Ford Explorer Problems

RepairPal has identified the most common problems with the Ford Explorer as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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32
Known Problems

Various problems with the 5-speed automatic transmission were common. These problems can be more common on the 2002 models with build dates before March, 2002. There are many service bulletins describing the diagnoses and repairs, which include fluid leak repairs, transmission software updates, or internal failures requiring a costly repair.

The intake manifold O-ring gaskets commonly leak, causing stalling and poor idle quality; the Check Engine Light will illuminate.

The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.

The Check Engine Light will illuminate and the engine will idle roughly when cold. There are updated upper intake manifold gaskets to resolve the problem.

A ticking noise may develop from the engine due to a cracked exhaust manifold. Damaged exhaust manifolds will require replacement to correct this issue.