Ford Explorer Years to AvoidThe weakest years — and the one you should buy instead

The 5R55E automatic transmission, particularly in V6 models, is notorious for failing prematurely. Common issues include solenoid pack failure, valve body wear, delayed shifts, slipping gears, and complete loss of drive. This is often due to poor internal design and inadequate cooling.

The lower ball joints on the front suspension are a widespread and dangerous failure point, often leading to wheel separation. This issue was subject to multiple TSBs and even a 'special warranty' program due to its severity, indicating a fundamental design flaw.

The 4.0L SOHC V6 engine is prone to timing chain guide failures, particularly on the rear bank. This manifests as a loud rattle or whine from the engine, and if neglected, can lead to severe engine damage or complete failure. The repair is labor-intensive and expensive.

The 5R55E transmission, common in V6 models, is notoriously problematic. Failures include shift solenoid packs, valve body issues, and premature wear leading to slipping gears or complete loss of drive. Often, a full rebuild or replacement is required.

The 4.0L SOHC V6 engine suffers from plastic timing chain guides that can break, causing chains to slap, jump timing, or even lead to catastrophic engine failure. Repair requires extensive engine disassembly, making it very expensive.

Frame rust, especially around suspension mounting points, is common in regions that use road salt. Body rust often appears on rocker panels, wheel wells, and the tailgate, compromising structural integrity and aesthetics.

The A4LD automatic transmission is notoriously prone to premature failure, often exhibiting slipping gears, delayed engagement, or complete loss of drive. Overheating, neglected fluid changes, and worn internal components (bands, clutches, solenoids) are common culprits.

For a vehicle of this age, rust is a pervasive issue. The frame, especially around mounting points, suspension components, rocker panels, wheel wells, and fuel tank straps are highly susceptible. Structural integrity can be compromised, leading to significant safety concerns and costly repairs.

Common electrical gremlins include failing power window motors, erratic door lock actuators, dim or inoperative dashboard illumination, and intermittent accessory power. Wiring harness deterioration and aged relays contribute to these issues.

The 5R55E automatic transmission, common with the V6 engines, is prone to valve body, solenoid pack, and internal clutch failures. Shift flares, delayed engagements, and eventually total failure are common, often requiring a rebuild or replacement.

The overhead cam (SOHC) version of the 4.0L V6 is infamous for prematurely failing plastic timing chain guides and tensioners, leading to excessive noise (rattling) and eventual catastrophic engine damage if not addressed. This is a complex, labor-intensive repair.

Given its age, rust is a widespread problem, particularly on the frame, body mounts, rocker panels, rear wheel arches, and tailgate. This can compromise structural integrity and make maintenance more difficult due to seized bolts.

The overhead cam (SOHC) V6 engine is notorious for timing chain guides/cassettes wearing out, causing severe rattling noises, oil starvation, and eventually catastrophic engine failure if neglected. This is a complex, engine-out repair.

The 5R55E automatic transmission is prone to hard shifts, delayed engagements, solenoid failures, and valve body issues, often leading to complete transmission failure. Shift quality degradation is a common precursor.

Significant rust issues affect the frame, especially in the rear sections, rocker panels, wheel wells, and tailgate. This can compromise structural integrity and make repairs difficult or impossible, particularly in salt-belt regions.

The overhead cam design utilizes plastic timing chain guides/cassettes that are prone to premature wear and failure. This can lead to loud rattling, timing chain jumping, and catastrophic engine damage. It's a design flaw, not just wear and tear.

This transmission is notorious for various issues including delayed shifts, slipping, harsh engagement, solenoid failures, and eventual complete failure. Valve body issues and worn internal components are common culprits, leading to expensive rebuilds or replacements.

Common problems include failures of power window motors/regulators, HVAC blend door actuators (resulting in no heat/AC direction control), and erratic behavior of the Generic Electronic Module (GEM) causing issues like 'door ajar' warnings or intermittent interior lighting.

The internal timing chain guides (especially the rear set) are prone to premature wear and failure, leading to a loud rattling noise and potential catastrophic engine damage if ignored. This is a design flaw that was never fully rectified.

Common issues include solenoid pack failure, leading to harsh shifting, slipping, or loss of gears. Valve body wear and internal clutch issues also contribute to transmission failure, often requiring a rebuild or replacement.

The frame, rear subframe, rocker panels, and wheel wells are highly susceptible to significant rust, particularly in areas exposed to road salt. This can compromise structural integrity and make maintenance difficult.

Internal clutch packs, solenoids, or pump issues lead to slipping, harsh shifts, or complete failure. Overheating is a major contributor to its demise.

Radiator leaks, water pump failure, and thermostat housing cracks are common due to age and plastic components, frequently leading to engine overheating if neglected.

Rear differential bearing failure and leaks are frequently reported, especially if fluid changes are neglected. Grinding noises or clunks often indicate a looming problem.

The 5R55W/S automatic transmission is infamous for premature failure, manifesting as slipping, delayed engagement, harsh shifts, and eventually complete loss of gears. This is often due to valve body and solenoid pack issues, leading to internal damage.

Severe rust is a prevalent issue, particularly on the frame rails, rocker panels, rear quarter panels, and suspension mounting points. This can compromise structural integrity and make maintenance tasks difficult or impossible.

The blend door actuator commonly fails, preventing proper temperature control or air direction (e.g., stuck on hot/cold, blowing only out of defrost). This is an uncomfortable and relatively common cabin issue.

The A4LD and later 4R44E/5R55E transmissions are prone to overheating, leading to premature wear of bands, clutches, and solenoids, often resulting in erratic shifting or complete failure. Overdrive band failure is common.

Significant rust can develop on the frame, suspension mounting points, rocker panels, wheel wells, and tailgate, especially in regions exposed to road salt. This compromises structural integrity and can lead to expensive, complex repairs.

The blend door actuator often fails, leading to a lack of temperature control (stuck on hot or cold), excessive noise from the dashboard, or improper air distribution. Repair involves extensive dashboard disassembly.

The 5-speed automatic transmission is notoriously problematic. Issues range from harsh shifts and slipping to complete failure, often stemming from solenoid pack issues, worn bands, or valve body problems. It's a critical and expensive failure point.

Rust is a severe issue, particularly in cold climates where road salt is used. Critical areas include the frame where lower control arms attach, leaf spring shackles, and body mounts. Severe corrosion here compromises safety and structural integrity.

The 4.0L SOHC V6 engine, while otherwise robust, is prone to timing chain guide and tensioner failures. This manifests as a loud rattling noise, especially on startup or during operation, and if ignored, can lead to catastrophic engine damage.

The 5R55 series automatic transmissions are notorious for solenoid pack failures, valve body issues, and internal wear leading to delayed shifts, slipping, or complete failure. Often starts with harsh 1-2 shifts or lack of reverse.

Lower ball joint separation (a safety concern that led to recalls in earlier models, still a high wear item), control arm bushings, tie rod ends, and wheel bearings are prone to premature wear, causing clunking, wandering steering, and uneven tire wear.

The plastic blend door actuator commonly fails, or the blend door itself breaks inside the dashboard, leading to either no heat/AC or only hot/cold air on one side. This requires extensive dash disassembly for repair.

The 4.0L SOHC V6 engine is notorious for timing chain guide wear and tensioner failure. This leads to a distinct rattling noise, especially on startup, and can result in catastrophic engine damage if not addressed. Repair involves extensive labor, often requiring engine removal.

The 5-speed automatic transmission is prone to solenoid body issues, valve body wear, and clutch pack degradation. Symptoms include harsh shifts, slipping, 'shift flare' between gears, and eventual total failure, particularly with neglected fluid changes.

Common failures include power window regulators (especially rear), HVAC blend door actuators leading to inconsistent cabin temperature, and occasional instrument cluster light malfunctions. These are more annoyances but can be costly to fix individually.

The 5R55S transmission is prone to solenoid body failures, delayed shifts, slipping, and harsh engagements, often requiring significant repair or replacement due to design weaknesses and wear.

Significant rust and corrosion on the frame, suspension components, brake lines, and fuel lines are common, especially in regions exposed to road salt, leading to structural integrity concerns and component failure.

The blend door actuators frequently fail, leading to improper temperature control (e.g., only hot or only cold air) or air only blowing from defrost vents. Repair is labor-intensive due to dash removal.

The 5-speed automatic transmission is prone to internal wear, solenoid pack failures, and delayed/harsh shifting. These issues often stem from inadequate fluid cooling and design flaws, leading to complete failure if not addressed.

The 4.0L V6 is notorious for premature wear of its plastic timing chain guides and tensioners, leading to rattling noises and eventual catastrophic engine damage if left unchecked. This is an engine-out repair.

Common electrical problems include faulty power window regulators, non-functional blend door actuators (affecting HVAC), and occasional issues with the instrument cluster or infotainment system.

The EPAS rack and pinion system is a widespread failure point, leading to a sudden loss of power steering. This is often caused by internal sensor or motor failures, requiring a complete replacement of the steering rack.

The 3.5L V6 engine features an internal water pump that, when it fails, leaks coolant directly into the engine's oil system. This can lead to rapid engine wear and catastrophic failure if not detected and addressed promptly.

On AWD models, the PTU is prone to premature fluid leaks and eventual failure if not serviced regularly. Overheating and lack of lubrication can cause internal component wear and binding.

The Power Transfer Unit (PTU) on AWD models is prone to fluid leaks, internal bearing failure, and premature wear, leading to grinding noises, vibrations, and eventual catastrophic failure if ignored. This is a common and expensive repair.

The 3.5L V6 engine's water pump is internally mounted, meaning a leak or failure can contaminate the engine oil, leading to timing chain damage and potentially engine seizure. Replacement requires significant labor and often includes timing chain components.

The MyFord Touch system is notorious for freezing, lagging, unresponsive screens, and Bluetooth connectivity issues, significantly detracting from the user experience. Additionally, the Electronic Power Assist Steering (EPAS) system can fail, leading to a loss of power steering.

Internal water pump failure on 3.5L V6 engines (non-EcoBoost) is a critical concern, often leaking internally and contaminating oil, leading to engine damage. The Power Transfer Unit (PTU) on AWD models is also highly prone to overheating and failure, manifesting as a loud whine or grinding.

The 6F55 6-speed automatic transmission is prone to harsh shifting, shuddering, hesitation, and occasional complete failure, often related to valve body issues or clutch pack wear. While some can be addressed with software updates, mechanical repairs are common.

MyFord Touch/SYNC infotainment system is notoriously glitchy, freezing, slow, or losing connectivity. Beyond that, A/C evaporator leaks are a widespread issue, requiring extensive dashboard disassembly for repair, leading to high labor costs.

Owners frequently report shuddering, harsh shifts, delayed engagements, and complete transmission failure. This often stems from valve body issues, torque converter problems, or worn internal components, necessitating costly rebuilds or replacements.

The water pump on the 3.5L V6 is internally mounted, meaning its failure can lead to coolant leaking into the oil or catastrophic engine damage. The repair is extremely labor-intensive, often requiring engine removal, leading to very high costs.

Reports of persistent water leaks from sunroof drains, A-pillars, or roof rails are common, leading to water in the footwells and potential damage to electrical modules, affecting everything from SYNC to power accessories.

The 10-speed automatic transmission is notorious for rough, jerky shifts, hesitation at low speeds, and occasional complete failures. These issues often stem from valve body problems, solenoid malfunctions, or software calibration. Many owners report inconsistent shifting behavior that significantly detracts from the driving experience.

Numerous complaints about the infotainment system freezing, going blank, or experiencing slow responses. Other electrical issues include random warning lights, parasitic battery drain, non-functional backup cameras (TSB 20-2216), and power liftgate malfunctions. These problems are often intermittent and difficult to diagnose.

Early models of this generation, including 2021, show signs of rushed production. Owners report misaligned body panels, poorly fitting interior trim pieces, rattles, and issues with weather stripping. Power liftgate motors can fail, leading to non-operation or excessive noise. Windshield cracking issues were also noted (TSB 20-2051).