A cosmetic crack may develop on the plastic liftgate trim panel. Ford has released a service procedure to replace the applique without damage the the liftgate glass.
Problems for specific Ford Explorer years:
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Most reported 2005 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.
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.
Rear diferential making loud whining noises at higher speeds. pinion and ring gear were replaced, happened on my 99 Explorer too
lost oil pressure while driving engine was full of oil and no leaks. pulled motor to take a look at the oil pump and drive (and to check bearings after loosing pressure) every thing looked new so went to top side of engine and pulled out oil pump drive which installs were the distributer belongs and drives off the jackshaft (camshaft) to run the oil pump. when i removed the oil pump drive it was as plain as day the gear had worn into the housi...
heater blows cold air even after letting warm up before driving after 6miles starts to get warm but not hot