1999 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
1999 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Ford Explorer has 13 documented known issues, with 7 rated critical. The most serious are 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), 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping ($900-$3,000 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), Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 repair) and 4.0L SOHC timing chain cassette, guide, and tensioner failure ($400-$3,000 repair). Across all issues with published estimates, repair costs range from $25 to $3,500. DIY maintenance guides at au7o.io.
EQUIPMENT
MARATHON IS RECALLING CERTAIN SEAT COVERS, BRAND SUPERHIDES WITH PART NUMBERS 593, 594, 578, 960, 228, 228-09, 267-08, 333, 625, AND 630, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE SEAT COVERS ARE MADE OF HEAVIER THREAD AND ARE NOT COMPATIBLE WITH SEATS CONTAINING SIDE AIRBAGS. THE HEAVIER SEAT COVER COULD INTERFERE WITH FULL DEPLOYMENT OF THE AIRBAG IN THE EVENT OF A CRASH.
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.
EXTERIOR LIGHTING
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE 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.
VISIBILITY:GLASS, SIDE/REAR
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Ford Explorer has 13 documented issues. The most frequently reported are: 4.0L OHV cracked cylinder heads and blown head gaskets from overheating, Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023), 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping. Of these, 7 are rated critical and should be addressed promptly.
The 1999 Ford Explorer has 13 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 7 issues are rated critical: 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 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping and Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Automatic transmission overdrive failure (A4LD / 4R55E) and 4.0L SOHC timing chain cassette, guide, and tensioner failure. 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 $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4.0L OHV cracked cylinder heads and blown head gaskets from overheating, typically costs $1,000-$2,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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 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.
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.
The 4-speed automatics behind the 4.0L - the early A4LD and the later electronically controlled 4R44E/4R55E - are a known weak point, commonly failing in the 120k-mile range, most often losing 4th gear (overdrive). The overdrive planetary is fragile (early units used a weaker pin… Repairs typically run $25-$3,500. Severity: high.
The 4.0L SOHC V6 (introduced in the Explorer for 1997) uses a complex three-chain system: a crank-to-jackshaft chain at the front plus two cam chains at the rear of the engine, all riding on plastic guide 'cassettes' with hydraulic/spring tensioners. The plastic cassettes and the… Repairs typically run $400-$3,000. Severity: high.
On 4.0L Explorers (both the OHV Cologne and the later SOHC V6) P1506 is a common high-idle complaint on higher-mileage trucks. The idle air control valve sits on the throttle body and meters bypass air around the closed throttle plate. Crankcase vapour routed through the PCV syst… Repairs typically run $120-$420. Severity: medium.
The 4.0L SOHC V6 is notorious for lean-bank codes P0171 and P0174 caused by unmetered air leaks rather than a dirty MAF. The plastic upper intake manifold and its rubber O-ring gaskets, plus the heat-degraded PCV elbow/hose near the throttle body, crack and collapse under vacuum,… Repairs typically run $120-$600. Severity: medium.
The 4.0L V6 uses a camshaft synchronizer (a gear-driven cylindrical housing that also drives the oil pump intermediate shaft) with the camshaft position sensor mounted on top. The plastic vane/'flag' on the synchronizer and the sensor's internal magnet wear or come apart, manglin… Repairs typically run $150-$500. Severity: medium.
The 4.0L (both OHV and SOHC) drives the camshaft position sensor off a gear-driven 'synchronizer' assembly in place of a conventional distributor. The synchronizer's shaft/bushing wears or gums up with varnish, developing play and producing a distinctive squeak/chirp that is ofte… Repairs typically run $150-$500. Severity: medium.
The Differential Pressure Feedback EGR (DPFE) sensor on the 4.0L/4.6L Explorer has a very high failure rate past ~60k miles. Internal corrosion makes it under-report EGR flow, so the PCM sets P0401 (insufficient EGR flow) and can hold the EGR valve open too long, producing a lean… Repairs typically run $80-$350. Severity: low.
The cable-drive window regulators on the Explorer/Mountaineer/Sport Trac fail as their plastic cable guides crack and the steel lift cable frays or jumps off the drum. The window then binds, drops crooked, or falls down inside the door — the motor often still runs. The front door… Repairs typically run $120-$400. Severity: low.
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.
