1994 Ford Explorer Problems: 4 Known Issues
1994 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1994 Ford Explorer has 4 documented known issues, with 3 rated critical. The most serious are Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (NHTSA EA00-023) ($0-$900 repair), Frame, rear subframe, and rocker/body-mount rust ($200-$3,000 repair) and Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 repair). Across all issues with published estimates, repair costs range from $25 to $3,500. DIY maintenance guides at au7o.io.
1994 · XLT · All engines
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All 4 Known Issues
NHTSA Recalls27 recalls
EXTERIOR LIGHTING
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
EXTERIOR LIGHTING:HEADLIGHTS
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
FUEL SYSTEM, GASOLINE
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
VEHICLE SPEED CONTROL
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
EXTERIOR LIGHTING
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
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Frequently Asked Questions
What are the most common Ford Explorer problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1994 Ford Explorer has 4 documented issues. The most frequently reported are: Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (NHTSA EA00-023), Frame, rear subframe, and rocker/body-mount rust, Automatic transmission overdrive failure (A4LD / 4R55E). Of these, 3 are rated critical and should be addressed promptly.
Is the Ford Explorer reliable?
The 1994 Ford Explorer has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 3 issues are rated critical: Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Automatic transmission overdrive failure (A4LD / 4R55E). 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.
How much does it cost to fix common Ford Explorer problems?
Repair costs for known Ford Explorer issues range from $0 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (NHTSA EA00-023), typically costs $0-$900 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 1991-2001 Ford Explorer Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (NHTSA EA00-023)?
The 1991-2001 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.
What is the 1991-1999 Ford Explorer Frame, rear subframe, and rocker/body-mount rust?
In salt-belt climates, 1991-1999 Explorers rot in predictable structural areas: the inner rocker panels, the tops of the front hangers of the rear leaf springs (dirt packs between the hanger and inner rocker, which the factory welded only at the bottom), rear spring hangers/shack… Repairs typically run $200-$3,000. Severity: high.
What is the 1991-1997 Ford Explorer Automatic transmission overdrive failure (A4LD / 4R55E)?
The 4-speed automatics behind the 4.0L - the early A4LD and the later electronically controlled 4R55E - are a known weak point, commonly failing in the 120k-mile range, most often losing 4th gear (overdrive). The overdrive planetary is fragile (early units used a weaker pinion de… Repairs typically run $25-$3,500. Severity: high.
What is the 1993-1999 Ford Explorer Camshaft synchronizer / CMP sensor bushing failure?
The 4.0L (both OHV and SOHC) drives the camshaft position sensor off a gear-driven 'synchronizer' assembly in place of a conventional distributor. The synchronizer's shaft/bushing wears or gums up with varnish, developing play and producing a distinctive squeak/chirp that is ofte… Repairs typically run $150-$500. Severity: medium.
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.