What is the 2011-2017 Ford Explorer Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007)?

Owners across the fifth-generation Explorer reported exhaust fumes and carbon monoxide odor entering the cabin, particularly under hard acceleration with the climate system in recirculate. NHTSA opened investigation PE16-007 (later EA17-002), reviewed more than 6,500 complaints,… Repairs typically run $0-$1,200. Severity: high.

What is the 2011-2019 Ford Explorer Power Transfer Unit (PTU) overheating and bearing failure on AWD models?

AWD Explorers use a compact Power Transfer Unit bolted to the transaxle that sends drive to the rear wheels. It holds only ~300-400ml of 'lifetime fill' fluid and sits next to the exhaust, so heat cooks the fluid and it degrades well before 100k miles. Once the fluid breaks down,… Repairs typically run $1,500-$3,100. Severity: high.

What is the 2011-2019 Ford Explorer PTU (Power Transfer Unit) Failure?

The Power Transfer Unit (PTU) on AWD-equipped Explorers is prone to premature failure due to its proximity to the exhaust pipe and catalytic converter, causing overheating. Fluid leaks from disconnected vent hoses are common, and if fluid level drops too low, the PTU can fail com… Repairs typically run $400-$2,200. Severity: medium.

What is the 2013-2020 Ford Explorer 3.5L EcoBoost Ignition Coil and Spark Plug Misfire (Often Caused by Broken Exhaust Manifold Studs)?

Explorers (especially the Sport and Platinum) with the twin-turbocharged 3.5L EcoBoost are widely reported to develop cylinder misfires, a flashing check-engine light, rough idle and a loss of power that owners frequently chase by replacing ignition coils and spark plugs. The tur… Repairs typically run $120-$900. Severity: medium.

What is the 2011-2019 Ford Explorer 6F50/6F55 six-speed automatic harsh 'bump' shifts, sluggish low-speed response and torque-converter shudder?

The 2011+ transverse Explorer switched to the 6F50/6F55 six-speed automatic, which is widely reported for a sluggish 0-5 mph roll-out followed by a harsh 'bump' or clunk, plus torque-converter shudder and occasional shift flare. Ford addressed the low-speed bump with TSB 11-12-10… Repairs typically run $150-$3,500. Severity: medium.

What is the 2013-2019 Ford Explorer Cam Phaser (Variable Cam Timing) Rattle on 3.5L EcoBoost Causing Cold-Start Knock?

3.5L EcoBoost-equipped Explorers (Sport, Platinum, and Police Interceptor Utility) commonly develop a rattling/knocking noise for 1-3 seconds on cold start-up caused by worn variable camshaft timing (VCT) phasers. The phaser lock pins fail to hold the cam sprockets in position af… Repairs typically run $1,800-$3,500. Severity: medium.

What is the 2011-2019 Ford Explorer Door Latch / Door Lock Actuator Failure Causing Persistent Door-Ajar Warning and Battery Drain?

The door latch assembly contains the ajar sensor and lock actuator; when the latch/actuator fails, the vehicle thinks a closed door is open. This produces a 'Door Ajar' message that won't clear, interior lights that stay on (parasitic battery drain and dead batteries), an alarm t… Repairs typically run $80-$450. Severity: medium.

What is the 2011-2019 Ford Explorer Exterior A-pillar windshield trim can detach and become a road hazard (Recall 24V031 / 24S02)?

Ford recalled approximately 1.9 million 2011-2019 Explorers because the exterior A-pillar trim applique (the molding flanking the windshield) may not be properly secured—the retention clips can be unengaged due to improper assembly or prior repair—allowing the trim to detach duri… Repairs typically run $0-$0. Severity: medium.

What is the 2011-2019 Ford Explorer Intake-Valve Carbon Buildup on Direct-Injected EcoBoost Engines Causing Rough Idle and Misfire?

First-generation gasoline direct-injection (GTDI) EcoBoost engines in the Explorer spray fuel directly into the cylinder, so no fuel washes the backs of the intake valves. Oil vapor and debris from the PCV system bake onto the valves over time, forming carbon deposits that restri… Repairs typically run $400-$800. Severity: medium.

What is the 2011-2019 Ford Explorer Rear A/C Line Corrosion and Leak Causing No Rear Air Conditioning?

The aluminum A/C lines running to the rear evaporator corrode and crack, leaking out the refrigerant. Ford's design uses a loose slip-over thermal wrap that traps sand, grit and moisture against the aluminum tubing, accelerating corrosion and rock-strike damage—especially at the… Repairs typically run $600-$2,200. Severity: medium.

What is the 2011-2020 Ford Explorer Aluminum Hood Paint Bubbling and Corrosion (Filiform/Iron-Contamination Defect)?

The aluminum hood (and to a lesser extent other aluminum panels) develops paint bubbling, blistering and flaking, most often along the leading edge of the hood. The defect is attributed to iron particle contamination of the aluminum panel before paint, which corrodes from within… Repairs typically run $500-$1,500. Severity: low.

What is the 2011-2020 Ford Explorer EVAP Canister Purge Valve Failure Triggering Small-Leak Check-Engine Codes?

A very common check-engine cause on the Explorer is an EVAP small-leak code, most often from a stuck or leaking canister purge valve, but also from the capless fuel filler seal, vent valve, or a loose/faulty gas cap. The purge valve controls fuel-vapor flow from the charcoal cani… Repairs typically run $150-$350. Severity: low.

What is the 2011-2019 Ford Explorer HVAC Blend Door Actuator Failure Causing Clicking Noise and No Heat or A/C?

The temperature/blend door actuator is a very common failure on the Explorer (shared with Taurus, Flex and Lincoln MKS/MKT). The actuator's internal plastic gears strip, producing a repeated clicking or knocking sound behind the dash and leaving the cabin stuck on hot or cold, or… Repairs typically run $25-$350. Severity: low.

What is the 2011-2019 Ford Explorer HVAC Blower Motor Resistor Failure With Melted Connector (Fan Only Works on High)?

The Explorer's HVAC blower motor resistor commonly fails, leaving the fan working only on the highest speed (which bypasses the resistor) or operating intermittently. The typical root cause is an aging blower motor drawing excessive current, which overheats the resistor and melts… Repairs typically run $150-$350. Severity: low.

Ford · Known Issues

2015 Ford Explorer Problems: 17 Known Issues

2015 model year · 3,179+ owner reports · Updated September 2026

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According to Au7o's analysis of 3,179+ owner reports, the 2015 Ford Explorer has 17 documented known issues, with 5 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), Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) ($0-$1,200 repair), Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction ($2,000-$4,000 repair) and Power Transfer Unit (PTU) overheating and bearing failure on AWD models ($1,500-$3,100 repair). The most commonly reported issue is Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) with 1,500 owner reports. Across all issues with published estimates, repair costs range from $25 to $8,000. DIY maintenance guides at au7o.io.

Frequently Asked Questions

What are the most common Ford Explorer problems?

According to Au7o's analysis of 3,179+ owner reports, the 2015 Ford Explorer has 17 documented issues. The most frequently reported are: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), 3.5L Internal Water Pump Failure, Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007). Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Explorer reliable?

The 2015 Ford Explorer has 17 known issues documented across 3,179+ owner reports. 5 issues are rated critical: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall) and 3.5L Internal Water Pump Failure and Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) 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. 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 $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.

What is the 2011-2017 Ford Explorer Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall)?

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.

All 17 Known Issues

Other Ford Models

Frequently Asked Questions

What are the most common Ford Explorer problems?

Is the Ford Explorer reliable?

How much does it cost to fix common Ford Explorer problems?

What is the 2011-2017 Ford Explorer Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall)?

What is the 2011-2019 Ford Explorer 3.5L Internal Water Pump Failure?

2011-2019 Ford Explorer: 3.5L Internal Water Pump Failure#

2011-2019 Ford Explorer: Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction#

2011-2017 Ford Explorer: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall)#

2011-2017 Ford Explorer: Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007)#

2011-2019 Ford Explorer: Power Transfer Unit (PTU) overheating and bearing failure on AWD models#

2013-2020 Ford Explorer: 3.5L EcoBoost Ignition Coil and Spark Plug Misfire (Often Caused by Broken Exhaust Manifold Studs)#

2013-2019 Ford Explorer: Cam Phaser (Variable Cam Timing) Rattle on 3.5L EcoBoost Causing Cold-Start Knock#

2011-2019 Ford Explorer: Intake-Valve Carbon Buildup on Direct-Injected EcoBoost Engines Causing Rough Idle and Misfire#

2011-2019 Ford Explorer: Rear A/C Line Corrosion and Leak Causing No Rear Air Conditioning#

2011-2019 Ford Explorer: HVAC Blend Door Actuator Failure Causing Clicking Noise and No Heat or A/C#

2011-2019 Ford Explorer: HVAC Blower Motor Resistor Failure With Melted Connector (Fan Only Works on High)#

2011-2019 Ford Explorer: PTU (Power Transfer Unit) Failure#

2011-2019 Ford Explorer: 6F50/6F55 six-speed automatic harsh 'bump' shifts, sluggish low-speed response and torque-converter shudder#

2011-2019 Ford Explorer: Exterior A-pillar windshield trim can detach and become a road hazard (Recall 24V031 / 24S02)#

2011-2020 Ford Explorer: Aluminum Hood Paint Bubbling and Corrosion (Filiform/Iron-Contamination Defect)#

2011-2019 Ford Explorer: Door Latch / Door Lock Actuator Failure Causing Persistent Door-Ajar Warning and Battery Drain#

2011-2020 Ford Explorer: EVAP Canister Purge Valve Failure Triggering Small-Leak Check-Engine Codes#