Ford · Known Issues
1991-2026 Ford Explorer Problems: 73 Known Issues
1991-2026 model years · 5,447+ owner reports · Updated September 2026
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According to Au7o's analysis of 5,447+ owner reports, the 1991-2026 Ford Explorer has 73 documented known issues, with 36 rated critical. The most serious are Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) ($0-$500 repair), 3.5L Internal Water Pump Failure ($1,500-$8,000 repair), Rear Axle Mounting Bolt Fracture ($0-$2,500 repair), Electric Power Steering Failure ($1,700-$3,700 repair), 2.3L EcoBoost Turbocharger Oil Supply Line O-Ring Leak and Under-Hood Fire Risk (Recall 23V597) ($0-$0 repair), Internal Radiator Transmission Cooler Rupture Causing Coolant/ATF Cross-Contamination ('Pink Milkshake') ($400-$3,500 repair), Incorrectly Installed Piston Circlips — Piston Failure and Loss of Drive Power ($0-$0 repair), Second-Row Outer Seat Belt Lower Anchor Bolts Improperly Secured ($0-$0 repair), Loose Trailer Hitch Assembly Bolts — Loss of Handling or Trailer Detachment While Towing ($0-$0 repair), Trailer Tail Lights Fail to Illuminate — Improperly Manufactured Body Control Module C ($0-$0 repair), Easy-Entry Second-Row Seat Switch Binds — Seats Unlatch, Tip or Slide Unexpectedly ($0-$0 repair), Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk, 4.0L OHV cracked cylinder heads and blown head gaskets from overheating ($1,000-$2,800 repair), Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) ($0-$900 repair), 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2) ($150-$1,500 repair), 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping ($900-$3,000 repair), Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk ($0-$250 repair), Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) ($0-$1,200 repair), Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) ($600-$1,000 repair), Frame, rear subframe, and rocker/body-mount rust ($200-$3,000 repair), Front Windshield Wiper Motor Failure (Recall 26V117 / 26S14) ($0-$500 repair), Hard / Dropping Brake Pedal and Loss of Braking Reported on 2025 Explorer, Improperly Secured Seat Belt Anchor / Buckle Bolts May Not Restrain Occupants in a Crash (Recall 25V093) ($0-$0 repair), Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction ($2,000-$4,000 repair), Power Transfer Unit (PTU) overheating and bearing failure on AWD models ($1,500-$3,100 repair), Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk ($250-$750 repair), Rear Driveshaft Weld-Seam Fracture (Recall 20V693000 / 20S65) ($0-$0 repair), Rear Suspension Toe Link Ball Joint Corrosion and Fracture Causing Loss of Steering Control (Recall 21V537 / 19S17-21S32) ($0-$0 repair), EGR Valve Poppet Head Detachment Causing Unexpected Loss of Drive Power (Recall 26V122) ($0-$0 repair), Engine Failure Requiring Long Block Replacement (Recall 26V343 / Ford 26S35) ($0-$0 repair), Powertrain Control Module Reset Damaging Park System, Causing Rollaway or Engine Stall (Recall 25V239 / 25S35) ($0-$0 repair), Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 repair), 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse ($900-$3,500 repair), 4.0L SOHC timing chain cassette, guide, and tensioner failure ($400-$3,000 repair), Timing Chain Cassette and Guide Failure on 4.0L SOHC V6 ($1,800-$4,500 repair) and Throttle Body Failure on 4.6L V8 Causing Wrench Light, Limp Mode, and Sudden Loss of Power ($350-$900 repair). The most commonly reported issue is Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) with 1,500 owner reports. Across all issues with published estimates, repair costs range from $25 to $8,000. DIY maintenance guides at au7o.io.
VISIBILITY:WINDSHIELD
Ford Motor Company (Ford) is recalling certain 2025-2026 Lincoln Corsair, Lincoln Aviator, and Explorer vehicles. The windshield glass may have visible air bubbles, which can obscure the driver's visibility. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 205, "Glazing Materials."
EXTERIOR LIGHTING:HEADLIGHTS
Ford Motor Company (Ford) is recalling certain 2025-2026 Explorer vehicles. The Dynamic Bending Light (DBL) system software may cause the passenger-side headlight to turn in the wrong direction when driving through curves in the road. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."
TRAILER HITCHES
Ford Motor Company (Ford) is recalling certain 2024-2026 Explorer and 2024-2026 Lincoln Aviator vehicles. The trailer hitch assembly bolts may be loose.
ENGINE
Ford Motor Company (Ford) is recalling certain 2026 Explorer, Mustang, Lincoln Corsair, and 2025 Maverick vehicles. The cylinder head may have been improperly manufactured, which can cause the ball plugs to fail, resulting in an oil leak.
VISIBILITY:WINDSHIELD
Ford Motor Company (Ford) is recalling certain 2026 Explorer vehicles. During manufacturing, the windshield may not have been properly bonded to the vehicle, allowing it to detach in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 212, "Windshield Mounting."
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According to Au7o's analysis of 5,447+ owner reports, the 1991-2026 Ford Explorer has 73 documented issues. The most frequently reported are: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), 3.5L Internal Water Pump Failure, Rear Axle Mounting Bolt Fracture. Of these, 36 are rated critical and should be addressed promptly.
The 1991-2026 Ford Explorer has 73 known issues documented across 5,447+ owner reports. 36 issues are rated critical: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) and 3.5L Internal Water Pump Failure and Rear Axle Mounting Bolt Fracture and Electric Power Steering Failure and 2.3L EcoBoost Turbocharger Oil Supply Line O-Ring Leak and Under-Hood Fire Risk (Recall 23V597) and Internal Radiator Transmission Cooler Rupture Causing Coolant/ATF Cross-Contamination ('Pink Milkshake') and Incorrectly Installed Piston Circlips — Piston Failure and Loss of Drive Power and Second-Row Outer Seat Belt Lower Anchor Bolts Improperly Secured and Loose Trailer Hitch Assembly Bolts — Loss of Handling or Trailer Detachment While Towing and Trailer Tail Lights Fail to Illuminate — Improperly Manufactured Body Control Module C and Easy-Entry Second-Row Seat Switch Binds — Seats Unlatch, Tip or Slide Unexpectedly and Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk and 4.0L OHV cracked cylinder heads and blown head gaskets from overheating and Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) and 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2) and 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping and Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk and Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) and Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Front Windshield Wiper Motor Failure (Recall 26V117 / 26S14) and Hard / Dropping Brake Pedal and Loss of Braking Reported on 2025 Explorer and Improperly Secured Seat Belt Anchor / Buckle Bolts May Not Restrain Occupants in a Crash (Recall 25V093) and Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction and Power Transfer Unit (PTU) overheating and bearing failure on AWD models and Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk and Rear Driveshaft Weld-Seam Fracture (Recall 20V693000 / 20S65) and Rear Suspension Toe Link Ball Joint Corrosion and Fracture Causing Loss of Steering Control (Recall 21V537 / 19S17-21S32) and EGR Valve Poppet Head Detachment Causing Unexpected Loss of Drive Power (Recall 26V122) and Engine Failure Requiring Long Block Replacement (Recall 26V343 / Ford 26S35) and Powertrain Control Module Reset Damaging Park System, Causing Rollaway or Engine Stall (Recall 25V239 / 25S35) and Automatic transmission overdrive failure (A4LD / 4R55E) and 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse and 4.0L SOHC timing chain cassette, guide, and tensioner failure and Timing Chain Cassette and Guide Failure on 4.0L SOHC V6 and Throttle Body Failure on 4.6L V8 Causing Wrench Light, Limp Mode, and Sudden Loss of Power. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Explorer issues range from $0 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), typically costs $0-$500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Reliability varies across model years of the Ford Explorer. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1991-2026 Ford Explorer with 73 documented issues documented across 5,447+ owner reports.
NHTSA opened an investigation in July 2016 into 2011-2017 Ford Explorer carbon monoxide intrusion after 6,500+ complaints, 657 alleged injuries, and 3 deaths. After 6 years of testing, NHTSA closed the investigation in January 2023 WITHOUT a recall — agency findings concluded tha… Repairs typically run $0-$500. Severity: high.
The 3.5L V6 engine (both naturally aspirated and EcoBoost versions) features an internal water pump located under the engine front cover. When this pump fails, it can leak coolant internally into the engine crankcase, contaminating the oil and potentially causing catastrophic eng… Repairs typically run $1,500-$8,000. Severity: high.
The rear axle horizontal mounting bolt may fracture, causing the rear axle housing to move out of position. This can result in the driveshaft or half-shafts becoming disconnected, leading to loss of forward power and loss of transmission torque to the rear wheels, significantly i… Repairs typically run $0-$2,500. Severity: high.
An intermittent connection in the electric power steering gear can cause the electric power steering assist system to shut down unexpectedly while driving. This results in significantly increased steering effort required, which can be dangerous especially at low speeds during par… Repairs typically run $1,700-$3,700. Severity: high.
A small population of 2023 Explorers with the 2.3L EcoBoost engine may have a torn or cut turbocharger oil supply line O-ring. The damaged O-ring can let pressurized engine oil escape and contact a hot engine, increasing the risk of an under-hood fire; oil loss can also cause an… Repairs typically run $0-$0. Severity: high.
The factory radiator integrates the automatic transmission fluid cooler in an internal tank inside one end of the radiator. Over time the barrier between the coolant side and the ATF side cracks or the internal fittings leak, letting the two fluids mix. Coolant pushed into the tr… Repairs typically run $400-$3,500. Severity: high.
A batch of 2026 Explorer engines (the same campaign also covers the 2026 Mustang) were built with engine piston circlips incorrectly installed. A displaced circlip lets the wrist pin walk and score or hole the cylinder wall, producing piston failure, severe engine damage and a lo… Repairs typically run $0-$0. Severity: high.
The seat belt anchor bolts at the second-row outer seating positions may not have been properly torqued during assembly, leaving the buckle or lower anchor loose. Ford recalled 2020-2026 Explorer and Aviator vehicles under NHTSA 26V159000 (Ford 26C18) in March 2026 — a repeat of… Repairs typically run $0-$0. Severity: high.
The trailer hitch assembly bolts on certain 2024-2026 Explorers and Aviators were left loose during assembly. Ford recalled 1,412 vehicles under NHTSA 25V687000 (Ford 25SA3) in October 2025. Under towing loads the loose hitch can shift, degrading vehicle handling and control, or… Repairs typically run $0-$0. Severity: high.
On 213,121 2025 Explorers and Aviators, an improperly manufactured Body Control Module C fails to drive the trailer lighting circuit, so a connected trailer's tail lights do not illuminate. Ford recalled these vehicles under NHTSA 25V543000 (Ford 25C42) in August 2025. The traile… Repairs typically run $0-$0. Severity: high.
The switch that operates the easy-entry (tip-and-slide) second-row outer seats can bind or stick in the actuated position, causing the seat to unlatch, tip forward or slide without the occupant commanding it. Ford recalled 387,911 vehicles under NHTSA 26V451000 (Ford 26S52) in Ju… Repairs typically run $0-$0. Severity: high.
NHTSA safety recall 91V189000 covers automatic-transmission-equipped 1991 Ford Explorers in which the park pawl does not always abut or engage the park gear when the shift lever is moved into Park. Because the lever still moves into the Park detent, an Explorer owner can shut the… Severity: high.
The pushrod 4.0L OHV V6 (Cologne) is otherwise regarded as a durable 'tank,' but the cast heads are intolerant of overheating and are prone to cracking and gasket failure, typically appearing around 100k miles or after any single serious overheat event. The root cause is usually… Repairs typically run $1,000-$2,800. Severity: high.
The 1995-2001 Explorer was factory-fitted with P235/75R15 Firestone Radial ATX, ATX II and Wilderness AT tires that suffered tread-belt separation, especially in hot climates and when underinflated to Ford's low placard pressure. A rear tread separation at highway speed frequentl… Repairs typically run $0-$900. Severity: high.
The optional 4.6L 2-valve modular V8 (shared with the Mercury Mountaineer) has aluminum heads that engage only a few spark-plug threads (~0.25 in). Under thermal cycling the plug can strip the threads and eject from the head, sometimes blowing out the coil boot with it. Ford ackn… Repairs typically run $150-$1,500. Severity: high.
The 5R55E five-speed automatic (behind the 4.0L before the 5R55W/S arrived for 2002) commonly loses reverse and/or slips in Drive/1st as the low/reverse sprag, reverse clutch pack, and forward clutch wear. A broken tab on the pressure-regulating (EPC) solenoid in the valve body d… Repairs typically run $900-$3,000. Severity: high.
Many Ford vehicles of this era, including the Explorer, were subject to recalls for the speed control deactivation switch mounted on the brake master cylinder. The switch can leak brake fluid internally, overheat, and in some cases cause an underhood fire even when the vehicle is… Repairs typically run $0-$250. Severity: high.
Owners across the fifth-generation Explorer reported exhaust fumes and carbon monoxide odor entering the cabin, particularly under hard acceleration with the climate system in recirculate. NHTSA opened investigation PE16-007 (later EA17-002), reviewed more than 6,500 complaints,… Repairs typically run $0-$1,200. Severity: high.
The defining safety issue of the 1990s Explorer: original-equipment and replacement Firestone ATX, ATX II, and Wilderness AT P235/75R15 tires (notably from the Decatur, IL plant) suffered tread/belt separation at highway speed. Combined with the Explorer's relatively high center… Repairs typically run $600-$1,000. Severity: high.
In salt-belt climates, 1991-1999 Explorers rot in predictable structural areas: the inner rocker panels, the tops of the front leaf-spring hangers (dirt packs between the hanger and inner rocker, which the factory welded only at the bottom), rear spring hangers/shackles, and the… Repairs typically run $200-$3,000. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.