Thinking about buying a used Ford Explorer (1996–2024) in New Zealand? We've documented 11 known faults for this model spanning engine, transmission, cooling, and suspension. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
11
Documented faults
Critical
Most serious
$1,800–$4,000
Typical repair
5
Systems covered
Known Ford Explorer faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
The 4.0 single-overhead-cam V6 in these Explorers has one famous fault and it is the one that decides whether the vehicle is worth buying. Its timing chain guides are plastic and its tensioners wear out, typically somewhere past 220,000 to 280,000 km, and the result is the noise owners call the death rattle. It starts as a rattle only on a cold start, then rattles all the time, then the engine sounds like a diesel. Two things make it worse than an ordinary chain job. First, this is an interference engine, so a chain that comes off puts the pistons into the valves and ends the engine. Second, one of the chain cassettes sits at the BACK of the engine against the bulkhead, so reaching it means removing the engine — which is why the repair costs a large multiple of the parts and why so many of these were scrapped rather than fixed.
Symptoms to notice
Rattle from the engine on a cold start, clearing after a few seconds at first
Rattle that becomes constant, or is loudest around 2,400 to 2,500 rpm under acceleration
Engine sounding like a diesel once the noise is established
Misfires or an engine warning light once the chain has jumped teeth
Rough running, or a no-start after the fact
What to check
Be there for a stone-cold start — this is the whole inspection and a seller who has warmed the engine before you arrive has removed the only evidence that matters, so arrange to come back rather than settle. Stand at the front with the bonnet up as it fires and listen hard to the first five to ten seconds: a healthy one is quiet almost immediately, and a rattle or chatter that hangs on is the fault. Then listen at the back of the engine as well, against the bulkhead, because the rear cassette is the expensive one. Once warm, take it for a drive and hold it at around 2,400 to 2,500 rpm under gentle acceleration, listening for a rattle that appears at that speed. Watch for an engine warning light and note any misfire or roughness. Ask the seller plainly whether it rattles on a cold morning and how long it has done so — owners of these know the noise and usually name it. Check the service history for any timing chain work, which transforms the vehicle's value. If a workshop inspection is possible: have the stored codes read for camshaft timing faults.
Where to look: Engine — timing chains, plastic guides and tensioners, including a cassette at the rear of the engine
Ask the seller
“Does it rattle when started on a cold morning, and for how long?”
“Have the timing chains and guides ever been replaced, and can I see the invoice?”
“How often has the oil been changed?”
02U502 6F55 Transmission Cooler Line Leak
MajorCommonFluid Leaks $300–$900 to fix
The 6F55 six-speed automatic transmission in the U502 Explorer has documented cooler line fitting leaks at the transmission case connections. Quick-connect fittings and the line body itself can fail from vibration and heat cycling. Documented across US and AU Explorer owner forums. ATF loss from cooler line failure leads to transmission overheating and can cause shift quality deterioration and internal damage if not caught early.
Symptoms to notice
Red ATF dripping under vehicle near transmission
ATF staining on transmission casing or underbody
Burning smell from transmission area
Transmission slip or harsh shifting if ATF level is low
What to check
Inspect transmission cooler lines at both the transmission case connection points and along their routing for cracks or wet fittings. Check ATF level and condition. Look for dried reddish-brown staining on the underside.
Where to look: Transmission cooler lines, fittings at transmission case and cooler
Ask the seller
“Any ATF drips noticed under the vehicle?”
“Has the transmission been serviced recently?”
“Any transmission slipping or shift quality concerns?”
TransmissionCritical
CoolingCritical
SuspensionCritical
EngineCritical
EngineMajor
TransmissionMajor
Fluid LeaksMajor
TransmissionMajor
Fluid LeaksMajor
9 more documented faults on the Ford Explorer
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 11 documented faults for the Ford Explorer, the recurring problem areas are engine, transmission, and cooling. A Ford Explorer with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Ford Explorer?
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We've catalogued 11 known faults for the Ford Explorer, covering engine, transmission, and cooling. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Ford Explorer?
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Most single repairs on the Ford Explorer fall between $1,800–$4,000 at NZ independent-workshop rates. Some of the 11 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Ford Explorer?
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Yes. A Ford Explorer inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.