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Ford1996–2024 Critical issues documented

Ford Explorer U625: common faults & what to check

The U625 is the Ford Explorer built 2020 onward. It was sold here with the 2.3 petrol, 3.0 petrol, and 3.3 hybrid. Of the 11 faults documented for the Explorer, 3 apply to this generation, each with its symptoms, what to inspect and a typical repair cost. Free, no account needed.

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  • Odometer history
  • Money owing
  • Reported stolen
  • Ownership history
  • Official NZ vehicle register data
  • NZ owned and operated

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11

Documented faults

Critical

Most serious

$1,800–$4,000

Typical repair

20

Service milestones

You're looking at the U625

3 engine variants are documented for this generation. Pick yours to narrow further, or keep reading for the generation as a whole.

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Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

A 2021 Ford Explorer is the U625 generation (2020 to now).

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Ford Explorer U625Engine not picked yet

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Can't confirm for this car

Ford Explorer · 2021

Narrowed to the year. No engine is recorded for this vehicle. Pick an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

  • No engine is recorded for this vehicle.

matched on year only

Ford Explorer service schedule

The 3 engines a 2021 Ford Explorer was sold with, each with its own intervals. Pick your engine above to narrow this to one. These are the model’s intervals — the car’s own service book is the only thing that can tell you what has actually been done to it.

Ford Explorer (Sixth Generation - ST-Line/Platinum/Active) · 2021–2024 · 2.3L EcoBoost I4 Hybrid

Hybrid

Due by distance

  1. 60,000 km

    Replace the spark plugs to maintain EcoBoost efficiency and inspect the hybrid cooling system.

  2. 100,000 km

    Evaluate the suspension bushings and consider replacing the turbocharger coolant lines, which show natural ageing.

  3. 150,000 km

    Refresh the transmission fluid and filter for longevity.

Ford Explorer (Sixth Generation) · 2020–2024 · 2.3L EcoBoost I4

Petrol

Due by distance

  1. 100,000 km

    Check the suspension bushings and steering rack components to maintain that refined Explorer ride quality.

  2. 150,000 km

    Service the transmission fluid and flush the cooling system professionally.

Ford Explorer (Sixth Generation) · 2020–2024 · 3.0L EcoBoost V6 ST

Petrol

Due by distance

  1. 100,000 km

    Evaluate suspension bushings and dampers to keep that 'new car' ride quality.

  2. 150,000 km

    Refresh the transmission fluid and filter for longevity.

See all 3 issues for this oneDocumented for the exact year and engine you picked, including 2 rated critical.
Body, brakes, suspension & interior1 critical1

01Rear axle mounting bolt fracture — loss of drive, or rolling away in Park

2020–2022Suspension
OccasionalSuspension $0–$4,000 to fix

Ford recalled around 238,000 Explorers from 2020 to 2022 because the rear axle horizontal mounting bolt can fracture, which lets the driveshaft or half-shafts disconnect from the rear axle. Two things then become possible: the vehicle loses drive while being driven, or it rolls away while parked without the parking brake applied. Ford has recorded 396 reports of the bolt failing. What makes this one worth real attention is its history — earlier campaigns in 2022 and 2023 delivered a powertrain software update that did not address the bolt itself, and a further recall followed because the problem persisted. So "the recall has been done" is not by itself the end of the question here; which recall, and when, both matter. There is a warning too: owners report a clunk or vibration under hard acceleration before the bolt fails completely.

Symptoms to notice

  • Clunk or heavy vibration from underneath during hard acceleration
  • Metallic noise from the rear axle area
  • A change in driveline vibration at open-road speed
  • Sudden loss of drive while the engine keeps running
  • Vehicle moving when left in Park without the parking brake applied

What to check

Take the VIN and ask a Ford dealer which of the rear axle campaigns have been applied to this vehicle and on what dates — ask it that way rather than "are there any outstanding recalls", because this vehicle had more than one attempt at the same fault and an early software-only fix does not mean the bolt was addressed. The check is free. Then drive it in a way that would provoke it: accelerate firmly from a standstill two or three times in a safe, clear place and listen and feel for a clunk from underneath or a vibration through the floor that arrives with the power. At open-road speed, note any driveline vibration or a change in the way it feels compared with lower speeds. Listen for a metallic noise from the rear when pulling away. Standing at the vehicle, park it on a slope, select Park and release the footbrake WITHOUT the parking brake applied, and confirm it holds solidly — then apply the parking brake before getting out. Ask the seller whether it has ever clunked under acceleration. If a workshop inspection is possible: ask specifically for the rear axle mounting bolt and bushing to be inspected.

Where to look: Rear axle — horizontal mounting bolt and bushing securing the axle assembly

Ask the seller

  • “Which rear axle recalls have been applied to this VIN, and on what dates?”
  • “Does it clunk or vibrate from underneath under hard acceleration?”
  • “Has it ever lost drive, or moved when parked?”
Fluid leaks1

02Rear main seal oil leak — a small part behind an expensive job

A rear main seal leak on the 2.3 is among the commonly reported faults on this Explorer.petrol2020–2024Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller
Depends on the exact engine — 1 moreDocumented for a specific engine we could not confirm from what you picked. Check the engine code on the car.
Engine, transmission & cooling1

01Ten-speed harsh shifting, clunks and sudden downshifts

Drive it long enough and in enough different ways for this to appear, because a short flat run will not find it.2020–2024TransmissionRead the full fault: symptoms, where to look, what to ask the seller
Other Ford Explorer engines and years8 documented issues that do not apply to the one you picked.
Engine, transmission & cooling6

014.0 SOHC timing chain 'death rattle' — plastic guides and rear cassette

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.petrol1997–2001EngineRead the full fault: symptoms, where to look, what to ask the seller

023.5 Cyclone V6 internal water-pump failure (coolant into engine)

Check the coolant reservoir level and look for a history of unexplained top-ups.petrol2011–2019CoolingRead the full fault: symptoms, where to look, what to ask the seller

03U502 2.0 EcoBoost Timing Chain Stretch

Cold-start the vehicle and listen immediately for chain rattle from the front of the engine.petrol2011–2019Engine
OccasionalEngine $1,800–$4,000 to fix

Does not apply

Unconfirmed. This entry does not match our record of which engines and years this model was sold with, and is awaiting review. Confirm it against the car before acting on it.

The 2.0L EcoBoost four-cylinder in the U502 Explorer exhibits timing chain stretch and tensioner wear at higher mileage. Chain slap on cold start is the first indicator; progression leads to timing deviation and potential chain failure with engine damage. Documented across US and AU Explorer owner forums and independent workshop reports. Oil change frequency is directly linked to the rate of tensioner wear.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Rattling or slapping from front of engine on cold start
  • Rattle that diminishes as engine warms
  • Camshaft position or timing-related fault codes
  • Rough idle or timing-related misfire on higher mileage

What to check

  1. Cold-start the vehicle and listen immediately for chain rattle from the front of the engine.
  2. Scan for camshaft or variable valve timing fault codes.
  3. Review oil change frequency and type in service records.

Where to look: Front of engine, timing chain and tensioner assembly on 2.0 EcoBoost

Parts involved: Timing chain.

Ask the seller

  • “Any rattling or slapping noise at cold start?”
  • “Has the timing chain or tensioner been replaced?”
  • “What is the oil change history?”
  • “Any engine warning lights related to timing?”

044.0 SOHC V6 timing chain cassette & tensioner rattle

Cold-start the engine and listen at the front timing cover for a chain rattle in the first few seconds and again on a light throttle blip.petrol1996–2001EngineRead the full fault: symptoms, where to look, what to ask the seller

055R55E automatic transmission 2-3 flare & band/servo wear

On a test drive feel for a flare between 2nd and 3rd and any slip under load up a hill.petrol1996–2001TransmissionRead the full fault: symptoms, where to look, what to ask the seller

06Power Transfer Unit (PTU) overheating & failure on AWD

On an AWD car, sniff for a hot burnt-oil smell after a drive and listen for a rising whine or grinding on acceleration.petrol2011–2019TransmissionRead the full fault: symptoms, where to look, what to ask the seller
Fluid leaks2

01U502 PTU and RDU Transfer Unit Seal Leaks

Check for dried or fresh oil residue.petrol2011–2019Fluid Leaks
Very commonFluid Leaks $500–$3,000 to fix

Does not apply

The Power Transfer Unit and Rear Drive Unit on the U502 Explorer have very widely documented front output shaft and pinion seal leaks. Reported by hundreds of owners across US and AU Explorer communities. Seals fail from heat and age, draining ATF and leading to progressive PTU and RDU bearing wear. One of the most consistently documented mechanical failures on this generation Explorer.

Symptoms to notice

  • Oil drips beneath PTU or rear differential area
  • ATF or gear oil smell from drivetrain
  • Whine from PTU or RDU at speed
  • AWD warning or traction control warning light

What to check

  1. Check for dried or fresh oil residue.
  2. Ask seller about any AWD or traction warning events.
  3. If a workshop inspection is possible: With vehicle on a hoist, inspect the PTU at the front of the gearbox and the RDU rear differential unit for oil seeping from shaft seals.

Where to look: Power Transfer Unit (front of transmission) and Rear Drive Unit (rear differential)

Parts involved: Transfer case.

Ask the seller

  • “Have the PTU and RDU seals been inspected or replaced?”
  • “Any drips noticed under the vehicle?”
  • “Has the AWD warning light ever appeared?”

02U502 6F55 Transmission Cooler Line Leak

Inspect transmission cooler lines at both the transmission case connection points and along their routing for cracks or wet fittings.petrol2011–2019Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller

Ford Explorer faults in detail

Narrowed to the Ford Explorer · 2021. Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

Rear main seal oil leak — a small part behind an expensive jobMajor · Fluid LeaksTen-speed harsh shifting, clunks and sudden downshiftsCritical · Transmission

What these repairs cost on other cars

Some of the Ford Explorer’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Ford models

Ford Ranger45 documented faultsFord Focus37 documented faultsFord Falcon36 documented faultsFord Fusion11 documented faultsFord Courier10 documented faultsFord Transit10 documented faults

Ford Explorer buyer questions

Is the Ford Explorer reliable?

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?

We've catalogued 11 known faults for the Ford Explorer, covering engine, transmission, and cooling. All 11 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Ford Explorer?

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?

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 $24.90 far less than the cost of missing one of the faults on this page.