Top 5 Problems Ford Explorer SUV 3rd Generation 2002-05
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Here are the top 5 problems with the 3rd generation Ford Explorer! In this video, Len explains common problems specific to the 2002 to 2005 model years of Ford's flagship SUV! He also gives you tips and suggestions on what you can do to fix those problems yourself!
Check out some other great videos here!
• Tips & Secrets only Me...
0:00 Top Problems Ford Explorer 3rd Gen 2002-05
0:15 Ignition Coils
2:45 Timing Chain and Tensioner
4:02 Blend Door
5:24 Fuel Pump
7:29 Rear Wiper Arm
9:25 Rear Hatch Panel
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Could you do a video for 2nd generation Ford Explorers, and a separate video for 2nd generation Ford Rangers?? Please. 😬
Mine shutos off while driving and may or May not start but before it shuts off the engine stutters please help
My co-worker has a 2002 Ford Explorer with 379,000 miles. He bought it brand new. Original engine, but he did put a brand new transmission in it at one point. He said that thing is like a tank and built to last, unlike these new vehicles.
Replaced a trans at 146K on my 2003 XLT 4 door. My trans guy said I was lucky because they usually go out between 120 and 129K. Did the thermostat housing and radiator, rear axle seals and I’m on my 3rd blend door. A tip on the fuel pump is to try and fill up when you get to a 1/4 tank if possible as the pump is cooled by the fuel. Front wheel bearings around 170k. It has a few noises here and there at start up but it currently has 257K on it. And yes I have that freaking crack on the hatch to to right of the blue oval.
That's too funny (but not, because it was expensive) - my 2005 Eddie Bauer V8's trans went somewhere around 120k, exactly where your guy said they usually do.
I have a 2002 Ford explorer utility with 188 000 miles on it and transmission is factory and great still.
My 2002 explorer tranny coughed it's guts about 350,000 kms,but my guess it was replaced before, I found a broken bolts. Got a good used one,all happened 2020,replaced every fluid, sensor I touched.Now the rest of my sad story, both front wheel bearing, rear strut assembles, and rear upper control arm's this spring. Have great week all,blessings 🇨🇦
My grandpa has a 2005 xlt. Its has like 168k on it right now. Original trans I'm betting cuz it slips a little here and there. Its got all its gears but once in a while when you're just cruising it feels like the clutch let's go for a split second (the engine also revs a little in this split second) and then grabs again and everything's good lmao. Idk if that would be the actual gear wearing out or if it's the clutch. You also have to hammer down on these to force them to downshift😂 otherwise it won't downshift very easily lmao. Definitely the worst gen Explorer there is. 1st gens are the best imo
This video is spot on. Had every single one of these issues happen all within a year, except the fuel pump 🤞. About to turn over 300,000 miles an she is still going strong.
Only mechanical issue I've had with mine was the, thermostat housing. It was like a 40 dollar part and a 10 minute fix.
I've driven old Dora around 7 states, through pouring rain, scorching desert, ice storms, dust storms, up mountains, in cities, and though the middle of nowhere.
She just keeps on rolling.
y que año es su explorer? que motor tiene?
We're just buying a luxury 2002 model. Single owner 300k, heavily maintained for $4000 CAD. Wife also wants to name it Dora. I'd like to Name it Gibson (after the Gibson Explorer guitar)
How many miles does yours have on it? Mine was 188 000 miles and drives great.
I don't like to name cars but I had to name my 02 Explorer Dora. I couldn't resist 😂
Thought I would see some of the common issues and yes, blend door & crack on the back panel. However, I absolutely love my 2005 4 x 4 Explorer. Fits a sheet of plywood and pretty much anything I can throw at it. Even had 12' sheets of 1/2" sheet rock, (about 10). Thanks for the info!!!
Thank you, thank you, thank you. You are a life saver!!I just purchased an 05 with idle, power issues, and the tailgate panel is cracked!The dealership is replacing the time &chain right now (and some gaskets they said). Woo hoo!!
I had previously owned an 05 Malibu Maxx and you helped me (I did it all myself) replace alternator, master cylinder, bleed brakes, and the water pump. And multiple fuses, lighters, and lights.
That tailgate panel is a SUPER common issue I had found a video saying that ford putting that emblem on the back made it weaker and prone to breaking
MY ULTIMATE FAVORITE VEHICLE OF ALL TIME!!!
Mine too, I call it Dora the Explorer. Been road tripping in it. Love this thing.
Encouraging as I just bought an 05' and am driving from Seattle to Ohio sight seeing along the way.
I’ve seen many 6 cylinders have transmission problems but we had a 8 cylinder Ford Explorer. All we have done is change the oil. No issues at all
Thank you for sharing Dora’s most common issues
Thanks bud! I have a 04 Explorer XLT 174k on the clock and I'm depending on it to get us around until car prices come back down to earth. She's a solid vehicle and I actually really like it enough to keep it until it's scrap. I need to keep this thing humming so I appreciate your video. I would really like to avoid the timing chain and tensioners but I fear that having a shop do it would total the vehicle. Hopefully I don't need to find out!
I’ve got a 04 Eddie Bauer, great daily for snowy slushy roads. Heated seats and steering wheel climate controls are amazing. Wish it had arm rests. Has 280,000 miles, steering and brakes are loose. Small problems when starting, having to turn key twice. Having to get a jump if I let it sit more than a week. Gonna try and run it into the ground
Mountain Man good job my dude u just helped me with my ignition coil issues going to try your suggestions in the morning
Waiting on this video! Thank you
You should add a number 6.... transmission issues. The torque converter strips out.. leaving you stranded 👌🏾😎
Not true.
You are not LYING mine is a 04 and mine started slipping 4 years ago.
I’ve had my solenoids go out. I’ve since replaced the entire transmission. No problem now.
Let’s see I’ve fixed:
Heater core(dash removal needed)
Replaced engine due to hydro lock (faulty intake gasket)
Blend door actuators
3 thermostats (POS Plastic)
2 radiators
Water pump
Both rear wheel bearings
Passenger window motor
Tubing for leaky sunroof
Complete replacement of Timing tensioner and guides on replacement engine.
In other words she’s been a dream to learn how to mechanic on!
Bought my Ford Explorer 2004 in 2006 and it's been the best vehicle I ever owned. Easy to fix and parts are available.
Love seeing that crack on the back lift gate. Got it on my 04 Explorer! Got the back wiper issue too. I'll have to try that fix!
Yeah that damn hatch crack. It was some kind of bad plastic. Just get a new panel and it most likely won’t happen again.
Mine too
@@OmegaHellHound543 How much is that back panel that cracks? My 05' has that crack; I just bought it and it runs and looks decent. It has 158,700 miles on it and I paid $3500 because of todays damned prices! Still I think it will be a great SUV for me.
They also had rear differential issues. Ford started out using 75W90 gear oil, but it wasn't enough and the cheap needle bearings that help support the half shafts would fail, along with the pinion and side bearings. Made a nice little rumbling sound going down the highway. Ford updated the oil to 75W140 Synthetic for those and later...seemed to help.
Ignition coil v fuel pump and i already fixed my ac/heater door. That was a different video but it was helpful!
Forgot the thermostat housing, water pump oh yes and ball joints lol
I'm sure that's in the following top 10. True story
LoL V6 model. I have a V8 model. No problem with it!
You hit facts on that brudda I got two of them. You forgot wheel bearings.
And the rear end
Ball joints my current issue along with oil leak
Timing chain main issue: Start-up rattle.
Sometimes new tensioners fix, sometimes not (but go OEM).
Also, turning the engine over for a few seconds without starting (by first pressing accelerator to floor) can work around all but the worst cases of this.
However, there are TWO chains, and the rear requires engine removal.
If that chain is rattling full-time with a broken plastic guide, then at this point you just need a new...
car. lol.
My top 5 Other issues:
* Transmission: banging into reverse, &/or TC shudder. Fluid change can help, plus possibly Dr Tranny additive.
* Thermostat housing: warping, cracking and leaking. You can replace this yourself.
* Wheel bearings: You'll definitely need to get 1 or 2 of these replaced at some point.
* Flasher relay unit: When your turn signal stops working you most likely need one of these. A cheap simple part. That is an absolute pain to access and remove. Enjoy, lol.
* Brakes: Front rotor 'warpage'. And/or Rear handbrake shoe disintegration.
Rotors can usually be machined. Once.
Brake shoes are another pain in the a$$ job, but you can do it yourself. That being said, if I had the car at the mechanic's anyway, I'd let him do it next time. 😉
Awesome thank you!
Must have got lucky. I have an 03 with 248000 miles and is still going
Without long list of repairs...no way!
Of course, great video. I just bought one of these, of course.
Of course.
Len is King 👑
For me it's been the blend door and the fuel pump, and the back latch if I recall.
Thank you for this videos cz I just bought my first 2003 Ford Explorer xls with only 123,563 miles on it
'Only' ?
This is about the mileage where you'll need to take care of all the things I mentioned in another comment here, unless already done.
My 04 was a total lemon. 6 common things like clockwork!
Two words...
Of Course
Great video
Got 2
08 260k miles v6 still runs like a champ , tranny went at 220k only major repair in 12 years of owning , rest just maintenance , handed it down to my son
02 180k miles v8 completely different vehicle , wheel hubs , suspension , iac sensor , coilpacks , good truck still works but the gen after the 02 -05 models are much better built and more reliable , ofcourse depends on your driving style
The 4.6 two valve is bulletproof however the next gen uses a three valve. 4.6 which has some issues
Thanks for the tips! Of course got cracked also from lift gate..but something bothering me ..bout my eng stalling if my remaining fuel is 1/4 ..but if i tap up to 3/4..idling is rock steady...for your comments bro! 2005 FE EB 3rd gen
+Gerry Avila Thanks for checking us out. Shop for high quality auto parts on 1AAuto.com:
1aau.to/m/Shop-1AAuto-c
The rear glass latch rust gets so that the bolts won't hold. Home depot stainless steel metric screws had been my replacement because the dealer didn't have any parts
I bought a used '02 Explorer. The previous owner told he had just replaced the fuel pump. And I just noticed the heater doesn't work.
When my blend door messed up I just reach their the glove box flip it down when I need heat!!!
Lol I used to do that until I had mine fixed
I stuck a long screwdriver from driver side and got hot cold that way.
Same I put a zip tie on it and I just reach over and pull it when I need heat lol
I always thought that this generation of explorers were notorious for transmission issues. has anyone else had transmission issues with theirs?
It's because no one changes the freaking fluid. Transmission fluid is suppose to be changed at 75,000 miles...
They had faulty shift solenoid!
My 2005 explorer transmission is blown
Yes transmission issues and a p420 even with a new cat I still got to p420
@@danacrook4203 what sort of symptoms does the shift solenoid cause?
Len I appreciate your comments. Great.
I just bought a 2003 with 48k miles. Thanks for the heads up
48k? That's it??? Wow that's awesome
Be ready...
I have a 2002 ford explorer 4.0, reg fuel, the oil pressure gauge drops to low at stops, and the ABS light sometimes comes on, any ideas? I'm thinking sensors and possibly the oil sender? really enjoy your videos, I replaced Fuel injectors on a 2000 dodge intrepid because of yall. Thank you!!!
It's my understanding that there are two timing chains on the 4.0L V6, one at the front and one at the back, because they used a single cam block converted to SOHC on each bank. So if you have a bad front chain situation, you have a back one too.
I was excited to find out my motor does not use a balance shaft, Then I found out about the dual- Front/Rear Timing system. Yeah, if the Timing chain goes, its toast.
Not happy with that.
Gary, your understanding is correct, the passenger side timing chain is on the back side of the engine on the 4.0 l SOHC V6. This has HUGE implications for head repair or timing chain guide repair because you MUST completely remove the engine to repair those items. This is a big missing piece from this video and it tells me that the 1A Auto mechanics need to do more homework - kinda neglectful if you aks me.
3 timing chains plus a balance shaft chain for engines used on 4x4s (4 total). Crank to jack shaft, jack to left bank-front; jack to right bank-rear, crank to balance shaft.
I just had the engine out and did this whole multiple timing chain replacement job. It's holding, but, it appears this week its a bad ECM 😫
Question: I have just purchased an 05 explorer with adv traction control, the undercarriage cover (shield, skid plate?) Is missing. Will it screw up my stuff if it's not replaced?
Lol no
Hey man. Now and then my 4X4 light flashers 5 or 6 times on my dash board, when I'm turning sharp going forward or backwards my explorer wants to stop so I have to push my accelerator down more just to move. When I do that it makes a loud bang then sometimes goes back to normal or stays the same. You have any clue what this may be? Thanks
For a couple of years I'm contemplating getting a 3rd generation 2010 Explorer. Actually rather a 2010 Sport Trac Adrenalin with V8 and navigation package and all bells and whistles. In lughtning blue. 💙
I have an 03 explorer 176k miles. On first start up whether it's cold out or not it chugs and takes a few seconds to actually get running. When it does get running normally it runs great. Any idea what could cause the chugging right away. I has no other symptoms. Like the ones u mentioned in the video relating to the fuel pump or filter. If there was something wrong with the pump or filter I would assume it would happen all the time but it doesn't so I'm not sure where to go from here.
Seriously i have similar issue now with mine
It doesn’t run smart at the beginning of the movement but after a minute or two then it run greatly
Perhaps you should consider getting the timing chain replaced. It's something two people on this thread were saying.
Don’t forget the blinker fluid if your out whistling diesel has some for sale on his website
The mountaineer has Same issue with back panel cracking.
It's in pretty good shape
I've had many more reliability issues with my Ford Explorer of this vintage with ~82k miles compared to the combined issues of a Toyota and Honda around the same age. Issues have included cracked rear panel, broken rear hatch, 4x4 control module, broken exhaust gas recirculation pressure feedback sensor, wheel bearings, loaded struts, front ball joints, climate diverter, power locks, cruise control, and now a chirping noise that may or may not be related to the camshaft position sensor, and intermittent no start issue that is related to the fuel pump or electrical system for the fuel pump
I was also going to say this guy didn't cover HALF of the problems I've paid thousands to fix on our '02. Currently I believe we have a bad ECM, involved intermittent no spark along other things.
I have a 2002 4L, with 83k. Transmission works fine. I've been doing preventative maintenance, and considering a Automatic transmission filter/fluid change and an improved/bigger Auxiliary Transmission cooler.
I am hesitant to change the filter, but wonder if I should be?
I was going to have a Ford dealer replace my trans filter ant about the same mileage as your and they didn't recommend doing it because of problems in doing so and said to wait until it failed. They could have made money, but it seemed they were warning me not to do it.
Why wouldn't you change the filter?
Only thing I'd be iffy about would be a flush.
On the other hand, if no issues whatsover, might not bother doing anything.
I’m picking up an 03, honestly I’d rather deal with these issues than what my 03 blazer gave me. Fuel pump, fan clutch, trans, transfer case, blower motor, you name it. That and 14 mpg on a v6 lol.
Great videos, but you left out the 2nd generation Explorer - you got all the others!
Hi. I have a 2004 Explorer. I replaced the transmission. But after the replacement, the I/O off lightning sometimes. Is it the transmission problem again? Thanks
Best car ever constructed
Hi, I have a 2004 UZ Ford Explorer and have issue with the back liftgate: the half window cannot open and there's a crack in the back panel ( as you have shown), however I am unable to open the glass window when I flick the window to open - so I'm assuming water got through the crack and rusted all parts. The full liftgate opens fine. So I'm asking what would I need to do or purchase to fix this issue + a key fob that is able to open the glass half of the liftgate. Thank u and appreciate any advice.
If you are talking the black latches that attach to the glass they sell replacements on Amazon took 10 min and a helper to hold the glass to fix
Be careful not to break the window glass!
My 02 has the 4.6L V8 in it, so the engine isn’t a problem. But all the other problems do exist. I’ve fixed most of them permanently, but my shift solenoids are shot. New transmission incoming! I’m getting a new transmission with a retrofit trans pan with a dipstick and filler tube so I can change the fluid.
+OmegaWolf543 Thanks for checking us out. Shop for high quality auto parts on 1AAuto.com:
1aau.to/m/Shop-1AAuto-c
Thanks cuh i got one and this helped
Hahahaha thank you for all that info I have a 2005 Ford explore and I have all those problems. But I love my car and I’m not getting rid of it.
Do the 05 Ford explorer Rims fit on a 03 Ford F150??
On the 4.0 6 bangers the heat / AC actuator breaks and also the plastic thermostat housing sitting on top of the engine blows out. But these Explorers last for $250,000 miles or more
Toyota - like longevity; I'm glad to hear it I just got a used one too.
Good to know i just picked up a 2002 with 74k original miles
Driving low on gas will burn out your fuel pump faster. Gas doesn’t splash against the body of the fuel pump to keep it cool. Gas actually flows through the electrical motor keeping it cool.
4L used a Plastic Intake Manifold. Plastic, and the changing temperatures of pressurized coolant, for 20 years, is a bad mix. Keep in mind, this vehicle also uses a plastic Radiator and Thermostat housing assembly.
I would put these items on a preventative replacement schedule, if they haven't been replaced already.
Hi. I have an 02 Ford Explorer XLT 4.0. I don't have any check engine or service engine lights on. I wanted to know of I have a bad timing chain would it throw a code to warn me to replace it or will it only make the sounds and run bad? Wish I could send you guys a video of it. TIA
My ac blower turns off when iam cruising going up 100kph..but if the road is even..comes back..any comments is appreciated
What about the elephant in the room (transmission)
That's GM
I have a 02 explorer xls. Misfire code with a rough idle but smooth while the car is moving. I routinely decided to just change all my coils and spark plugs. Issue was still there, I checked for hose leaks checked my o2 sensors. One of them was very bad and saw that they can cause a rough idle with a misfire code. Changed it and the code was still there. I’ve pretty much given up cause I’m pretty much certain it’s something in the engine. Very annoyed
PLEASE MAKE A VIDEO FOR THESE MODEL YEARS FOR A FOG LIGHT WIRING AND HARNESS INSTALL WITH FOG LIGHT BUMPER KIT CHANGE.
I have a 2002 Explorer that is making a rubbing noise that sound like it is coming from the wheels, it stops when I take my foot off the exccelarator and starts again when I re-exccelarate again. What do you think the problem could be?
What does it mean when the for low light blinks and what's is the button for with the foot and the p button behind the steering wheel I Ned to now because I just bought one but no owners manual
Well I have a loud rattling noise coming from the transmission whenever I'm in drive/reverse while braked, sounds like the TC wants to just get going instead of sitting still. Great waiting at traffic lights!
What did you do to fix it cause mine doing the same thing was it the tire sensors or what
how about those two bolts under the dash that come loose and cause a starting and trans issue just lucky i found them i guess
Hey question I own a 2010 explorer xlt I drove it through a puddle and now it’s squeaks somewhere in the belt. I sprayed it went away and now it’s back.
My 2009 Explorer has wheel bearing issues. Is this common to this model? I've had other Explorers with the same issues. What's up with this model?
Of course
Number 2 & 3 has gotten my 04 Explorer! Number 2 requires 22 hrs of labor because the engine has to be pulled!!
+Pizzaman Hall Thanks for the feedback!
That's on the v6, what about the v8 version? That's what I have and they have a different set of problems.
Also you forgot to mention the OEM front wheel bearings only rated for 80k miles. I've put about 80k on mine and I have went through 3 wheen bearing on each side.
4.6 is solid af. Only thing I would be worried about is it's going to be harder on the already weak transmission
Hello I own a 2005 Ford Explorer.. It’s taking about 20 to 30 minutes to get warm .. The Temperature gauge indicator stay at C… no movement, then my gauge light flashes.. then the gauge starts to move.. However with the Temperature set at 85 degrees it’s not really hot inside the truck .. I replace the housing/ Sensor.. flush the heater core also..
hey I'm already subscribed to you guys been following you since 2020, I have the same exact car 05 Ford explorer Eddie Bauer but the problem I'm having is my fuel gauge it goes up and down when I fill it up and then as I'm driving it tends to go down and then it goes below e as if it start to say on the screen low fuel level I don't think it's broke because it goes up and down it just doesn't go up enough to tell me if I'm full of fuel always seemed empty even when I fill it up can you help don't want to spend too much money if I don't have to can you help me out do you have any tips
door ajar light always on. fixed it with wd40 and tie wraps
This video didn't even get close to talking about the biggest problem with this car, the transmission. 2002-2005 transmissions were built with plastic parts that break. Ford is responsible for building low quality vehicles but they do nothing about making good on their junk.
Watching this after catching mine on fire lol
I just bought an 02 4.6L V8 and it’s having some starting issues have to turn the key twice sometimes before it actually starts. Any ideas what it might be?
And yes the starter is good and so is the battery
Very well could be the security system. The keys are chipped and have to sometimes be reprogrammed by a dealership.
Don't forget that the glass part of the lift gate stops working
My 2003 timing chain jumps or broke. I’m tempting to get another vehicle of same kind.
How to fix the problem of 2005 model explorer it signal in the sensor the door is open while all doors are locked and we are driving help us please
These motors have 2 timing chains so you may have to remove the engine if the one in the back needs replaced
U didnt mention locking the cam shafts so they wont turn when u take timing chains off... So it can be timed rite and run great......
what about the door ajar switch common problem or thermostat housing
Got any more about this make of vehicle and year?
They forgot the transmission, no dip stick and it’s made out of aluminum, also the ground wire in the drivers door it will brake I still drive a 2002
+John Rumbaugh Thanks for the tip! We'll pass this info along to our production team.
My Ford explorer is not working. I have the ignition worked on but I only heard a clicking noise. I tried wiggling the key but it still doesn't crank
Another common problem is timing chain guides and chains. I had mine replaced at 150000 miles.
+Richard Ross Thanks for the feedback!
If anybody could give me some help with the p420 and it has a brand new cat that would be awesome I've already changed out the transmission I've changed out the ignition coil I've changed out the thermostat and thermostat housing I've changed out the oxygen sensors I've changed the shock struts. I've changed the mass air flow sensor. Lost on what this damn p420 is
what ended up happening?
My list of problems, transmission, rear glass hinges recall not fun at all, thermostat leaking , rear doors windows getting stuck when they are all the way up, temperature blend door actuator stuck on hot( left side of dash) mode door actuator (vacuum operated ) door plastic linkage broken . And just in case anyone id wondering the price to fix that rear cracked plastic trim, well it is really expensive to fix because of labor at least 9hrs trying to remove that glue , it is really time consuming
do you have the V8 or the V6?
I just Julius Manuel only owner of a Ford Explorer car of the year 2006, I wonder how many liter of water from the radiator enters the car.
Shocked to see nothing about the catastrophic transmission failures
It's because it isn't true. I would know, I have one.
@@hermanjohnson9180 LOL you are dead wrong. The 5R55W/5R55S are notorious for being one of the most problematic transmissions ever made. Can't count how many failed transmissions I've seen in these at the dealer auctions.
Can you show a radiator replacement for this model?
+Morgan We're always cycling through common cars. We'll add this repair to our list! 1aau.to/m/Shop-1AAuto-c
@@1AAuto thanks!
What could be the be the problem when the it doesn’t run smartly from beginning of the movement. Though it select gear normal but doesn’t move smartly
+Wole Sentimenta We wouldn't be able to diagnose an issue like that here, you may want to have a local mechanic take a look at it. Thanks for checking us out! 1aau.to/m/Shop-1AAuto-c
Rear end differential at
60k miles
+Zdenko Rakitnican Thanks for the feedback!
The white paint job they did on these is terrible everyone ive seen its flaking off
And yet no mention of the notorious transmission problems.