Ford Explorer Problems by Year (2011-2026): Issues, Costs & Best Years to Buy

The most common problems with the Ford Explorer are transmission shudder on 2011-2019 models, exhaust odor in the cabin on 2011-2015 models, timing chain stretch on the 3.5L EcoBoost (2013-2018) and coolant leaks from the thermostat housing and water pump. Repairs run from about $400 for a thermostat housing to as much as $5,500 for a transmission replacement. The best used buys are a 2019 Explorer with documented recall work and the 2020-2023 sixth generation.

For more, see our guide on most reliable SUVs.

The Big Picture: 5th Gen vs. 6th Gen Explorers

The fifth-generation Explorer (2011-2019) carries most of the known problems: transmission shudder, exhaust odor in the cabin, coolant leaks and, on the 3.5L EcoBoost, timing chain stretch. The sixth generation (2020-2026) fixed the exhaust problem and has a more refined transmission. Its reported issues so far are mostly electrical and software faults.

Ford Explorer Problems by Year at a Glance

2011-2015 Explorer Exhaust Fumes in the Cabin

The most serious fifth-generation problem is exhaust odor inside the cabin. It was reported most often on 2011-2015 Explorers and is a safety issue, not just an annoyance.

What happened was carbon monoxide (CO) was leaking into the cabin through faulty welds in the exhaust system. We're talking about toxic gas seeping into the air you and your family are breathing. This wasn't just an inconvenience: it was a safety hazard. The National Highway Traffic Safety Administration (NHTSA) launched formal investigations into these vehicles, and Ford issued multiple recalls.

The root cause came down to manufacturing defects in the welds connecting the exhaust manifold and intermediate pipes. The 2011-2013 model years were particularly susceptible, with the problem stemming from inadequate welding in the production process. Under certain conditions (particularly when the vehicle was operating at low speeds or idling, which is when exhaust backs up more easily), these weak welds would fail and allow CO to seep into the cabin instead of being properly expelled outside.

The symptoms? Drivers reported unusual exhaust smells inside the cabin, especially when the vehicle was idling or sitting in traffic. Some people complained of headaches and nausea, which are classic signs of CO exposure. In severe cases, owners described experiencing dizziness and fatigue during short drives, all caused by inhaling small amounts of this colorless, odorless poison.

What made this issue so insidious was that many owners didn't immediately recognize the danger. They thought the smell was just part of owning an SUV or attributed their headaches to other causes. It wasn't until NHTSA investigations and media reports raised awareness that the true scope of the problem became clear.

Ford issued recalls starting in 2014 and continuing through 2019, covering hundreds of thousands of vehicles across multiple model years. The fix involved repairing or replacing the exhaust manifold and associated components. In many cases, Ford dealers completely replaced the manifold and welded connections to ensure they met quality standards. Some vehicles required additional repairs to the intermediate exhaust pipes as well.

If you own a 2011-2015 Explorer, check its recall history with your VIN and make sure every exhaust recall has been completed. If you are buying one, ask the seller for proof of the recall work and have a mechanic check for exhaust smells at idle during a pre-purchase inspection.

2011-2019 Explorer Transmission Shudder

The six-speed automatic transmission in these vehicles became notorious for shuddering and hesitation, especially during acceleration. Owners described it as a rough, jerky feeling that felt like the transmission couldn't decide what gear to be in.

The issue typically showed up around 40,000 to 80,000 miles, right when you were getting comfortable with the vehicle. Some mechanics traced it to a problem with the torque converter or internal transmission wear, while others blamed faulty solenoids. The real frustration for owners was that the problem was inconsistent: sometimes it would be really bad, and other times the transmission would shift smoothly for a while, making it hard for mechanics to diagnose on the first visit.

What's happening inside is usually a combination of factors. The torque converter can develop internal wear where the fluid isn't circulating properly, causing a loss of hydraulic pressure and those jarring shifts. Meanwhile, the transmission control solenoids, which manage fluid flow and gear selection, can fail or become sluggish, sending incorrect signals to the transmission computer about which gear to engage.

Ford released several transmission software updates that were supposed to address this. Many owners got temporary relief from a reprogramming session at the dealership, which costs around $150 to $300 and just recalibrates how the transmission responds to throttle input. For a while, that would smooth things out. But for a lot of folks, the shudder eventually came back.

If the shudder keeps coming back, the next step costs real money. A solenoid repair or reprogramming runs about $800 to $1,500 and may not fix the problem for good. A full transmission replacement costs about $3,000 to $5,500, depending on the shop and the parts used.

3.5L EcoBoost Timing Chain Stretch (2013-2018)

This one spans multiple years and generations. The timing chain in certain Explorer engines, particularly the 3.5L EcoBoost in some 2013-2018 models, has shown premature stretching and wear. Ford's EcoBoost engines were designed to be efficient and powerful, but the timing chain in some units was apparently undersized for the stress they endure.

Your timing chain is basically the heartbeat of your engine. It synchronizes the crankshaft and camshaft so that the valves open and close at precisely the right moment. If it fails, you're looking at catastrophic engine damage: we're talking bent valves, damaged pistons, and a complete engine rebuild or replacement. The warning signs include a rattling noise from the front of the engine, especially on cold starts when oil pressure is low and lubrication isn't optimal yet. Some owners reported this noise at 60,000 to 100,000 miles, which is alarmingly early for a timing chain failure.

What happens is the chain stretches over time due to normal wear, but in these Explorers, it stretches too fast. As the chain gets longer and looser, it can slip on the gears that drive it, which throws off the engine's timing and causes that distinctive rattle. Ignore it, and the chain can break entirely, leading to catastrophic failure.

The tricky part is that a timing chain rattle might not show up on every cold start, so owners sometimes convince themselves it's not a big deal. But once you hear it consistently, it's a warning sign that your chain is in trouble and needs to be replaced before it breaks.

Timing chain wear is not only an Explorer issue. Our Chevy Equinox problems guide covers a similar pattern in another midsize SUV, and our Ford F-150 problems by year guide shows how other Ford engines compare.

A timing chain replacement isn't cheap. You're looking at $1,200 to $2,500 in parts and labor, depending on whether your engine needs additional repairs. At a dealership, expect to pay closer to $2,000 to $3,000. It's a significant job that requires partially disassembling the front of the engine, and it's not something a backyard mechanic should attempt unless they're very experienced.

Coolant Leaks From the Thermostat Housing and Water Pump

Multiple generation Explorers have developed coolant leaks from the thermostat housing and water pump areas. The plastic components degrade over time, especially in hotter climates, and start weeping coolant.

You'll notice this as a sweet-smelling puddle under your vehicle or a gradually dropping coolant level. Ignore it, and you'll overheat your engine.

Thermostat housing replacement runs $400 to $700. A water pump job is typically $600 to $1,000. Not catastrophic, but annoying maintenance.

2011-2015 Rear Axle and Differential Problems

Some 2011-2015 Explorers developed issues with the rear differential and axle bearings. Owners reported whining sounds from the rear, especially during acceleration, along with some vibration.

This is often a sign of worn bearings or low/contaminated fluid. A fluid change and seal replacement might run $300 to $500 early on. If you let it go, an axle replacement could be $1,500 to $2,500.

2020-2026 Explorer Problems to Watch

The sixth-generation Explorer is substantially better built, but it's not immune to problems. The good news is the exhaust intrusion issue is gone, and the transmission is more refined.

However, newer Explorers have shown some electrical and software-related issues. Some owners reported SYNC infotainment system glitches, door lock failures, and occasional warning lights that don't correspond to actual problems. These are usually warranty-covered, but they're annoying.

This generation is still fairly new, so long-term data on major mechanical failures is limited. Keep your service records, and report any electrical fault to a Ford dealer while the factory warranty is still active.

Police Interceptor Utility Explorer Problems

Ford made a special Police Interceptor Utility version of the Explorer for law enforcement, specifically engineered to handle the rigorous demands of patrol work. These high-duty vehicles are built tougher than civilian models with upgraded cooling, electrical systems, and engine management, but they still face additional strain from the way they're operated.

Think about what a police vehicle goes through: hours of idling while the officer is handling calls, frequent hard acceleration for pursuits, constant use of the electrical system (lights, radios, computer equipment), and driving in all weather conditions. That's a brutally harsh duty cycle compared to what the average family does in their Explorer.

Cops reported more frequent transmission issues, battery drain problems, and accelerated wear on cooling systems compared to civilian models. The transmission shudder problem we discussed earlier hit police units particularly hard because of all that idling and stop-and-go driving. The cooling system gets worked harder too, and some departments reported overheating issues in traffic-heavy patrol scenarios where the vehicle is constantly stopping and starting.

Battery drain was also a significant issue with some police models, particularly when the vehicle was parked for long periods with the electrical accessories running. The upgraded electrical system in police models is designed to handle more load, but some units apparently had issues with parasitic drain that could kill the battery.

If you're buying a used police Explorer, it's important to get a thorough pre-purchase inspection and expect a potentially higher maintenance history than a civilian model of the same year. Ask about transmission service records, cooling system repairs, and electrical work. The upside is that police vehicles are usually very well-maintained by their agencies: they tend to get regular service and are less likely to have been abused through neglect, even if they've been driven hard. The downside is that harsh duty means more mileage and more wear on critical components.

Best and Worst Ford Explorer Years to Buy

Ford Explorer Years to Avoid

• 2011-2013: Absolute worst for exhaust intrusion issues: these years had the highest failure rates. Also dealing with early transmission problems and solenoid failures in the first 40,000 miles. If you're looking at this range, the vehicle should have been recalled and the exhaust system repaired, but verify this before buying.
• 2013-2015: Timing chain problems start appearing in this range, particularly in the 3.5L EcoBoost models. Transmission shudder is also still very common. The good news is that some of the earlier exhaust issues had been addressed, but you're still taking on risk.
• 2016-2017: Still dealing with transmission shudder in some units, though Ford's software updates had begun helping. These years are in that awkward middle ground where they're not new enough to have sixth-gen reliability, but not old enough that all the kinks have been worked out of the previous generation.

Best Ford Explorer Years to Buy

• 2019: The last fifth-generation year, with most known fixes applied. It is the best fifth-gen choice if the seller can show completed recall work and transmission software updates.
• 2020-2023: The most reliable stretch so far. The exhaust problem is gone and the transmission is more refined. Expect to pay more than for a fifth-gen model.
• 2024-2026: The newest models. No major mechanical pattern has shown up yet, but long-term data is limited, and most are still under the factory warranty.

Ford Explorer Repair Costs by Problem

Typical costs at an independent repair shop:

These figures assume average labor rates across the US. Dealer prices are usually higher: a timing chain job, for example, runs about $2,000 to $3,000 at a dealer.

Before buying a used Explorer with high mileage, review our comprehensive guide on what to expect.

Does an Extended Warranty Make Sense for a Ford Explorer?

An extended car warranty, legally a vehicle service contract, pays for covered breakdowns after the factory warranty ends. It is not car insurance, and it does not cover accidents or routine maintenance.

It makes the most sense for a 2011-2019 Explorer with no factory coverage left, because one transmission or timing chain repair can cost thousands. It is usually not worth it if your Explorer is still under factory warranty, you plan to sell it within two years, or you can pay a large repair from savings.

Here is how CoverageX plans line up with the Explorer's common problems:

• Essential covers the engine, transmission and drivetrain, including seals and gaskets. That is where the costliest Explorer repairs sit: the transmission, the timing chain and the rear axle.
• Signature adds electrical systems and air conditioning, which matters for the electrical faults reported on newer Explorers.
• Premium adds near-comprehensive coverage, including advanced technology components.
• Executive is exclusionary: everything is covered unless the contract lists it as excluded.

Know the limits before you buy. Coverage starts 30 days after purchase and after you drive 1,000 miles past the starting odometer reading. Problems that already exist are not covered, so a transmission that shudders today will not be covered later. Open recalls, such as the exhaust recalls, are handled by a Ford dealer.

When a covered part fails, call the claims team before any repair starts. CoverageX pays the licensed repair shop directly, and you pay only your deductible. See how to file a claim and compare our extended coverage plans.

Protect your Explorer's transmission and engine. Enter your year, make, model and mileage for an instant quote. The quote shows which plans fit your Explorer. Prefer to talk? Call 1-800-258-3413.

The Bottom Line on Ford Explorer Reliability

The Ford Explorer is still a solid SUV if you choose the right years. If you shop used, aim for a 2019 with documented recall work or a 2020 or newer model. If you already own a 2011-2018 Explorer, keep up with recalls, service the transmission and cooling system on time, and do not ignore a cold-start engine rattle.

With regular maintenance, many Explorers reach 150,000 miles. Plan for the big repairs before they happen, with savings or with CoverageX auto protection.

Get your Explorer quote in minutes. Enter your year, make, model and mileage at buy.coveragex.com or call 1-800-258-3413 to compare plans.

Ford Explorer Problems: Frequently Asked Questions

Which Ford Explorer years should I avoid?

The 2011-2013 Explorers are the riskiest, mainly for exhaust odor in the cabin and early transmission problems. The 2013-2015 models add timing chain stretch on the 3.5L EcoBoost, and some 2016-2017 models still show transmission shudder. If you buy one of these years, ask for proof that the recall work and transmission software updates were done.

What is the most common problem with the Ford Explorer?

On 2011-2019 Explorers, the most common problem is shudder or hesitation from the six-speed automatic transmission, often starting around 40,000 to 80,000 miles. Software updates help many owners but the shudder can come back. A full transmission replacement costs about $3,000 to $5,500.

Is the Ford Explorer a good used SUV to buy?

Yes, if you pick the right years and check the history. A 2019 model with documented recall work, or a 2020-2023 sixth-generation Explorer, avoids most of the known fifth-generation problems, and many owners reach 150,000 miles with steady maintenance. Get a pre-purchase inspection before you buy any used Explorer.

How expensive are Ford Explorer coolant leak repairs?

Most Explorer coolant leaks come from the plastic thermostat housing or the water pump. A thermostat housing replacement costs about $400 to $700, and a water pump job about $600 to $1,000. Fix a leak early, because driving with low coolant can overheat the engine and turn a small repair into a much bigger one.

What Explorer problems are most likely after 100K miles?

After 100,000 miles, watch for transmission shudder, a timing chain rattle on cold starts on the 3.5L EcoBoost, coolant leaks from the thermostat housing or water pump, and rear axle whine on 2011-2015 models. Timing chain stretch can show up between 60,000 and 100,000 miles. See our guide to buying a used car with 100,000 miles.

Are 2020 and newer Ford Explorers reliable?

So far, yes. The sixth generation fixed the exhaust odor problem and has a more refined transmission. Owners report electrical and software issues such as SYNC glitches, door lock failures and false warning lights, which are usually handled under the factory warranty. Long-term data on major mechanical failures is still limited.

Are used Police Interceptor Explorers a good buy?

They can be cheap, but expect more wear. Police Interceptor Utility models spend hours idling, accelerate hard and carry a heavy electrical load, so owners report more transmission problems, battery drain and cooling strain. Get a thorough inspection and the service records before you buy one.

Is an extended warranty worth it on a Ford Explorer?

It can be for a fifth-generation Explorer that is out of factory warranty, because one transmission or timing chain repair can cost thousands. It is usually not worth it if your Explorer is still under factory warranty, you plan to sell within two years, or you have a large emergency fund. Compare the cost of an extended car warranty with the repair costs above.

Does an extended warranty cover Ford Explorer transmission problems?

A CoverageX plan can cover transmission failures that start after coverage begins. The Essential plan covers the engine, transmission and drivetrain, and higher plans add more systems. Problems that existed before you bought the plan, like a shudder you already have, are not covered. Coverage starts 30 days after purchase and after the first 1,000 miles.