Thinking about a 2004-2007 Ford Explorer... any known issues to watch for?

Discussion
1

I’m considering getting a Ford Explorer from 2004 to around 2008. I know there was a facelift in 2006. Ideally, I’d go for the 4.6L V8 since I hear it’s more reliable than the 4.0L V6. The mileage difference doesn’t seem significant, and I’ve heard the modular V8s can last a long time with proper care.

I’m more of a Jeep guy, so I don’t have much experience with Explorers. Are there any common problems with these years? Or are they just not worth it?

The ones in my price range are between 90,000 km (about 56,000 miles) and 130,000 km (81,000 miles). Planning to use it for winter driving in Canada, summer camping trips, and some light towing. Appreciate any advice!

2

I haven’t owned one, but I see a lot of them on the road, so people seem to hold onto them. Good call avoiding the 4.0—it’s known for cam chain tensioner issues. The 4.6 V8 is a better choice. One thing to note is that the rear hatch tends to crack near the Ford emblem. It’s very common and not much you can do about it.

3

@Remington
Yep, the hatch crack is a thing. About 90% of these models have it. We sell quite a few of them, and almost all have that issue.

4

Can anyone provide more info about the issues with the 4.0L? My girlfriend just bought one, and now I’m worried.

5

Ellington said:
Can anyone provide more info about the issues with the 4.0L? My girlfriend just bought one, and now I’m worried.

The timing chain tensioners fail often, and the thermostat housing is another weak spot. I’m a mechanic, and I see these problems all the time.

6

Besides the infamous rear hatch crack (Dorman makes cheaper replacement parts now), here are two other issues I’ve seen:

  1. The defrost actuator in the plenum can break, leaving you stuck in defrost mode. I had to zip tie mine open so air could get into the cabin.
  2. Blend door actuators fail often. Some are a pain to replace because you have to remove the dash.
7

I own a 2004 4.0 XLT, and if you’re handy, it’s not a bad choice. Parts are cheap and easy to find. I tow a 17’ boat with no issues. Had an overheating problem for ages that turned out to be just a bad reservoir cap—cost me $9 to fix after throwing $1600 at it.

Other issues I’ve dealt with: blend door repairs, alternator replacement ($145), and the usual cracked rear hatch. It’s not perfect, but it’s reliable enough for me and decent on gas for its size. Plus, my wife likes it, so there’s that.

8

They’re called Exploders for a reason.

9

Ariya said:
They’re called Exploders for a reason.

I thought that nickname came from the Firestone tire recall?

10

Blake said:

Ariya said:
They’re called Exploders for a reason.

I thought that nickname came from the Firestone tire recall?

No, it’s because they have a reputation for being unreliable.

11

@Ariya
Not as bad as people think. I’ve sold over 60 of them, and only one had a major engine issue due to the timing chain tensioner. They’re not Honda, but for domestic brands, they’re solid.

12

@Ariya
After owning a Ford with a dropped valve seat, I’m never buying another one.

13

@Ariya
I’ve got a 2002 Ranger with a 3.0L engine. Not as reliable as my old Hondas, but it’s decent. I’ve done some major repairs myself, but overall, it’s held up fine.

14

I think I’ll just find a low-mileage XJ Cherokee since I know how to work on those. These comments are brutal! I assumed Explorers would be similar to Expeditions since my buddy has had five of those with no issues. Thanks for the reality check!

15

@Maxwell
Odd. I’ve owned three Explorers (a ‘93, ‘95, and ‘02), and they were all reliable. The first one only went because it got hit by a semi.

16

@Maxwell
Before you buy an XJ, look up the 0331 head issue. I just replaced one for a friend—it cost $900 and a lot of work.

17

Darby said:
@Maxwell
Before you buy an XJ, look up the 0331 head issue. I just replaced one for a friend—it cost $900 and a lot of work.

Good point. I know about the later heads, but swapping them doesn’t scare me. Ideally, I’ll find a ‘98. For anyone else looking, just remember every vehicle has its quirks.

18

Avoid the 4.0L at all costs.

19

Starters on these are a nightmare. Ford trucks in general seem to have this issue.