2001 Ford Explorer Problems

A failed heater blend door or actuator can cause the temperature control for the HVAC system to stop working. A clicking sound from the dash area would commonly indicate an actuator fault. If the heater gets stuck on the hottest setting, the heater blend door may be broken requiring replacement of the heater box to repair the issue.

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 Ford Explorer is known for a rough idle, engine stalling, loss of power, and misfires, accompanied by the check engine light.

The intake manifold O-ring gaskets commonly leak, which creates a large vacuum leak. This vacuum leak causes unmetered air to enter the engine, and the fuel system becomes insufficient to compensate for the large amount of air reaching the engine. 

Replacing the intake manifold gaskets corrects this concern.

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

A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.

The 1997-2001 Ford Explorer V8 with a 100% plastic intake manifold  is known for engine overheating, even with normal use, and a coolant leak from the front of the manifold. This will often trigger the check engine light and low engine coolant warning light.

The engine coolant leak is from a factory defect, which causes cracking on the front coolant passage of the intake manifold. In a very short time, this leak will lead to engine overheating issues, especially while the vehicle is idling.   

Between 1999 and 2001, Ford released an updated version of this engine, known as the 'PI' version with a metal coolant passage on the front of the intake manifold, to prevent future issues.

There is no factory authorized repair for the intake manifold, and replacement is required to correct the engine coolant leak and overheating issues.

The Ford Explorer with the optional 5.0L/302ci V8 may develop misfires, rough running, and loss of power, accompanied by the check engine light illuminating.

Ignition wires can rest on the exhaust manifolds if they are not properly secured. The hot manifolds will melt the insulation on the wires, damaging the wires and causing the mentioned condition. 

Replacement of the ignition wires, and securing them away from the exhaust manifold is necessary to remedy the rough running conditions. 

The rear window wiper may not fully contact the rear window. Our technicians tell us that replacing both the wiper blade and wiper arm will generally correct this issue.

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.

The rear wiper may stop working. This could be due to a rear wiper motor that has failed requiring replacement.

4wd vehicles may develop a squealing noise coming from the front wheels when driving below 30 mph. This is generally caused by dry excluder seals, lubricating the seals will commonly correct this concern.