Ford · Known Issues

2016 Ford Explorer Problems: 8 Issues Every Owner Should Know

2016 model year · 3,179+ owner reports · Updated June 2026

According to Au7o's analysis of 3,179+ owner reports, the 2016 Ford Explorer has 8 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), Power Transfer Unit (PTU) overheating and bearing failure on AWD models ($1,500-$3,100 repair), Exhaust/carbon monoxide odor entering the cabin (NHTSA investigation PE16007) ($0-$1,200 repair) and Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction ($2,000-$4,000 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, repair costs range from $150 to $8,000. DIY maintenance guides at au7o.io.

All 8 Known Issues

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Community Reported

890 owners

On the 2011-2019 Ford Explorer, 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 engine damage if not caught immediately.

This issue also affects: Audi A4 allroad, Audi Q5, Audi Q7

Common Symptoms

Coolant level dropping with no visible external leak
Engine overheating
Milky or frothy engine oil on dipstick
Sweet smell from engine compartment
Coolant weeping from front of engine
White smoke from exhaust

How to Fix

Replace internal water pump (requires removing timing cover). If coolant contaminated oil: complete engine oil flush and new oil/filter. If engine damage occurred: engine rebuild or replacement. Monitor coolant levels regularly as preventive measure.

What Owners Are Using

Parts and tips from 890+ owners who fixed this issue

TipCheck coolant level every 1,000 miles - internal leaks show no external signs
UpgradeGates water pump — OE-quality replacement with gasket (Gates Water Pump)
View on Amazon
UpgradeGMB water pump — reliable OEM alternative (GMB Water Pump)
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Typical repair cost:$1,500 - $8,000

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890+ owners have reported this issue

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Community Reported

High Confidence890 reportsLast reported by owners Feb 2024Reviewed Feb 2026

On the 2011-2019 Ford Explorer, on the 2011-2019 transverse Explorer, Ford located the water pump INSIDE the engine, behind the timing cover, driven off the primary timing chain. When the pump's internal shaft seal fails, coolant first weeps from a passage on the passenger side of the block, but if ignored (or if the bearing fails) coolant is dumped directly into the crankcase, contaminating the oil ('milky' oil) and risking bearing/engine destruction. Because the pump is buried behind the timing cover, replacement is a 10-12+ hour teardown. This generated a class-action lawsuit (no recall was issued). Typical onset is roughly 100k-200k miles but failures as early as ~60k miles are documented in NHTSA complaints.

This issue also affects: Alfa Romeo Giulia, BMW M5, BMW Z3

Common Symptoms

Coolant leak/weep from passenger side of engine
Slowly dropping coolant reservoir with no obvious external leak
Milky/tan oil on dipstick or under oil fill cap
Engine overheating / temperature warning light
Cold-start timing chain rattle as coolant thins the oil

How to Fix

At the first sign of a passenger-side coolant weep or low coolant, have the internal water pump replaced before coolant reaches the oil. Best practice is to replace the timing chain, guides and tensioners while the front of the engine is open. If oil is already milky, stop driving and tow it in, then flush the oil after repair. Some owners preemptively replace the pump around 100k miles.

Typical repair cost:$2,000 - $4,000

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Community Reported

High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Community Reported

1,500 owners

On the 2011-2017 Ford Explorer, 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 that CO levels in the cabin met current health standards in correctly-configured vehicles, and elevated levels traced to (a) aftermarket upfitter modifications on Police Interceptor variants and (b) rear-end collision damage compromising exhaust seals. Ford issued Field Service Action 17B25 (NOT a recall) for affected Police Interceptors, addressing sealing issues and adding HVAC reprogramming. Consumer Explorers were generally cleared. Owners experiencing odors should have the exhaust system inspected for collision damage or aftermarket leaks; sealing repairs and HVAC reprogramming are available.

Common Symptoms

Exhaust odor inside vehicle cabin
Headaches, dizziness, or nausea while driving
Symptoms worsen during highway driving or going uphill
Symptoms increase when A/C is on recirculation mode
Drowsiness while driving

How to Fix

Inspect and seal rear lift gate gaskets. Check and repair drain valves. Reprogram HVAC system to increase fresh air intake. Inspect and repair exhaust system leaks. Ford Customer Satisfaction Program 17B27 provides free repairs.

What Owners Are Using

Parts and tips from 1,500+ owners who fixed this issue

NoteThis is a high-severity issue - ignoring it can lead to costly repairs or safety concerns. Address it promptly.
TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
TipSearch Ford Explorer forums and owner groups for real-world experiences and DIY guides
TipGet multiple quotes from independent mechanics - dealer prices can be 2-3x higher for the same repair
UpgradeBlueDriver OBD-II scanner — reads ABS, SRS, and engine codes (BlueDriver Bluetooth OBD-II Scanner)
View on Amazon

Typical repair cost:$0 - $500

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1,500+ owners have reported this issue

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Community Reported

High Confidence1,500 reportsLast reported by owners Feb 2024Reviewed Feb 2026

On the 2011-2019 Ford Explorer, 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, the internal bearings and gears fail, producing whine/grind, a burnt/propane-like odor, vibration, and AWD warning lights; the case-mounted bearing often destroys the housing, making rebuild impossible. Ford TSB (2013-2014 AWD Explorer/Taurus/MKS) also covers PTU fluid leaks from a missing/disconnected vent hose.

Common Symptoms

Whine or grind from front of vehicle that changes with speed
Burnt/propane or natural-gas odor
Drivetrain vibration or shudder on takeoff
AWD warning light
Fluid leak near the transaxle/PTU

How to Fix

Treat the PTU fluid as a service item, not lifetime: drain and refill every 30,000-60,000 miles with the correct synthetic fluid before it breaks down. If there is whine, grinding, burnt odor or fluid leaking from the vent, the PTU is failing and must be replaced (it cannot be rebuilt once the case bearing is gone). Verify the vent hose is connected per Ford TSB.

Typical repair cost:$1,500 - $3,100

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Community Reported

High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2011-2017 Ford Explorer, 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, and recorded reports of three deaths and 657 injuries allegedly linked to fumes. Root causes traced to body sealing gaps at the rear of the vehicle and cracked/leaking exhaust manifolds; police-fleet units were worst due to aftermarket holes drilled for lights/sirens. NHTSA closed the investigation in January 2023 concluding measured CO was not high enough to require a recall, but Ford had already offered a free Customer Satisfaction Program repair.

Common Symptoms

Exhaust/rotten-egg odor in cabin under acceleration
Odor strongest with A/C on recirculate
Headaches, nausea, drowsiness reported by occupants
Worse in heavily-modified police/fleet units

How to Fix

Take the vehicle to a Ford dealer for the free Customer Satisfaction Program: seal the rear liftgate/body openings, recalibrate the HVAC to bring in more fresh air during heavy acceleration, and replace any cracked exhaust manifolds. Avoid driving with the rear hatch/windows open with HVAC on recirculate. Police/upfit vehicles should have any aftermarket body penetrations properly resealed.

Typical repair cost:$0 - $1,200

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Community Reported

High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Community Reported

789 owners

On the 2011-2019 Ford Explorer, 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 completely, disabling the AWD system.

This issue also affects: BMW X6, Chevrolet Equinox, Chrysler 200

Common Symptoms

Fluid leak underneath vehicle near front of transmission
Whining or grinding noise from front of drivetrain
AWD system malfunction warning
Shuddering during acceleration
Burning smell from drivetrain area
Complete loss of AWD functionality

How to Fix

Check and reconnect PTU vent hose if disconnected. Replace PTU seals if leaking. Complete PTU replacement if internal damage has occurred. Install aftermarket PTU cooler to prevent overheating. Regular PTU fluid changes every 30,000 miles.

What Owners Are Using

Parts and tips from 789+ owners who fixed this issue

TipPTU fluid is NOT included in Ford's regular maintenance schedule - change it every 30,000 miles anyway
UpgradeQuality automatic transmission fluid for routine service (Valvoline MaxLife ATF Full Synthetic)
View on Amazon
UpgradeTransmission filter kit with pan gasket for complete fluid service (ATP Transmission Filter Kit)
View on Amazon
UpgradeOBD-II scanner with transmission live data for diagnosing shift issues (BlueDriver Bluetooth Pro OBD2 Scan Tool)
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Typical repair cost:$400 - $2,200

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789+ owners have reported this issue

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Community Reported

High Confidence789 reportsLast reported by owners Feb 2024Reviewed Feb 2026

On the 2011-2019 Ford Explorer, 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 and the sluggish-acceleration-then-harsh-bump pattern with TSB 13-3-18, both calling for a PCM/TCM reflash; check-ball and separator-plate revisions were also used. Higher-mileage units can develop internal clutch/drum wear and lose 3rd/5th or reverse.

This issue also affects: Audi A4 Avant, Audi A4, Audi A6

Common Symptoms

Harsh bump/clunk from a rolling stop (0-5 mph)
Sluggish or delayed acceleration then sudden engagement
Torque-converter shudder/vibration at light throttle
Shift flare or harsh/jerky 1-2 shifts
High-mileage loss of 3rd, 5th or reverse

How to Fix

Have the dealer apply the latest PCM/TCM calibration per TSB 13-3-18 / 11-12-10 to fix the harsh-bump and sluggish-roll-out behavior. Service the fluid with the correct Mercon LV (do not mix fluids); for shudder, a proper fluid exchange or torque-converter service helps. Persistent slipping/loss of gears at high mileage indicates an internal rebuild.

Typical repair cost:$150 - $3,500

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Community Reported

Medium ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2011-2019 Ford Explorer, 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 during driving. A piece coming off at highway speed creates a road hazard for following traffic and increases crash risk. NHTSA campaign 24V031; Ford recall number 24S02.

Common Symptoms

A-pillar trim molding lifting, loose or rattling
Wind noise from the windshield pillar
Missing trim piece after highway driving

How to Fix

Take the vehicle to a Ford dealer for the free recall (24S02): they inspect and, if needed, replace/re-secure the A-pillar trim with properly engaged clips/adhesive. If the trim is visibly loose or lifting, avoid highway speeds until repaired.

Typical repair cost:$0 - $0

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Community Reported

High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Frequently Asked Questions

What are the most common Ford Explorer problems?

According to Au7o's analysis of 3,179+ owner reports, the 2016-2016 Ford Explorer has 8 documented issues. The most frequently reported are: Exhaust Fumes / Carbon Monoxide Cabin Intrusion (NHTSA Investigation Closed Without Recall), 3.5L Internal Water Pump Failure, Power Transfer Unit (PTU) overheating and bearing failure on AWD models. Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Explorer reliable?

The 2016-2016 Ford Explorer has 8 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 Power Transfer Unit (PTU) overheating and bearing failure on AWD models 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. 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 8 Known Issues

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

Common Symptoms

How to Fix

What Owners Are Using

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

Common Symptoms

How to Fix

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

Common Symptoms

How to Fix

What Owners Are Using

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

Common Symptoms

How to Fix

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

Common Symptoms

How to Fix

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

Common Symptoms

How to Fix

What Owners Are Using

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

Common Symptoms

How to Fix

Research This Issue

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

Common Symptoms

How to Fix

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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?

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

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

What is the 2011-2019 Ford Explorer Internal timing-chain-driven water pump failure leading to coolant-in-oil and possible engine destruction?

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

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

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