Deployment of the seat-mounted side airbag may result in serious burn injuries to front seat occupants,
the National Highway Traffic Safety Administration (NHTSA) stated in a preliminary evaluation opened on Nov. 6.
Federal regulators are investigating an estimated 1,236,155 Ford Explorer SUVs from the 2021 to 2026 model years following reports of severe burn injuries. The probe, managed by the NHTSA’s Office of Defects Investigation (ODI), centers on allegations that seat-mounted side airbags caused second- and third-degree burns during deployment.
Injuries reported to drivers and officers
The investigation follows 11 documented incidents that resulted in 10 reported injuries, according to FOX Business. While the agency has received eight Vehicle Owner Questionnaires and four Early Warning Reporting injury logs, no fatalities have been reported.
NHTSA Opens Probe Into 1.2 Million Ford Vehicles Over Burn Risk from Airbag https://t.co/Axczfmawzh
The reported burn injuries were typically diagnosed as second- or third-degree burns that required medical treatment to heal. These injuries have been reported for both front-seat passengers and drivers. According to NHTSA documentation, while the side-impact airbags deployed as intended to protect occupants’ torsos during collisions, the deployment mechanism itself caused the secondary burns.
Some of the reported injuries involved law enforcement officers operating Ford Explorer Police Interceptor vehicles. Torque News reported that one complaint detailed a crash in a Police Interceptor where the airbag vent allegedly faced the driver.
During a traffic accident the driver side seat airbag deployed. The airbag vent faces towards the driver when it deploys. The air escaping the vent burned through the shirt of the officer driving the vehicle and also caused a mixture of 2nd and 3rd degree burns to the hip and side abdomen region of their body.
Vehicle Owner Questionnaire, as reported by Torque News
A separate complaint involving a 2022 Ford Explorer Police Interceptor describes a collision with a UPS truck. In that instance, an officer’s clothing and side suffered thermal burns from the airbag’s exhaust port, Torque News reported. One filing from February 2025 noted that an officer’s tactical vest and three layers of clothing caught fire, resulting in third-degree burns that necessitated skin graft surgery.
The investigation includes several other complaints that describe burns from deployment without specifying the vent, and they do not all present the same details. Some reports have highlighted issues involving melted utility belts and direct exposure to hot gas where airbag vents were directed toward occupants.
While three of the eight complaints allege the exhaust port faced the occupant, NHTSA has not yet reached a conclusion regarding the direction of the vents.
Ford responds to federal inquiry
Ford Motor Co. is cooperating with the federal government’s assessment of the potential defect. The Detroit News reported that Ford spokesperson Michael Albano told officials, Safety is a top priority at Ford. We are working with NHTSA to support its investigation.
The investigation is a preliminary evaluation to determine the scope and frequency of the issue. This phase does not constitute an official product recall. The ODI will evaluate the safety-related consequences of the alleged defect before deciding on further action. NHTSA aims to complete this Preliminary Evaluation within eight months.
Industry analysts noted the technical challenges of side airbag design. The Detroit News cited Sam Fiorani, vice president of global vehicle forecasting at AutoForecast Solutions, who noted that side airbags present challenges due to limited space compared to front airbags.
Fiorani stated that while Ford has been “considerably” focused on safety over the last year, recent changes may not resolve past quality issues, noting the difficulty of replacing airbags in vehicles that have been on the market since 2021. However, he added that the fact Ford is investigating is positive and noted the relatively low number of reported injuries compared to the total number of vehicles on the road.
The probe covers both civilian trim levels and the specialized Police Interceptor variants used extensively by law enforcement agencies across North America, Auto123 reported. This follows a CNBC report stating that more than half of the 12,000 U.S. police departments drive Ford vehicles.
Context of recent Ford safety issues
Ford has faced a high volume of safety-related actions this year. According to the NHTSA website, Ford leads the industry with 85 recalls so far this year, while Chrysler, owned by Stellantis, ranks second with 41. The company is currently under an independent federal monitor to oversee its compliance, data analytics, and recall processes after NHTSA found the automaker had not acted quickly enough to recall vehicles with faulty rearview cameras.
Other recent Ford safety matters include:
- In August, a recall affected nearly 150,000 Mustang vehicles manufactured between 2024 and 2026 due to a defect causing some vehicles to suddenly stall and lose their ability to accelerate or maintain speed.
- An investigation was launched in September regarding reports that an engine coolant defect could lead to a sudden loss of power in approximately 500,000 Ford Edge vehicles. This issue was previously the subject of a class action lawsuit.
- More than 100,000 vehicles, including 2026 Ford F-150s, were part of a recall last month due to a speedometer defect that fails to display accurate vehicle speed.
- A recall of 4.4 million vehicles was announced by Ford in February because a software issue could cause tail lights, turn signals and brakes to fail, impacting models including 2021-2026 Ford F-150 and F-250 trucks.
For Canadian owners, safety bulletins or recall notices can be tracked through Transport Canada’s online database using a 17-digit Vehicle Identification Number (VIN).