Ford · Known Issues
1991-2027 Ford Explorer Problems: 74 Known Issues
1991-2027 model years · 4,880+ owner reports · Updated October 2026
All years · All trims · All engines
Choose the year and equipment for your written issues and visual request.
1991-2027 model years · 4,880+ owner reports · Updated October 2026
All years · All trims · All engines
Choose the year and equipment for your written issues and visual request.
According to Au7o's analysis of 4,880+ owner reports, the 1991-2027 Ford Explorer has 74 documented known issues, with 39 rated critical. The most serious are Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) ($0-$500 repair), 3.5L Internal Water Pump Failure ($1,500-$8,000 repair), Rear axle mounting bolt can fracture — recall 23V675, Electric Power Steering Failure ($1,700-$3,700 repair), 2.3L EcoBoost Turbocharger Oil Supply Line O-Ring Leak and Under-Hood Fire Risk (Recall 23V597) ($0-$0 repair), Piston Circlip Recall: Possible Engine Damage and Loss of Drive Power (26V205 / 26S23) ($0-$0 repair), Trailer hitch bolts may be under-torqued — recall 25V687, Trailer Tail Lights Fail to Illuminate — Improperly Manufactured Body Control Module C ($0-$0 repair), Second-row easy-entry switch can stick, seat may tip or slide — recall 26V451, Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk, Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) ($0-$900 repair), Front wiper motor can stop working — recall 26V117, Seat-belt buckle anchor bolts may be loose — recall 25V093, Second-row outer seat-belt lower anchors may be loose — recall 26V159, .
HYBRID PROPULSION SYSTEM
Ford Motor Company (Ford) is recalling certain 2024 Ford Explorer vehicles equipped with 3.3L Hybrid engines. The 12-Volt battery cable may chafe against the Belt-integrated Starter Generat (BiSG) and short circuit.
EQUIPMENT:OTHER:LABELS
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
SEATS:MID/REAR ASSEMBLY
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator, and Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, folding, or sliding unexpectedly while driving.
BACK OVER PREVENTION:SOFTWARE
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
TRAILER HITCHES
Ford Motor Company (Ford) is recalling certain 2024-2026 Explorer and 2024-2026 Lincoln Aviator vehicles. The trailer hitch assembly bolts may be loose.
+ 36 more recalls. Check all on NHTSA.gov
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's analysis of 4,880+ owner reports, the 1991-2027 Ford Explorer has 74 documented issues. The most frequently reported are: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), 3.5L Internal Water Pump Failure, Rear axle mounting bolt can fracture — recall 23V675. Of these, 39 are rated critical and should be addressed promptly.
The 1991-2027 Ford Explorer has 74 known issues documented across 4,880+ owner reports. 39 issues are rated critical: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) and 3.5L Internal Water Pump Failure and Rear axle mounting bolt can fracture — recall 23V675 and Electric Power Steering Failure and 2.3L EcoBoost Turbocharger Oil Supply Line O-Ring Leak and Under-Hood Fire Risk (Recall 23V597) and Piston Circlip Recall: Possible Engine Damage and Loss of Drive Power (26V205 / 26S23) and Trailer hitch bolts may be under-torqued — recall 25V687 and Trailer Tail Lights Fail to Illuminate — Improperly Manufactured Body Control Module C and Second-row easy-entry switch can stick, seat may tip or slide — recall 26V451 and Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk and Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) and Front wiper motor can stop working — recall 26V117 and Seat-belt buckle anchor bolts may be loose — recall 25V093 and Second-row outer seat-belt lower anchors may be loose — recall 26V159 and PCM reset may have damaged the park system — recall 23V069 and 2.3L connecting rod bearing may seize — recall 26V532 and 2.3L piston domes may crack — recall 26V548 and Windshield may not be properly bonded — recall 26V024 and Passenger air bag vent may not open — recall 26V581 and 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2) and 5R55E Automatic Transmission Reverse Loss and Forward Clutch Slipping and Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk and Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) and Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Hard / Dropping Brake Pedal and Loss of Braking Reported on 2025 Explorer and Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction and Power Transfer Unit (PTU) overheating and bearing failure on AWD models and Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk and Rear Driveshaft Weld-Seam Fracture (Recall 20V693000 / 20S65) and Rear Suspension Toe Link Ball Joint Corrosion and Fracture Causing Loss of Steering Control (Recall 21V537 / 19S17-21S32) and EGR Valve Poppet Head Detachment Causing Unexpected Loss of Drive Power (Recall 26V122) and Engine Failure Requiring Long Block Replacement (Recall 26V343 / Ford 26S35) and Powertrain Control Module Reset Damaging Park System, Causing Rollaway or Engine Stall (Recall 25V239 / 25S35) and Automatic transmission overdrive failure (A4LD / 4R55E) and 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse and 4.0L SOHC timing chain cassette, guide, and tensioner failure and Timing Chain Cassette and Guide Failure on 4.0L SOHC V6 and Throttle Body Failure on 4.6L V8 Causing Wrench Light, Limp Mode, and Sudden Loss of Power. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Explorer issues range from $0 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), typically costs $0-$500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Reliability varies across model years of the Ford Explorer. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1991-2027 Ford Explorer with 74 documented issues documented across 4,880+ owner reports.
NHTSA opened an investigation in July 2016 into 2011-2017 Ford Explorer carbon monoxide intrusion after 6,500+ complaints, 657 alleged injuries, and 3 deaths. After 6 years of testing, NHTSA closed the investigation in January 2023 WITHOUT a recall — agency findings concluded tha… Repairs typically run $0-$500. Severity: high.
The 3.5L V6 engine (both naturally aspirated and EcoBoost versions) features an internal water pump located under the engine front cover. When this pump fails, it can leak coolant internally into the engine crankcase, contaminating the oil and potentially causing catastrophic eng… Repairs typically run $1,500-$8,000. Severity: high.
The rear axle horizontal mounting bolt can fail from fatigue after repeated peak-torque launches, letting the axle housing move out of position with loud grinding or clunking. If it breaks, the driveshaft or halfshafts can disconnect, causing loss of drive and, without the parkin… Severity: high.
An intermittent connection in the electric power steering gear can cause the electric power steering assist system to shut down unexpectedly while driving. This results in significantly increased steering effort required, which can be dangerous especially at low speeds during par… Repairs typically run $1,700-$3,700. Severity: high.
A small population of 2023 Explorers with the 2.3L EcoBoost engine may have a torn or cut turbocharger oil supply line O-ring. The damaged O-ring can let pressurized engine oil escape and contact a hot engine, increasing the risk of an under-hood fire; oil loss can also cause an… Repairs typically run $0-$0. Severity: high.
Ford recall 26V205000 / 26S23 includes 210 specific 2026 Explorers with the 2.3L engine, built February 17-26, 2026. Missing or incorrectly installed piston circlips can cause piston failure, engine damage and loss of propulsion. Increasing knocking is a reported possible warning… Repairs typically run $0-$0. Severity: high.
Bolts attaching the trailer tow hitch may be below specified torque because the line operator did not complete the bolt secure. Towing handling can suffer and, in the worst case, the hitch can detach while towing; a rattle from the rear may be the warning. Applies to: 1,237 speci… Severity: high.
On 213,121 2025 Explorers and Aviators, an improperly manufactured Body Control Module C fails to drive the trailer lighting circuit, so a connected trailer's tail lights do not illuminate. Ford recalled these vehicles under NHTSA 25V543000 (Ford 25C42) in August 2025. The traile… Repairs typically run $0-$0. Severity: high.
The bezel around the second-row outboard easy-entry (tip-and-slide) switch can become misaligned or unseated, letting the switch bind or stick down. The seat can then tip or slide unexpectedly, possibly while driving, increasing injury risk in a crash. With the button stuck down,… Severity: high.
NHTSA safety recall 91V189000 covers automatic-transmission-equipped 1991 Ford Explorers in which the park pawl does not always abut or engage the park gear when the shift lever is moved into Park. Because the lever still moves into the Park detent, an Explorer owner can shut the… Severity: high.
The 1995-2001 Explorer was factory-fitted with P235/75R15 Firestone Radial ATX, ATX II and Wilderness AT tires that suffered tread-belt separation, especially in hot climates and when underinflated to Ford's low placard pressure. A rear tread separation at highway speed frequentl… Repairs typically run $0-$900. Severity: high.
The front windshield wiper motor cover terminal may be misaligned with the brush-card terminal, causing loss of electrical continuity over time. Wipers can work intermittently and then stop completely, reducing visibility and increasing crash risk. Applies to: Certain 2020–2022 F… Severity: high.
Seat-belt buckle anchor bolts at one or more seating positions, and the second-row center belt and retractor anchor bolts if equipped, may not have been secured during seat assembly. A loose belt or buckle may not restrain an occupant properly in a crash. Applies to: Certain 2020… Severity: high.
On a small number of Explorers, the left and/or right second-row seat-belt lower anchor may not be secured to the body because of an incomplete repair at the assembly plant. A loose anchor may not restrain an occupant properly in a crash; a rattle may be the only warning. Applies… Severity: high.
A connected-vehicle data request could overflow a powertrain control module buffer and reset the PCM, which shifts the transmission to Park; if that happened while moving, the park system may be damaged. A damaged park system may not shift into Park, allowing unintended vehicle m… Severity: high.
A connecting rod bearing may seize, causing engine failure and loss of motive power; an engine block breach can also raise fire risk. An engine knocking noise may come before the failure. Ford says the cause is still under investigation. Applies to: 6 specific 2026 Ford Explorers… Severity: high.
A supplier machining fault may have cracked pistons at the Ni-Resist ring insert, which can lead to piston dome failure and loss of motive power. Warnings can include the check-engine light, engine noise or misfire. Applies to: 3,071 specific 2026 Ford Explorers with the 2.3L eng… Severity: high.
An equipment failure at the assembly plant may have left improperly applied urethane between the windshield and its frame, so the windshield may not stay retained in a crash and the vehicle may not meet FMVSS 212. Increased wind noise or water leaks can be signs. Applies to: 8 sp… Severity: high.
The active vent on the passenger air bag may not open as intended in a crash that deploys it, leaving a higher-pressure cushion against the occupant and increasing injury risk. Ford lists no warning. Applies to: 7 specific 2026 Ford Explorers built August 2, 2026 (recall 26V581,… Severity: high.
The optional 4.6L 2-valve modular V8 (shared with the Mercury Mountaineer) has aluminum heads that engage only a few spark-plug threads (~0.25 in). Under thermal cycling the plug can strip the threads and eject from the head, sometimes blowing out the coil boot with it. Ford ackn… Repairs typically run $150-$1,500. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
