Ford Explorer’s Worst Years Are Marked by Failed Transmission, Possible Carbon Monoxide Leak

S.D. Grady
Oct 20, 2021

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.

2018 Ford Explorer-Ford

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-Ford

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 - Photo by Ford

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 - Photo by Ford

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 

Owner Reviews

accountCircle Akith M on October 22, 2021
2013 Explorer with too many issues
All the front end cost me a fortune to get it replaced. I.E. Suspension etc. Also had to replace power supply unit to wheels. Not the best experience I've had too many problems constantly costing too much additional expenses. Suspension, shocks, tire rotors etc basically the whole front.
accountCircle Lauren F on October 25, 2021
2013 Explorer has poor quality headlights
My only complaint with this car is that the headlights are horrible. They're an odd shape and create a harsh line between light and dark in my field of view. Subsequently, it creates an optical illusion and makes it harder to see clearly when driving in the dark or in poor weather.
accountCircle Candace H on October 23, 2021
2016 Explorer is good when functioning properly
We have had several issues with our Ford Explorer. With only 80 miles it broke down for no reason in the middle of a road. Happened one other time after about 5 months later. The power steering recently had an issue. There was also a recall problem that needed to be fixed.
accountCircle Rae M on October 24, 2021
2002 Explorer door sensors cause battery drain
The 2002 model is prone to having its door sensors stop registering that the door is closed making your light stay on and drain your battery. The light is hard to recognize as on during the day so it's easy to have a battery die while out if the issue occurs.
accountCircle mckinley S on October 27, 2021
The 2016 Explorer is okay, there are better ones out there.
The car is really nice, however I have had a few issues with the power steering. After only 50,000 miles I had to replace the rack and pinion. This is not a normal thing. There have been recalls on the car for a couple of parts.
accountCircle Marie O on October 20, 2021
2002 Explorer is old with a lot of problems.
It cuts off sometimes, it stalls sometimes. The speedometer don't work. 1 of the windows don't go down. It makes noise that I can't figure out where its coming from. The drivers seat doesn't go back or fourth its jammed.
accountCircle Margaret L on October 21, 2021
Cracked trim pieces on the 2002 Explorer
The complaint I have is that the trim on this vehicle and all models like it was cheaply made and put on. We see other models that are the same with the same pieces of trim in the same spots cracked.
accountCircle Ashley V on October 24, 2021
A couple of hiccups with my 2002 Explorer
My vehicle issue that I have dealt with is that the heater went out of nowhere and this was a issue what Ford trucks mainly have. Also the window’s also just stopped working out of nowhere as well.
accountCircle Rebekah B on October 28, 2021
2013 Explorer brakes keep needing repair
Not sure if all explorers are like mine but it has a few problems. The armrest on drivers door has split seams and it seems like I've had to work on brakes multiple times since I've owned it.
accountCircle Michelle F on October 24, 2021
A few minor problems with my 2002 Explorer
I have had problems with my car not wanting to shift gears into reverse and or will pop into neutral sometimes. I had problems with the windows went down but then wouldn't go back up.
accountCircle Nancy D on October 25, 2021
2002 Explorer issues due to age
I love my vehicle do not get me wrong. But these cars seem to have lots of electrical issues when they get older. And they also tend to have transmission issues, and sensor issues.
accountCircle Tasha W on October 23, 2021
Seat belt recall in 2002 Explorer
My car is very old so we're starting to have tons of issues with the car (electrical panel). There has been 2 recalls on the car, one regarding the seatbelt.
accountCircle Levi D on October 22, 2021
Stay away. 2013 Explorers are not worth the money.
Issues. Transmission issues, compute ecu issues, Power takeoff unit replaced. Bad o2 sensors. Battery has been replaced every year.
accountCircle Ashley R on October 29, 2021
Electrical issues with my 2002 Explorer
Electrical issues. When it rains it will shut off at random. The air just recently stopped blowing out of the main air vents.
accountCircle brittney c on October 28, 2021
2002 Explorer with temperamental transmission
The only real issue I have is the transmission acts up in this vehicle. I have spent a lot of money trying to fix it.
accountCircle Angie C on October 24, 2021
I have a 2013 Ford Explorer
A few weeks ago, my SUV started having problems. I have to replace the transmission which is going to set me back 5K.
accountCircle Perry T on October 29, 2021
2002 Explorer issues come after many miles
After 150,000 miles problems all around car start to wear and tear. Wheel bearings, tranny, door controls.
accountCircle Jakob M on October 28, 2021
2002 Explorers can have wheel bearing issues
It is older so I need to repair it semi often. The wheel bearing is a issue that affects that model.
accountCircle Glenn D on October 26, 2021
Water pump failure caused engine damage in my 2016 Explorer
The water pump failed at approximately 80,000 miles causing engine failure. The engine was replaced.
accountCircle Noelle T on October 28, 2021
2002 Explorer has some flaws
I dislike the standard flaws known for this vehicle, such as steering column issues, transmission.
accountCircle Jessi W on October 23, 2021
2016 Ford explorer: family vehicle.
I had to replace some power steering mechanisms, the low profile tires do have a short lifespan.
accountCircle Penny N on October 23, 2021
Dealing with transmission problems in the 2002 Explorer
Transmissions start giving you issues early on. This one has been rebuilt twice.
accountCircle Diana D on October 22, 2021
2002 Explorer doesn't have enough trunk space and it isn't a great suv.
The car keeps having problems. Brakes, radiator, I feel like getting rid of it.
accountCircle Dorothy G on October 28, 2021
2013 Ford Explorer has had suspension issues
The only big problems I have had so far is some suspension trouble.
accountCircle Em C on October 20, 2021
My 2002 Explorer Transmission
It has transmission issues but that is my main complaint.
avatar S.D. Grady
Sonya is a vastly experienced journalist who loves to share her passion for everything automotive. You can usually find her at the track covering NASCAR, taking a test drive, or drooling over the latest models at the local auto show.
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