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2002-2005 Ford Explorer Reliability
Date Published: 2/20/08
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.
2002-2005 Ford Explorer Reliability
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
NHTSA Recall History
2002: Tires on the right side of the vehicle may have horizontal slashes on them, increasing the risk of tire failure over time. Dealers will inspect and replace affected parts.
2002-03: Liftgate glass strut may disengage or hinge may fracture, allowing glass to fall and possibly break.
2002-03: The courtesy lights inside the running boards may overheat when exposed to excessive moisture or road salt. Dealers will inspect and replace affected parts.
2002-03: The liftgate strut may become disengaged or the hinge may fracture on certain vehicles, allowing the glass to fall and break. Dealers will inspect and replace affected parts.
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