2002-2005 Ford Explorer: Reliability
Updated: 11/23/08
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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.
Coolant leak:
Coolant may leak at the intake manifold crossover due to a crack in the manifold on 4.2L engines. (2002)
Engine noise:
A ticking noise on 4.6L engines may have problems with the valve guides requiring possible replacement of the cylinder head(s). (2001-04)
Fuel gauge:
Fuel gauge may suddenly drop to empty on vehicle with 4.0L engine due to an electrical problem with the flex fuel module. (2002)
Fuel pump:
Stumbling or hesitation when making aggressive right turns caused by cavitation in the fuel tank as fuel sloshes to one side requiring a redesigned fuel pump. (2002)
Oil leak:
Oil leak from right side axle may be caused by the seal coming loose and spinning in the housing requiring complete axle assembly replacement. (2003-04)
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)
Timing belt:
Rattling noise from front of engine caused by timing chain slop requiring a redesigned primary chain tensioner. (1999-2002)
Windows:
The rear window (liftgate) glass supports may come loose and cause the window to break on some vehicles, and dealers were repositioning the brackets and tightening the screws. (2002)
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 | $655 |
| Alternator | $525 |
| Automatic Transmission or Transaxle | $2,995 |
| Brakes | $350 |
| Clutch, Pressure Plate, Bearing | $455 |
| Constant Velocity Joints | $2,340 |
| Exhaust System | $295 |
| Radiator | $945 |
| Shocks and/or Struts | $650 |
| Timing Chain or Belt | $510 |
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