The Ford Explorer has a reputation for hauling heavy loads and big families, but not every year produced a reliable ride. Some particularly bad years, 2002, 2013 & 2016, suffer from faulty transmissions, odors in the cabin, and expensive water pump repairs.
Key Points
- The 2002 Ford Explorer struggles to stay on the road over the 100,000-mile mark as its transmission starts to fail. Other extensive complaints and recalls include faulty seat hinges, rear liftgate glass that shatters, and cracking body panels. There are also reports of it rolling away when parked.
- The 2013 Explorer is the worst model year of the fifth generation. Its power steering system fails and has a recall on the rear suspension. An open National Highway Traffic Safety Administration (NHTSA) investigation is looking at exhaust odors and carbon monoxide in the cabin.
- Ford’s 2016 Explorer is part of the same suspension recall and exhaust investigation as the 2013 model. It also has a steering assembly that fails. A lawsuit is pending for a bad water pump hidden inside its engine.
Ford Explorer is a Mostly Great SUV, but Some Years Fell a Bit Flat
Designed for a growing family, the Ford Explorer features third-row seating and 4X4 capability. It has earned a loyal following since its 1991 debut, and even survived an SUV-to-crossover transition in 2011.
However, there have been some problem years that are better to steer clear of, starting with the third-generation’s 2002 model, due to some serious transmission issues and faulty body panels. Other models on our “years to avoid” list include the 2004, 2013, and 2016.
2002 Ford Explorer Suffers from Transmission and Suspension Problems, and a Common Issue with Cracking Body Panels
When looking at full-size SUVs over the last 20 years, the 2002 Ford Explorer wins the trophy for the worst-rated vehicle by owners at Vehicle History. It sits at the bottom of the list of eight, beaten by the 2002 Dodge Durango and 2002 Ford Expedition.
The NHTSA collected over 1,500 complaints regarding the powertrain, nearly half of its 3,600 registered complaints. As the SUV approaches the 100,000-mile mark, a variety of symptoms appear, including a blinking overdrive warning light and a clunking noise. At Car Complaints, more than 440 owners reported total transmission failure, many where the fix meant totally rebuilding the unit or replacing it entirely.
The NHTSA issued 14 recalls, most fairly minor. Those include side marker lenses that failed to meet federal standards and a bad set of tires. However, a major recall affected the high-backed seats in over 1.5 million SUVs. The bolt that connected the reclining back to the seat could fail, resulting in serious injury to the driver during an accident. Another major recall referred to the hinge for the rear liftgate glass, which could fail and cause the window to shatter.
Besides its pile of complaints and recalls, the NHTSA opened eight investigations for the model. That is unusually high for any car or truck. Concerns included reports of the vehicle rolling away while in park, spark plugs being ejected from the V8 engine, and a stuck throttle.
A chronic issue for this generation of Explorer is a cracked body panel below the back window, a fix that many claim costs about $500 to replace.
2004 Ford Explorer Repeats Problems from 2002, Plus Fails Safety Tests
Even though the 2002 Ford Explorer was noted for poor reliability, the 2004 Ford Explorer should also be ranked among the worst years. It only gathered 1,400 NHTSA complaints and five recalls, but it still has the same transmission problems and cracking body panels.
It also scored terribly in rollover testing with the NHTSA. The 4X4 did not tip over in the test. However, it does have a 22.8% chance of doing so in a high-speed wreck. The 4X2 did tip, and has a 28.3% chance of a rollover. Also, during the side impact test, the driver’s door popped open.
2013 Ford Explorer Dinged for Faulty Suspension, Bad Power Steering, and Exhaust Odors in the Cabin
While the 2013 Ford Explorer is the worst year of the fifth generation for complaints and recalls, it should be noted that all 2011 to 2017 Ford Explorer vehicles are part of an active NHTSA investigation regarding the presence of carbon monoxide and an exhaust odor in the driver’s cabin. After extensive testing by the NHTSA, there is no clear evidence of an identifiable problem. However, the investigation is still ongoing, even after four years.
The other NHTSA action that is of particular concern for this year is a recall for the rear suspension toe link that may fracture. The first recall appeared in June 2019, and applied to over one million vehicles. It has expanded the campaign over the past two years, adding another 700,000 rides to the list. If the link fractures, it may drastically affect the handling and result in an accident.
The power steering system produced more than one-third of the 1,433 NHTSA complaints. Drivers report a loss of function while traveling at high speeds. The recall recommends a software update for the power steering control module. If the owner reports a history of repeat trouble, the entire steering assembly is replaced. However, more than one driver at Car Complaints reported the same problem, and was told their ride was not part of the recall.
2016 Ford Explorer Struggles with Steering, Exhaust, and Water Pump Problems that can Be Surprisingly Costly
The 2016 Ford Explorer sits in second place for the worst year for the fifth generation, with over 1,100 complaints and 11 recalls at the NHTSA. It is part of the exhaust odor investigation and the rear toe link recall noted in the 2013, but has its own unique problems.
The steering system earned the most attention from unhappy owners, with 309 registered comments. Multiple drivers state that they lost power steering while traveling at highway speeds. That sounds the same as the 2013 complaint, but it has not resulted in a recall for the 2016. The failure tends to happen around the 50,000-mile mark and requires the replacement of the power steering rack or assembly, costing owners an average of $2,100 for the fix.
Its engine logged over 240 complaints at the NHTSA, with a growing number of owners reporting a failed water pump. While replacing a water pump should be no big deal, it is in the standard Duratec 3.5L V6 engine. The pump is inside the engine, increasing the difficulty and cost of the repair.
Ford Explorer had Some Problems in Third and Fifth Generation but is Overall a Decent SUV, Especially the Fourth Generation
We focused on the 2002, 2004, 2013, and 2016 as the standout worst years of the Ford Explorer, but many of the highlighted problems– from faulty transmissions to mysterious odors in the cabin–apply to the entire third generation and most of the fifth. When considering a Ford Explorer as a used vehicle purchase, look at a 2020 model year or newer, or the popular 2006 to 2010 fourth generation.
Photos: Ford