2010 Ford Explorer Problems: 8 Known Issues

On the 2006-2010 Ford Explorer 4.6L V8, later 4th-generation Explorers with the 4.6L 3-valve V8 commonly suffer electronic throttle body problems. Owners report the wrench light illuminating, the vehicle abruptly entering fail-safe mode, and the engine losing throttle response or dropping to idle while driving. This issue is well documented across Ford products using similar electronic throttle bodies and is frequently associated with internal motor or throttle position sensor faults.

On the 2000-2010 Ford Explorer 4.0L SOHC V6, the 4.0L SOHC Cologne V6 is notorious for timing chain guide and cassette failures, especially the rear cassette that is difficult to access with the engine installed. Plastic guide material breaks down over time, causing startup rattle, persistent chain noise, cam timing errors, and eventually severe engine damage if the chain jumps timing. This is one of the best-known Explorer engine problems of the era and is documented across owner forums, repair databases, and NHTSA complaints.

On the 2002-2010 Ford Explorer, a very common failure on third- and fourth-generation Explorers with the 5R55W/5R55S automatic is wear in the overdrive and intermediate servo bores inside the transmission case. As the bores wear, hydraulic pressure leaks past the servo pistons, leading to 1-2, 2-3 and 4-5 flare, slipping, harsh engagement, and delayed or missing reverse. This issue is widely documented in owner complaints, transmission repair communities, and Ford service literature addressing shift flare and servo-related repairs.

On the 2006-2010 Ford Explorer, the fourth-generation (U251) Explorer commonly develops front lower ball joint and control-arm-bushing wear, producing a clunk or pop over bumps and during low-speed (parking-lot) maneuvers, along with vague steering and uneven tire wear. The ball joint is integrated into the lower control arm on these models, so wear often means replacing the arm assembly. Worn factory sway-bar end links contribute additional clunking. A severely worn ball joint can let the control arm separate from the steering knuckle, so it should not be ignored.

On the 2002-2010 Ford Explorer, the independent front suspension on the 2002-2010 Explorer/Mountaineer uses upper control arms with pressed-in ball joints that wear out relatively early. Worn upper (and lower) ball joints produce a clunk over bumps, vague/loose steering, and cupped or inner-edge tire wear. On these stamped-steel upper arms the ball joint is a press fit, and owners frequently report it will not stay seated once worn, so the practical fix is often the complete control arm.

On the 2002-2010 Ford Explorer, rear wheel bearing and hub assemblies are a frequent wear/failure item on independent rear suspension Explorers from this period. Owners commonly report a humming or growling noise that increases with road speed and can be mistaken for tire noise or differential problems. In some cases, excessive play also affects wheel speed sensor readings and can trigger ABS or traction control warnings.

On the 2002-2010 Ford Explorer, the 2002-2010 Explorer/Mountaineer/Sport Trac door handles use brittle plastic pivot pieces in the latch/handle mechanism. The exterior handle typically cracks first and jams the linkage, then the interior handle snaps when forced. Owners are eventually left with doors that won't open from inside or outside. It is an extremely common wear complaint with no recall — treated by Ford as normal wear-and-tear.

On the 1995-2010 Ford Explorer, the cable-drive window regulators on the Explorer/Mountaineer/Sport Trac fail as their plastic cable guides crack and the steel lift cable frays or jumps off the drum. The window then binds, drops crooked, or falls down inside the door — the motor often still runs. The front door regulators are the most common, and the original glass/regulator is riveted, complicating the repair. A very high-frequency 'window fell down' search across the whole 1994-2010 range.