Ford Explorer problems and known issues

By CarWhere Research · Updated

The 2011–2019 Explorer’s best-documented problems are exhaust odor in the cabin (a federal investigation and Ford’s free 17N03 service), the 3.5L V6’s internal water pump, AWD power transfer unit leaks and a 1.19-million-vehicle rear toe link recall. The 2020-on Explorer is defined by launch-era recalls, led by the rear axle bolt campaign.

CarWhere lists 8 documented Explorer issues, including 5 NHTSA safety recalls, each with affected years, engines, symptoms, pre-purchase checks and a source.

Explorer generations at a glance

Ford Explorer generations and the known issues listed for each
GenerationModel yearsIssues on this page
5th gen2011–2019Exhaust odor in the cabin (2011–2017) · Internal water pump failure on the 3.5L V6 · AWD power transfer unit (PTU) leaks and overheating · Rear suspension toe link fracture recall · Loss of power steering assist (2011–2013)
6th gen2020–presentRear axle mounting bolt fracture (driveshaft disconnect) · Rear lower control arm bolts not heat-treated · 2.3L/10R60 park system damage from PCM reset

5th gen Explorer problems (2011–2019)

Exhaust odor in the cabin (2011–2017) (2011–2017)

Moderate
Generation:
5th gen (2011–2019)
Years:
2011–2017
Engine:
All engines

NHTSA opened a preliminary evaluation in 2016 and upgraded it to Engineering Analysis EA 17-002 in July 2017, covering an estimated 1.33 million 2011–2017 Explorers after owners reported smelling exhaust in the cabin. The investigation also examined cracked exhaust manifolds found on Police Interceptor versions. In October 2017 Ford offered retail owners a complimentary service that included rear-end body sealing and an HVAC recalibration; Ford stated the vehicles were safe.

Symptoms

  • Exhaust or sulfur smell inside the cabin, most often under hard acceleration with the A/C in recirculate
  • Headache or nausea reported by occupants on longer drives
  • Odor strongest from the rear cargo area

Check before buying

  • Ask for dealer records showing the 17N03 service (or later liftgate drain/HVAC updates) was completed
  • Test drive with the HVAC on recirculate and accelerate hard; note any exhaust smell
  • Inspect the liftgate weatherstrip, liftgate drain valves and any aftermarket parts mounted on the liftgate spoiler

Sources: [1][2]

Internal water pump failure on the 3.5L V6 (2011–2019)

Major repair
Generation:
5th gen (2011–2019)
Years:
2011–2019
Engine:
3.5L Ti-VCT V6 (non-turbo)

The naturally aspirated 3.5L V6 uses a water pump mounted inside the engine and driven by the timing chain. When its seal fails, coolant can leak internally into the oil, and a class action (since dismissed after a settlement with the named plaintiffs only) alleged this can destroy the engine. Replacing the pump is labor-intensive because the front of the engine must be opened.

Symptoms

  • Coolant level dropping with no visible external leak
  • Milky or tan sludge on the oil cap or dipstick
  • Sweet coolant smell or seepage near the weep hole behind the accessory drive
  • Overheating or a rough-running engine

Check before buying

  • Pull the dipstick and oil cap and look for milky contamination
  • Ask whether the water pump and timing chain were ever replaced and get the invoice
  • Have a shop run a cooling-system pressure test and oil analysis on higher-mileage examples

Reported repair cost: Lawsuit alleged about $1,500 in labor for the pump; up to $8,500 for a replacement engine[3]

Sources: [3]

AWD power transfer unit (PTU) leaks and overheating (2011–2019)

Moderate
Generation:
5th gen (2011–2019)
Years:
2011–2019
Engine:
AWD models (3.5L V6, 3.5L EcoBoost, 2.3L EcoBoost)

The power transfer unit that sends torque to the rear axle sits next to the exhaust, and owners report fluid leaks, burnt gear oil and failed units on AWD Explorers. Ford’s TSB 18-2255 addresses a right-side intermediate shaft seal leak on 2016–2018 2.3L EcoBoost Explorers that requires removing the PTU to repair.

Symptoms

  • Burning-oil smell after driving, sometimes with light smoke from the passenger side
  • Dark fluid drips near the right front of the transmission
  • Grinding, clunking or vibration on acceleration; AWD warning messages

Check before buying

  • Inspect the PTU and right-side intermediate shaft seal area on a lift for wet residue
  • Smell the PTU fill plug fluid; burnt, black oil means the unit has been overheated
  • Ask whether the PTU fluid has ever been changed or the unit replaced

Sources: [4][5]

Loss of power steering assist (2011–2013) (2011–2013)

Safety recall
Generation:
5th gen (2011–2019)
Years:
2011–2013
Engine:
All engines

An intermittent connection in the electric power steering gear can cut the motor position sensor signal and shut off steering assist. Ford recalled about 179,000 2011–2013 Explorers built through February 2012; the fix is a software update, with the steering rack replaced on vehicles that have a history of the fault.

Symptoms

  • Steering suddenly becomes heavy, especially at low speed
  • Power steering warning message on the dash

Check before buying

  • Confirm recall 14V-286 is closed on the VIN
  • Check for stored power steering module fault codes during the inspection

NHTSA recall: 14V-286 (2014-05) · 179,027 vehicles

Sources: [9]

6th gen Explorer problems (2020–present)

Rear axle mounting bolt fracture (driveshaft disconnect) (2020–2022)

Safety recall
Generation:
6th gen (2020–present)
Years:
2020–2022
Engine:
All rear-drive-based powertrains (2.3L, 3.0L EcoBoost, 3.3L, hybrid, PHEV)

The rear axle horizontal mounting bolt on 2020–2022 Explorers can fracture and let the driveshaft disconnect, causing loss of drive power or unintended rolling in Park if the parking brake is not set. The first remedy (22V-255) added a software change that applies the electronic parking brake in Park; follow-up recalls 23V-199, 23V-675 and 25V-166 added hardware repairs and fixed incorrect prior repairs.

Symptoms

  • Clunk from the rear when shifting into gear or accelerating
  • Sudden loss of drive power while the engine still runs
  • Vehicle rolling in Park on a slope

Check before buying

  • Confirm 22V-255, 23V-199, 23V-675 and 25V-166 show as completed on the VIN
  • Ask for the dealer invoice showing the rear axle bolt and subframe bushing were replaced
  • Listen for driveline clunks during the test drive

NHTSA recall: 23V-675 (2023-10) · 238,364 vehicles

Sources: [10][11][12][13]

Rear lower control arm bolts not heat-treated (2020)

Safety recall
Generation:
6th gen (2020–present)
Years:
2020
Engine:
All engines

Some 2020 Explorers were built with rear lower control arm bolts that may not have been heat-treated, which can let them break and affect handling. It is one of several early-production 2020 recalls tied to the redesign’s launch.

Symptoms

  • Clunking from the rear suspension
  • Rear wheel alignment change or pulling

Check before buying

  • Confirm recall 21V-154 is closed
  • On any 2020 Explorer, run the VIN for all open recalls; early builds carry several

NHTSA recall: 21V-154 (2021-03)

Sources: [14]

2.3L/10R60 park system damage from PCM reset (2020–2022, 2024)

Safety recall
Generation:
6th gen (2020–present)
Years:
2020–2022, 2024

On 2020–2022 Explorers with the 2.3L EcoBoost and 10R60 transmission, an unintended powertrain control module reset while driving can damage the park system, so the vehicle may not hold in Park. Ford issued a similar recall (26V-371) for 2024 models with the same powertrain.

Symptoms

  • Warning messages or brief loss of power followed by a restart of dash displays
  • Vehicle not staying put after shifting to Park

Check before buying

  • Confirm 23V-069 (2020–2022) or 26V-371 (2024) is closed
  • Always test that the vehicle holds in Park on an incline with the parking brake released

NHTSA recall: 23V-069 (2023-02)

Sources: [15][16]

Related Explorer research

This page explains specific mechanical issues and recalls. Which model years drew the most owner complaints is a different question, answered in the years-to-avoid research from NHTSA complaint counts.

Confirm exactly how a Explorer was built before you buy.

Engine, transmission and equipment decide which of these issues apply. The CarWhere build sheet decodes a Ford Explorer VIN into its factory record — powertrain, equipment groups and options as built. $9.99, instant.

Ford build sheet by VIN

Frequently asked questions

What are the most common Ford Explorer problems?

The best-documented Ford Explorer issues are exhaust odor in the cabin (2011–2017) (5th gen, 2011–2017), internal water pump failure on the 3.5L V6 (5th gen, 2011–2019) and AWD power transfer unit (PTU) leaks and overheating (5th gen, 2011–2019). Which ones matter depends on the generation and engine, so check the section for the exact truck or car you are looking at.

Has the Ford Explorer had any recalls?

Yes. Recalls covered on this page include rear suspension toe link fracture recall (NHTSA 19V-435), loss of power steering assist (2011–2013) (NHTSA 14V-286), rear axle mounting bolt fracture (driveshaft disconnect) (NHTSA 23V-675) and rear lower control arm bolts not heat-treated (NHTSA 21V-154). Recall repairs are free at a Ford dealer; check any specific vehicle’s VIN with NHTSA to see whether the work was completed.

What should I check before buying a used Explorer?

Ask for dealer records showing the 17N03 service (or later liftgate drain/HVAC updates) was completed. Pull the dipstick and oil cap and look for milky contamination. Inspect the PTU and right-side intermediate shaft seal area on a lift for wet residue. A pre-purchase inspection by an independent mechanic covers these and should include a scan for stored fault codes.

Is the Ford Explorer reliable?

Most well-known Explorer problems are tied to a specific generation, engine or transmission rather than the model as a whole, and many have a published fix, updated part or recall remedy. Owner-complaint volume by model year is tracked separately in CarWhere’s years-to-avoid research.

Sources

Issue descriptions are CarWhere’s own summaries of the sources below. Repair costs are shown only where a source states them and vary by shop and region.

  1. ODI Resume EA 17-002: Ford Explorer exhaust odor — NHTSA
  2. Ford announces complimentary service for 2011–17 retail Explorer — Ford Motor Company
  3. Ford Water Pump Class Action Lawsuit Dismissed — CarComplaints.com
  4. TSB 18-2255: AWD right side transfer case fluid leak — Ford Motor Company (via NHTSA)
  5. Ford Explorer power transfer unit owner complaints — CarComplaints.com (secondary reference)
  6. NHTSA recall 19V-435: rear suspension toe link may fracture — NHTSA
  7. NHTSA recall 26V-101: rear toe links may fracture (2017–2019) — NHTSA
  8. NHTSA recall 21V-537: corroded toe link ball joint, salt states — NHTSA
  9. NHTSA recall 14V-286: loss of electric power steering assist — NHTSA
  10. NHTSA recall 23V-675: rear axle horizontal mounting bolt may fracture — NHTSA
  11. NHTSA recall 22V-255: rear axle bolt / parking brake update — NHTSA
  12. NHTSA recall 23V-199: rear axle bolt and park-brake software — NHTSA
  13. NHTSA recall 25V-166: remedy repaired incorrectly under 23V-199 or 22V-255 — NHTSA
  14. NHTSA recall 21V-154: rear lower control arm bolts may break — NHTSA
  15. NHTSA recall 23V-069: PCM reset may damage park system (2.3L, 10R60) — NHTSA
  16. NHTSA recall 26V-371: PCM reset may damage park system (2024 2.3L) — NHTSA

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Independent reference compiled by CarWhere — not affiliated with or endorsed by Ford Motor Company. Ford, Power Stroke, EcoBoost, Coyote and the model names are trademarks of their owner.