# Service bulletin SSM 54646

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

- Type: Service bulletin
- NHTSA id: 11032252
- Published by NHTSA: 2026\-05\-05
- Manufacturer's number: SSM 54646
- Manufacturer's date: 2026\-04\-29
- NHTSA component: FUEL/PROPULSION SYSTEM; UNKNOWN OR OTHER; STRUCTURE:BODY

## NHTSA's summary

Some 2020\-2024 Explorer/Police Interceptor Utility hybrid vehicles may exhibit a "Refuel Error See Manual" message in the instrument panel cluster \(IPC\) after installing a replacement fuel filler door assembly \(7827936\). This may be due to a concern with the replacement fuel filler door assembly. If diagnostics in the Workshop Manual \(WSM\), Section 501\-14 Body \> Handles, Locks, Latches and Entry Systems \> lead to fuel filler door switch replacement, install a new fuel filler door assembly ordered from depot stock to correct this condition. Suspect parts have been cleared from parts depot inventory.

## The document

- [NHTSA's copy of the document (PDF)](https://static.nhtsa.gov/odi/tsbs/2026/MC-11032252-0001.pdf)
- [If that address does not open, try this one](https://static.nhtsa.gov/odi/tsbs/2026/MC-11032252-9999.pdf)

The document is the manufacturer's. This site does not hold it.

## Components

Body and frame, Fuel system

## Vehicles listed

- 2020 to 2024 FORD EXPLORER
- 2020 to 2023 FORD EXPLORER HYBRID

## Recalls for the same vehicles and component

- [2025548](/recalls/tc/2025548.md), 2025-10-11: Structure
- [2025366](/recalls/tc/2025366.md), 2025-07-08: Fuel System
- [25V455000](/recalls/nhtsa/25V455000.md), 2025-07-07: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
- [2022522](/recalls/tc/2022522.md), 2022-09-16: Fuel System
- [22V685000](/recalls/nhtsa/22V685000.md), 2022-09-14: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
- [2022336](/recalls/tc/2022336.md), 2022-06-24: Structure
- [22V454000](/recalls/nhtsa/22V454000.md), 2022-06-24: ENGINE; STRUCTURE:FRAME AND MEMBERS
- [2022069](/recalls/tc/2022069.md), 2022-02-16: Fuel System
- [22V088000](/recalls/nhtsa/22V088000.md), 2022-02-16: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
- [20V730000](/recalls/nhtsa/20V730000.md), 2020-11-24: FUEL SYSTEM, GASOLINE:STORAGE

## Other bulletins for the same vehicles and component

- [SSM 55069](/bulletins/11036103.md), 2026-08-11, Service bulletin: VISIBILITY/WIPER; ELECTRICAL SYSTEM; STRUCTURE:BODY. Some 2020\-2025 Explorer vehicles equipped with a power roof opening panel may exhibit a sunshield with localized bunching or binding/inoperative. This may be due to a broken or missing sunshield fabric retainer/clip. A revised sunshield clip \(LJ6Z\-5452118\-B\) is now available to address this condition. It is not necessary to replace the entire sunshield assembly if the clip\(s\) are broken or missing. Refer to Workshop Manual \(WSM\), Section 501\-17 Roof Opening Panel \> General Procedures \> Inspection and Replacement of the Roof Opening Panel Shield Clip.
- [SSM 55060](/bulletins/11035581.md), 2026-08-04, Service bulletin: STRUCTURE:BODY; ELECTRICAL SYSTEM; VISIBILITY/WIPER. Some 2024\-2026 Explorer vehicles built on or before 27\-Feb\-2026 and equipped with the panoramic glass roof may exhibit an uneven gap at the front edge of the roof opening panel shield when fully closed. The gap is an appearance issue only, but may allow outside light to pass through the opening. A new gap hider seal has been released to correct this condition \(service part number SB5Z\-7851884\-A\). Adjustment or replacement of the glass, shade or headliner assembly is not necessary. The new seal is installed directly onto the existing vertical flange that is present and visible at the front of the opening when the shade is opened. Once installed, the front edge of the shade will press against the new seal when fully closed. To install, center the seal in the opening with the flexible material facing the power shade and press the seal u\-channel over the vertical flange. Explorer vehicles built on or after 27\-Feb\-2026 have the seal already installed and can be referenced if necessary. Once the seal is installed, perform the shield/shade initialization procedure in Workshop Manual \(WSM\), Section 501\-05 \> Gen
- [SSM55059](/bulletins/11035556.md), 2026-08-03, Service bulletin: POWER TRAIN; ELECTRICAL SYSTEM; UNKNOWN OR OTHER; FUEL/PROPULSION SYSTEM. Some 2021\-2023 F\-150 vehicles equipped with a 3.5L PowerBoost engine, 2020\-2026 Explorer vehicles equipped with a 3.3L hybrid engine, and 2020\-2023 Lincoln Aviator vehicles equipped with a 3.0L EcoBoost hybrid engine may exhibit an illuminated powertrain malfunction \(wrench\) indicator with diagnostic trouble code \(DTC\) P0A1E stored in the powertrain control module \(PCM\). The vehicle may be unable to enter electric\-only drive modes as expected during normal drive cycles. This may be due to the belt integrated starter generator \(BISG\). For vehicles with this condition, follow the necessary Pinpoint Test in Workshop Manual \(WSM\), Section 303\-06 for DTC P0A1E and repair the vehicle as directed. Note that previous replacement of the BISG does not negate the need for subsequent BISG replacements if directed to do so by the appropriate Pinpoint Test diagnostics. Engineering is investigating this BISG quality concern. Monitor PTS for updates regarding this investigation.
- [TSB 26\-2349](/bulletins/11035508.md), 2026-08-03, Service bulletin: FUEL/PROPULSION SYSTEM; ENGINE; UNKNOWN OR OTHER. This bulletin supersedes 25\-2415. Reason for update: To add production build dates of the right\-side engine valve cover. Some of the vehicles listed in the Model statement above may exhibit oil consumption and blue smoke from the tailpipe. This may be due to the sealing process of the positive crankcase ventilation \(PCV\) baffle which is part of the valve cover assembly.
- [SSM 55031](/bulletins/11035269.md), 2026-07-28, Service bulletin: UNKNOWN OR OTHER; FUEL/PROPULSION SYSTEM; ELECTRICAL SYSTEM. Some 2021\-2026 Ford/Lincoln vehicles may exhibit various symptoms including but not limited to the auto start/stop system not operating as intended with a "Check Charging System" message in the instrument panel cluster \(IPC\) while the charging system is operating properly with no charging related diagnostic trouble codes \(DTC\) stored. This may be due to someone using an aftermarket programmer to change the body control module \(BCM\) configuration to disable the auto start/stop system or perform other unsupported programming modifications. To correct this condition on F\-150 and Bronco vehicles, download and run the Ford Diagnosis and Repair System \(FDRS\) application titled "BCM\-Charging System Configuration Correction". Running this application will determine if the BCM configuration was modified by the customer and if so, provide the option to return the configuration back to factory settings. For other vehicle models exhibiting concerns related to unsupported aftermarket BCM programming, submit a Technical Support Request \(TSR\) requesting support to revert the BCM configuration
- [SSM 54857](/bulletins/11032924.md), 2026-05-26, Service bulletin: FUEL/PROPULSION SYSTEM. 2020\-2026 Explorer/Escape/Corsair, 2021\-2026 Bronco Sport/Bronco, 2022\-2026 Maverick, 2024\-2026 Mustang/Ranger/Nautilus vehicles equipped with a 2.0L or 2.3L EcoBoost engine may require removal of the turbocharger wastegate control actuator linkage for various reasons. The Workshop Manual \(WSM\), Section 303\-04 Fuel Charging and Controls \- Turbocharger \- 2.0L/2.3L EcoBoost \> Removal and Installation \> Wastegate Control Actuator Linkage service procedure been added. In addition, the wastegate actuator rod \(9E408\), associated retention springs \(9342\) and retaining clips \(00817\) have been released as lower\-level components to complete the repair without replacing the entire turbocharger wastegate actuator assembly.
- [23B64](/bulletins/11031780.md), 2026-04-30, Other: ELECTRICAL SYSTEM; FUEL/PROPULSION SYSTEM. Customer Satisfaction Program 23B64 Certain 2020\-2024 Model Year Multiple Vehicle Lines Equipped with High Voltage Batteries Battery Energy Control Module \(BECM\) Software Update
- [TSB 26\-2112](/bulletins/11030178.md), 2026-03-23, Service bulletin: FUEL/PROPULSION SYSTEM; UNKNOWN OR OTHER; POWER TRAIN. This bulletin supersedes TSB 26\-2059. Reason For Update: To add missing labor operations. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: \- No upshift past second gear \- Unable to achieve third gear ratio \- Illuminated malfunction indicator lamp \(MIL\) with DTCs P0757 and P2701 This may be due to a damaged one\-way clutch \(OWC\).
- [SSM 54614](/bulletins/11029539.md), 2026-03-04, Service bulletin: FUEL/PROPULSION SYSTEM. Some 2020\-2024 Explorer vehicles equipped with a 2.3L engine and 2020\-2026 Explorer/Police Interceptor Utility/Aviator vehicles equipped with a 3.0/3.3L engine may require various repairs associated with the fuel tank and/or fuel pump and sender unit. Workshop Manual \(WSM\), Section 310\-00 \> Removal and Installation for the fuel tank and fuel pump and sender unit have been revised to eliminate the need to remove the driveshaft as part of the service procedure. Labor times have also been updated to reflect this WSM revision.
- [SSM 54593](/bulletins/11029082.md), 2026-02-27, Service bulletin: ENGINE; POWER TRAIN; FUEL/PROPULSION SYSTEM. Some 2024\-2025 F\-150, Expedition/Navigator, Escape/Corsair, Bronco, Explorer, Mustang, Maverick vehicles equipped with a 1.5/2.0/2.3/3.5L EcoBoost engine and built on 01\-Oct\-2024 and through 31\-May\-2025 may exhibit an extended crank condition, strong fuel smell in the engine oil, high engine oil level and/or may have various drivability diagnostic trouble codes \(DTCs\) stored in the powertrain control module \(PCM\) with an illuminated malfunction indicator lamp \(MIL\). This may be due to an internal fuel leak of the high\-pressure fuel pump causing fuel to enter the crankcase and reduce fuel pressure in the direct injection fuel rail. Diagnose this condition using Pinpoint Test HP located in Workshop Manual \(WSM\), Section 303\-04. If no DTCs are stored in the PCM, proceed from Step HP1 to Step HP5 and continue testing. Repair as necessary outside of this article. For claiming, if high\-pressure fuel pump replacement is required, use causal part number 9D376 and labor operation code 9543A. If the root cause is identified as anything other than the fuel injection pump, claim the repair outside of this article.

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