Ford · Known Issues
2016 Ford Explorer Problems: 21 Known Issues
2016 model year · 3,179+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2016 model year · 3,179+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
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According to Au7o's analysis of 3,179+ owner reports, the 2016 Ford Explorer has 21 documented known issues, with 5 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), Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) ($0-$1,200 repair), Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction ($2,000-$4,000 repair) and Power Transfer Unit (PTU) overheating and bearing failure on AWD models ($1,500-$3,100 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.
BACK OVER PREVENTION: SENSING SYSTEM: CAMERA
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
EQUIPMENT:OTHER:LABELS
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
SUSPENSION:FRONT:MACPHERSON STRUT
Ford Motor Company (Ford) is recalling certain 2023 Explorer vehicles. The right-front lower fastener connecting the steering knuckle and strut may be loose or missing.
BACK OVER PREVENTION: SENSING SYSTEM: CAMERA
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
POWER TRAIN:AUTOMATIC TRANSMISSION
Ford Motor Company (Ford) is recalling certain 2022-2023 F-150, Mustang, Explorer, Bronco, and 2023 Lincoln Aviator vehicles equipped with automatic transmissions. The transmission may contain a loose bolt which could prevent the transmission from engaging the park gear, although the gear shifter position may indicate that the vehicle has been shifted to "PARK."
+ 44 more recalls. Check all on NHTSA.gov
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According to Au7o's analysis of 3,179+ owner reports, the 2016 Ford Explorer has 21 documented issues. The most frequently reported are: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), 3.5L Internal Water Pump Failure, Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007). Of these, 5 are rated critical and should be addressed promptly.
The 2016 Ford Explorer has 21 known issues documented across 3,179+ owner reports. 5 issues are rated critical: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) and 3.5L Internal Water Pump Failure and Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) 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. 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.
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.
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.
On the 2011-2019 transverse Explorer, Ford located the water pump INSIDE the engine, behind the timing cover, driven off the primary timing chain. When the pump's internal shaft seal fails, coolant first weeps from a passage on the passenger side of the block, but if ignored (or… Repairs typically run $2,000-$4,000. Severity: high.
AWD Explorers use a compact Power Transfer Unit bolted to the transaxle that sends drive to the rear wheels. It holds only ~300-400ml of 'lifetime fill' fluid and sits next to the exhaust, so heat cooks the fluid and it degrades well before 100k miles. Once the fluid breaks down,… Repairs typically run $1,500-$3,100. Severity: high.
The Power Transfer Unit (PTU) on AWD-equipped Explorers is prone to premature failure due to its proximity to the exhaust pipe and catalytic converter, causing overheating. Fluid leaks from disconnected vent hoses are common, and if fluid level drops too low, the PTU can fail com… Repairs typically run $400-$2,200. Severity: medium.
3.5L EcoBoost-equipped Explorers (Sport, Platinum, and Police Interceptor Utility) commonly develop a rattling/knocking noise for 1-3 seconds on cold start-up caused by worn variable camshaft timing (VCT) phasers. The phaser lock pins fail to hold the cam sprockets in position af… Repairs typically run $1,800-$3,500. Severity: medium.
Owners report repeated dead batteries from a parasitic draw that exceeds Ford's ~50 mA key-off spec; affected Explorers have measured ~200 mA, killing a battery in about three days of sitting. Culprits traced on the forums include the in-vehicle WiFi hotspot/modem module, the API… Repairs typically run $100-$600. Severity: medium.
The 2011+ transverse Explorer switched to the 6F50/6F55 six-speed automatic, which is widely reported for a sluggish 0-5 mph roll-out followed by a harsh 'bump' or clunk, plus torque-converter shudder and occasional shift flare. Ford addressed the low-speed bump with TSB 11-12-10… Repairs typically run $150-$3,500. Severity: medium.
Explorer owners frequently report the A/C compressor failing internally, leaving the system unable to produce cold air. A failing compressor can seize or shed metal debris, sometimes accompanied by a whining noise and a burning smell. When the compressor comes apart it can contam… Repairs typically run $800-$1,600. Severity: medium.
The door latch assembly contains the ajar sensor and lock actuator; when the latch/actuator fails, the vehicle thinks a closed door is open. This produces a 'Door Ajar' message that won't clear, interior lights that stay on (parasitic battery drain and dead batteries), an alarm t… Repairs typically run $80-$450. Severity: medium.
Ford recalled approximately 1.9 million 2011-2019 Explorers because the exterior A-pillar trim applique (the molding flanking the windshield) may not be properly secured—the retention clips can be unengaged due to improper assembly or prior repair—allowing the trim to detach duri… Repairs typically run $0-$0. Severity: medium.
First-generation gasoline direct-injection (GTDI) EcoBoost engines in the Explorer spray fuel directly into the cylinder, so no fuel washes the backs of the intake valves. Oil vapor and debris from the PCV system bake onto the valves over time, forming carbon deposits that restri… Repairs typically run $400-$800. Severity: medium.
Explorers equipped with the dual-panel/panoramic moonroof are widely reported to leak water into the cabin and, less often, to have the tempered roof glass spontaneously shatter ('exploding sunroof'). Leaks typically present as water dripping from the overhead console / map-light… Repairs typically run $0-$1,500. Severity: medium.
The aluminum A/C lines running to the rear evaporator corrode and crack, leaking out the refrigerant. Ford's design uses a loose slip-over thermal wrap that traps sand, grit and moisture against the aluminum tubing, accelerating corrosion and rock-strike damage—especially at the… Repairs typically run $600-$2,200. Severity: medium.
Explorers (especially the Sport and Platinum) with the twin-turbocharged 3.5L EcoBoost are widely reported to develop cylinder misfires, a flashing check-engine light, rough idle and a loss of power that owners frequently chase by replacing ignition coils and spark plugs. The tur… Repairs typically run $120-$900. Severity: medium.
The temperature/blend door actuator is a very common failure on the Explorer (shared with Taurus, Flex and Lincoln MKS/MKT). The actuator's internal plastic gears strip, producing a repeated clicking or knocking sound behind the dash and leaving the cabin stuck on hot or cold, or… Repairs typically run $25-$350. Severity: low.
A very common check-engine cause on the Explorer is an EVAP small-leak code, most often from a stuck or leaking canister purge valve, but also from the capless fuel filler seal, vent valve, or a loose/faulty gas cap. The purge valve controls fuel-vapor flow from the charcoal cani… Repairs typically run $150-$350. Severity: low.
The aluminum hood (and to a lesser extent other aluminum panels) develops paint bubbling, blistering and flaking, most often along the leading edge of the hood. The defect is attributed to iron particle contamination of the aluminum panel before paint, which corrodes from within… Repairs typically run $500-$1,500. Severity: low.
The Explorer's HVAC blower motor resistor commonly fails, leaving the fan working only on the highest speed (which bypasses the resistor) or operating intermittently. The typical root cause is an aging blower motor drawing excessive current, which overheats the resistor and melts… Repairs typically run $150-$350. 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.