishing pad used during production. The polishing pad is a precisely profiled abrasive tool that finish-machines the bearing surfaces of the crankshaft, making them smooth, round, and compliant with extremely tight tolerances.
Factory data recorded a change in ovality readings for the crankshaft connecting rod journals within this small batch. Ford has not yet determined exactly what caused this change in measurements, but it apparently saw enough reason to treat all six affected Explorers as a group with a 100 percent probability of defect. As of August 11, Ford knew of 11 warranty claims related to this fault; the first arrived on March 26. The company said it is not aware of any accidents or injuries caused by this defect.
What will be done for owners
Although only six vehicles are affected, the problem is serious. Ford plans to contact owners directly by phone whenever possible. Owner letters were already sent on August 24. All affected vehicles will receive a new complete engine assembly entirely free of charge.
Photos: Ford
What this means in practice
Ford’s move looks unusual, since recalls usually involve far larger numbers of cars. Here, however, the manufacturer seems to have decided not to take risks: even if the defect could only affect these six examples, the potential consequences — from sudden loss of power to fire — are too serious to rely on luck. Owners should wait for a call from an official dealer and not postpone a visit to the service center, especially if there is already an unusual knocking sound coming from the engine. The engine replacement is fully covered by the manufacturer, so there will be no additional costs.
This story also reminds us that even minor changes in the manufacturing process, such as replacing a polishing tool, can lead to defects that affect reliability and safety. The fact that Ford found the problem through warranty replacement analysis and factory data shows just how important quality monitoring is at all stages of production.
