2010 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2010 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2010 Ford Explorer has 9 documented known issues, with 4 rated critical. The most serious are Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk ($0-$250 repair), 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse ($900-$3,500 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). Across all issues with published estimates, repair costs range from $40 to $4,500. DIY maintenance guides at au7o.io.
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.
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.
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."
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.
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.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2010 Ford Explorer has 9 documented issues. The most frequently reported are: Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk, 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse, Timing Chain Cassette and Guide Failure on 4.0L SOHC V6. Of these, 4 are rated critical and should be addressed promptly.
The 2010 Ford Explorer has 9 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 4 issues are rated critical: Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk and 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse 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 $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk, typically costs $0-$250 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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.
A very common failure on third- and fourth-generation Explorers with the 5R55W/5R55S automatic is wear in the overdrive and intermediate servo bores inside the transmission case. As the bores wear, hydraulic pressure leaks past the servo pistons, leading to 2-3 flare, 3-5 flare,… Repairs typically run $900-$3,500. Severity: high.
The 4.0L SOHC Cologne V6 is notorious for timing chain guide and cassette failures, especially the rear cassette that is difficult to access with the engine installed. Plastic guide material breaks down over time, causing startup rattle, persistent chain noise, cam timing errors,… Repairs typically run $1,800-$4,500. Severity: high.
Later 4th-generation Explorers with the 4.6L 3-valve V8 commonly suffer electronic throttle body problems. Owners report the wrench light illuminating, the vehicle abruptly entering fail-safe mode, and the engine losing throttle response or dropping to idle while driving. This is… Repairs typically run $350-$900. Severity: high.
Rear wheel bearing and hub assemblies are a frequent wear/failure item on independent rear suspension Explorers from this period. Owners commonly report a humming or growling noise that increases with road speed and can be mistaken for tire noise or differential problems. In some… Repairs typically run $250-$700. Severity: medium.
The independent front suspension on the 2002-2010 Explorer/Mountaineer uses upper control arms with pressed-in ball joints that wear out relatively early. Worn upper (and lower) ball joints produce a clunk over bumps, vague/loose steering, and cupped or inner-edge tire wear. On t… Repairs typically run $250-$750. Severity: medium.
The fourth-generation (U251) Explorer commonly develops front lower ball joint and control-arm-bushing wear, producing a clunk or pop over bumps and during low-speed (parking-lot) maneuvers, along with vague steering and uneven tire wear. The ball joint is integrated into the low… Repairs typically run $150-$700. Severity: medium.
The 2002-2010 Explorer/Mountaineer/Sport Trac door handles use brittle plastic pivot pieces in the latch/handle mechanism. The exterior handle typically cracks first and jams the linkage, then the interior handle snaps when forced. Owners are eventually left with doors that won't… Repairs typically run $40-$300. 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.
