The Ford Explorer is a popular three-row SUV but a few years carry serious risk. The 2011-2017 exhaust-leak recall over carbon monoxide intrusion is one of the most publicized. The 2020 6th gen launch was the most chaotic in recent Ford history. Here is the year-by-year breakdown.
Avoid: 2011-2013 (first-year 5th gen), 2020 (first-year 6th gen)
Buy: 2018-2019 (post-exhaust-recall, mature 5th gen)
Scores 1-10 based on NHTSA complaint volume, severity of reported issues, recall history, and class-action exposure. Higher is better.
| Year | Score | Summary | Top 3 Problems | Verdict |
|---|---|---|---|---|
| 2011 | 4.5/10 | First-year 5th gen. Exhaust manifold cracks, MyFordTouch. | · Exhaust manifold (CO recall) · MyFordTouch freezes · Power steering |
AVOID |
| 2012 | 5/10 | Continued first-gen growing pains. | · Power steering recall (15V-340) · Water pump (internal) · MyFordTouch |
AVOID |
| 2013 | 5.5/10 | MyFordTouch still buggy. Water pump risk on 3.5L. | · Water pump (3.5L) · MyFordTouch · Brake judder |
AVOID |
| 2014 | 6.5/10 | Mid-cycle refresh. Improving. | · Water pump (3.5L) · Power steering · Touchscreen |
AVOID |
| 2016 | 7.5/10 | Refresh. Sync 3 replaces MyFordTouch. | · Water pump (carryover) · Sync 3 (better) · Power liftgate |
CAUTION |
| 2017 | 7/10 | CO exhaust class action filed for police-fleet Explorers. | · Exhaust CO intrusion (class action) · Water pump · Liftgate |
CAUTION |
| 2018 | 8/10 | Most exhaust complaints addressed. Mature 5th gen. | · Water pump (3.5L NA) · Liftgate latch · Sync 3 freezes |
CAUTION |
| 2020 | 5.5/10 | All-new 6th gen. Multiple recalls and quality complaints. | · Driveshaft/transmission recall (20V-051) · Rear axle bolt · Suspension toe link · Infotainment |
AVOID |
Exhaust manifold cracks and seal failures allowed CO into cabin. NHTSA opened investigation; Ford issued CSP 17N03 for police vehicles and a class action followed. Civilian vehicles addressed via TSB.
Run AI diagnosis →Internal timing-cover water pump on 3.5L Cyclone fails and dumps coolant into oil. Often before 100,000 miles. No external warning until major damage.
Run AI diagnosis →NHTSA recall 20V-051 covered rear driveshaft attachment that could detach. Verify completion.
Run AI diagnosis →NHTSA recall 20V-440 covered rear axle horizontal mounting bolt that could fracture. Verify completion.
Run AI diagnosis →Recall 15V-340 covered EPS gear failures. Some non-recall units have failed at high mileage.
Run AI diagnosis →Power liftgate latch motor or struts fail. TSB 16-0021 addresses some.
Run AI diagnosis →Universally panned head unit. Sync 3 retrofit possible on some years.
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If your Explorer is throwing a check engine light, these codes are most often associated with the problems above. Click any code for diagnosis steps.
2011 (first-year 5th gen with exhaust and MyFordTouch issues) and 2020 (first-year 6th gen with multiple recalls) are the most-cited worst years.
2011-2017 Explorers had documented exhaust manifold and seal failures that allowed CO into the cabin. Police Interceptor versions were the focus of a class action; civilian fixes were issued via TSB.
The naturally aspirated 3.5L has the internal water pump risk. The 3.5L EcoBoost shares cam phaser concerns with the F-150 EcoBoost.
2020-2021 had a rough launch with multiple recalls. 2022+ models are more sorted but Explorer still trails Toyota Highlander on reliability rankings.
If buying 2011-2017, verify exhaust TSB completion. If buying 2020-2021, verify all open recalls are closed. The 2018-2019 sweet spot is the safer used pick.
The 2.3L EcoBoost has been comparatively reliable. The 3.5L NA has internal water pump risk; the 3.5L EcoBoost has cam phaser risk.