1991-2005 Ford Explorer/Sport Trac/Sport: Reliability

Updated: 11/23/08

1996 Ford Explorer V8 4-door wagon
2005 Ford Explorer Sport Trac
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1991-2005 Ford Explorer/Sport Trac/Sport 

  • Price Range:  $600 - $13,100
CG Rating

51

out of 100

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Our reliability study for this generation Ford Explorer includes details on average repair costs, manufacturer recalls, and everything you need to know to gauge the long-term reliability of this generation Ford Explorer .

Trouble Spots

Consumer Guide's® Auto Editors have scoured repair bulletins and questioned mechanics to search for commonly occurring problems for a particular vehicle. In some cases we also give possible manufacturer-suggested solutions. In many instances these trouble spots are Technical Service Bulletins posted by the manufacturer, however, we have our own expert looking at additional vehicle problems.

Air conditioner: Water may drip onto the floor when the air conditioner is operated because the evaporator strip seals were not properly positioned. (1995-96)

Brakes: Brakes may be grabby after being parked in damp weather due to moisture absorbed by linings. Revised rear shoes are offered. (1991-94)

Clutch: Hopping, binding sensation from rear axle caused by binding limited-slip clutch packs requires revised clutch packs and reformulated gear lube. (2002-04)

Hard starting: If the engine does not start or cranks for a long time then stalls, the idle air-control valve may be sticking. (1996)

Heater core: Installing a restrictor in the heater inlet hose may repair heater cores leaks. (1991-20002)

Keyless entry: Remote keyless entry quits due to Remote Anti-theft Personality (RAP) module damaged by static electricity requiring a redundant ground on the passenger seats. (1995-97)

Radiator: The radiator may leak in cold weather because of a bad seal between the tank and core. (1995-96)

Spark plugs: Spark plug hole threads in cylinder heads are easily damaged or stripped out when removing plugs because carbon builds up on them. (2004-05)

Suspension problems: The sway bar links bend or break because the original bushings are too rigid. (1995-2002)

Transmission problems: Transmission flare when shifting from 2nd to 3rd gear is due to shift solenoid malfunction. (1997-2001)

Vehicle noise: Synthetic-rubber radius-arm bushings separate internally, causing noise and degraded steering control. (All)

Vehicle noise: A chattering noise that can be felt coming from the rear during tight turns after highway driving is caused by a lack of friction modifier or over-shimming of the clutch packs in the Traction-Lok differential. (1991-96)

Vehicle noise: Loose frame rivets should be replaced with bolts (welding is not approved). (1991-96)

Consumer Guide® Estimated Repair Costs

This table lists costs of likely repairs for comparison with other vehicles. The dollar amount includes the cost of the part(s) and labor (based on $50 per hour) for the typical repair without extras or add-ons. Like the pricing information, replacement costs can vary widely depending on region. Expect charges at a new-car dealership to be slightly higher.
Item Name Repair Cost
A/C Compressor $505
Alternator $280
Automatic Transmission or Transaxle $840
Brakes $265
Clutch, Pressure Plate, Bearing $435
Exhaust System $295
Radiator $440
Shocks and/or Struts $175
Timing Chain or Belt $400
Universal Joints $105
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