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Ford · Known Issues

2001-2010 Ford Explorer Sport Trac Problems & Issues

2001-2010 model years · 430+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 430+ owner reports, the 2001-2010 Ford Explorer Sport Trac has 4 documented known issues, with 3 rated critical. The most serious are 4.0L SOHC Timing Chain Cassette and Tensioner Failure ($1,500-$3,500 repair), Truck Bed and Frame Rust ($200-$2,000 repair) and Cam Phaser Rattle on 4.0L SOHC ($800-$2,000 repair). The most commonly reported issue is 4.0L SOHC Timing Chain Cassette and Tensioner Failure with 250 owner reports. Across all issues with published estimates, repair costs range from $30 to $3,500. DIY maintenance guides at au7o.io.

In This Article

  • Explorer Sport Trac Engine2
  • Explorer Sport Trac Body/Panels2
  • Recalls4
  • FAQ
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In This Article

  • Engine2
  • Body/Panels2
  • Recalls4
  • FAQ

All 4 Known Issues

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ALL YEARS201020092008200720052004200320022001
Community reported
250 owners

The 4.0L SOHC V6 uses three timing chains with plastic cassette guides and hydraulic tensioners. The guides crack and the tensioners lose pressure, causing chain slack that leads to jumped timing and engine damage. This is the same issue affecting the Explorer and Ranger with this engine.

This issue also affects: Ford Aerostar, Ford Bronco, Ford Bronco Sport

Common Symptoms

  • Rattling on cold startup
  • Persistent timing chain noise
  • Check engine light with cam/crank correlation codes
  • Rough idle
  • Loss of power
  • Engine misfires

How to Fix

Replace all three timing chains, guides, tensioners, and sprockets. This is a major job requiring significant disassembly. Many owners opt for a remanufactured engine due to the high labor cost.

Typical repair cost:$1,500 - $3,500

Research This Issue

Based on 250 owner reports

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Community Reported
High Confidence250 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026

The 4.0L SOHC V6 cam phasers develop a loud rattle on cold startup that can persist for 30+ seconds. The phaser internal mechanism wears, causing timing chain slack and potential timing issues.

This issue also affects: Ford Bronco, Ford Edge, Ford Expedition

Common Symptoms

  • Loud rattle on cold start
  • Rattling for 30+ seconds
  • Check engine light
  • Reduced power

How to Fix

Replace the cam phasers, timing chain, tensioners, and guides as a complete kit. This is a labor-intensive repair requiring removal of the front of the engine. Use updated Ford phasers.

Typical repair cost:$800 - $2,000

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Community Reported
Medium Confidence

The truck bed floor and frame rails are prone to severe rust, especially in northern climates. The bed is separate from the cab and traps moisture underneath. Frame rot near the rear leaf spring mounts is a safety concern.

This issue also affects: Ford F-150

Common Symptoms

  • Visible rust on bed floor
  • Holes in truck bed
  • Frame rail flaking
  • Leaf spring mount deterioration

How to Fix

Inspect frame rails annually. Treat with rust converter and undercoating. In severe cases, frame reinforcement plates can be welded on. Bed floor panels can be replaced with aftermarket steel.

Typical repair cost:$200 - $2,000

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Community Reported
Medium Confidence
Community reported
180 owners

The first-generation Sport Trac's rear flip-up glass window suffers from hinge wear and gas strut failure, causing the glass to not stay open. The defroster grid also cracks at the same hinge flex points, rendering the rear defroster inoperable.

Common Symptoms

  • Rear glass won't stay open
  • Glass slams shut unexpectedly
  • Rear defroster doesn't clear fog
  • Partial defroster pattern visible
  • Hinge feels loose or wobbly
  • Gas struts have no resistance

How to Fix

Replace the gas struts to restore the flip glass hold-open function. For the defroster grid, apply conductive paint repair to the broken traces. In severe cases, the entire rear glass must be replaced.

Typical repair cost:$30 - $300

Research This Issue

Based on 180 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence180 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026
NHTSA Recalls4 recalls

EXTERIOR LIGHTING

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Campaign #06E02600023/03/2006

SEATS:FRONT ASSEMBLY:RECLINER

FORD IS RECALLING CERTAIN MODEL YEAR 2010 FUSION, EXPLORER, EXPLORER SPORT TRAC, AND MERCURY MILAN AND MOUNTAINEER VEHICLES MANUFACTURED BETWEEN DECEMBER 15, 2009 THROUGH FEBRUARY 3, 2010 EQUIPPED WITH FRONT SEAT MANUAL RECLINERS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 202, "HEAD RESTRAINT." THE RECLINER GEAR PLATE TEETH MAY BE OUT OF DIMENSION SPECIFICATION WHICH COULD RESULT IN LIMITED PAWL TO GEAR PLATE TOOTH ENGAGEMENT.

Campaign #10V16100020/04/2010

POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH THE 4.6L ENGINE AND 6R TRANSMISSION, THE BOLT SECURING THE TRANSMISSION OIL COOLER LINE FITTINGS AT THE TRANSMISSION MAY NOT HAVE BEEN SUFFICIENTLY TORQUED DURING VEHICLE ASSEMBLY. AS A RESULT, THE BOLT MAY LOOSEN AND THE TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION, CAUSING A TRANSMISSION FLUID LEAK.

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Frequently Asked Questions

What are the most common Ford Explorer Sport Trac problems?

According to Au7o's analysis of 430+ owner reports, the 2001-2010 Ford Explorer Sport Trac has 4 documented issues. The most frequently reported are: 4.0L SOHC Timing Chain Cassette and Tensioner Failure, Truck Bed and Frame Rust, Cam Phaser Rattle on 4.0L SOHC. Of these, 3 are rated critical and should be addressed promptly.

Is the Ford Explorer Sport Trac reliable?

The 2001-2010 Ford Explorer Sport Trac has 4 known issues documented across 430+ owner reports. 3 issues are rated critical: 4.0L SOHC Timing Chain Cassette and Tensioner Failure and Truck Bed and Frame Rust and Cam Phaser Rattle on 4.0L SOHC. 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.

How much does it cost to fix common Ford Explorer Sport Trac problems?

Repair costs for known Ford Explorer Sport Trac issues range from $30 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4.0L SOHC Timing Chain Cassette and Tensioner Failure, typically costs $1,500-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Ford Explorer Sport Trac is the most reliable?

Reliability varies across model years of the Ford Explorer Sport Trac. 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 2001-2010 Ford Explorer Sport Trac with 4 documented issues documented across 430+ owner reports.

What is the 2007-2010 Ford Explorer Sport Trac 4.0L SOHC Timing Chain Cassette and Tensioner Failure?

The 4.0L SOHC V6 uses three timing chains with plastic cassette guides and hydraulic tensioners. The guides crack and the tensioners lose pressure, causing chain slack that leads to jumped timing and engine damage. This is the same issue affecting the Explorer and Ranger with thi… Repairs typically run $1,500-$3,500. 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.

Data sourced from 430+ owner reports, NHTSA recalls, TSBs, and automotive forums.

Campaign #07V45300026/09/2007

STEERING

ON CERTAIN SPORT UTILITY VEHICLES, THE TWO BOLTS THAT ATTACH THE STEERING GEAR ASSEMBLY TO THE FRAME MAY HAVE BEEN OVER-TIGHTENED. THIS CONDITION COULD RESULT IN ONE OR BOTH OF THE BOLTS FRACTURING, CAUSING THE STEERING GEAR TO BECOME LOOSE.

Campaign #07V18100025/04/2007

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

What is the 2001-2005 Ford Explorer Sport Trac Truck Bed and Frame Rust?

The truck bed floor and frame rails are prone to severe rust, especially in northern climates. The bed is separate from the cab and traps moisture underneath. Frame rot near the rear leaf spring mounts is a safety concern. Repairs typically run $200-$2,000. Severity: high.

What is the 2007-2010 Ford Explorer Sport Trac Cam Phaser Rattle on 4.0L SOHC?

The 4.0L SOHC V6 cam phasers develop a loud rattle on cold startup that can persist for 30+ seconds. The phaser internal mechanism wears, causing timing chain slack and potential timing issues. Repairs typically run $800-$2,000. Severity: high.

What is the 2001-2005 Ford Explorer Sport Trac Rear Window Defroster Grid and Flip Glass Hinge Failure?

The first-generation Sport Trac's rear flip-up glass window suffers from hinge wear and gas strut failure, causing the glass to not stay open. The defroster grid also cracks at the same hinge flex points, rendering the rear defroster inoperable. Repairs typically run $30-$300. Severity: low.