2012–2019 U502 (5th generation)
2012–2019 Ford Explorer Common Problems and Years to Avoid
6 documented problems with the 2012–2019 Ford Explorer, with symptoms, affected years, and typical repair costs. 3 of them are serious. 4 carry a recall or TSB number.
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2012–2019 Ford Explorer recalls and service bulletins
| Recall / TSB | Issue | Severity |
|---|---|---|
| NHTSA PE16-008 / EA17-002 (closed Jan 2023, no recall); Ford TSB 19-2346; CSP 17N03 (Police Interceptor) | Exhaust odor / carbon monoxide in cabin (the 'CO saga') | major |
| No recall; Roe v. Ford class action dismissed Jan 2024 after settlement | 3.5L water pump failure, internal, chain-driven (also 3.5L EcoBoost) | major |
| NHTSA 21V-537 (Ford 21S32); expanded to 2017–2019 in late 2025 (412,774 vehicles) | Rear suspension toe link fracture (recalls) | major |
| NHTSA 24V-031 (Ford 24S02) | A-pillar trim can fly off (recall) | minor |
Recall work is free at a franchised dealer regardless of the vehicle's age, mileage, or how many owners it has had. Check your VIN against the NHTSA database to see what is still outstanding on your specific vehicle, a recall listed here may already have been performed.
Exhaust odor / carbon monoxide in cabin (the 'CO saga')
majorThousands of owners, and police departments running the Police Interceptor Utility, reported exhaust smell and carbon monoxide readings in the cabin, typically during full-throttle climbs with the A/C on recirculate. NHTSA opened investigation PE16-008 in July 2016 and upgraded it to engineering analysis EA17-002 in 2017 covering 2011–2017 Explorers (1.3M+ vehicles); it closed the probe in January 2023 without ordering a recall, citing CO levels below harmful thresholds in testing. Ford issued free 'complimentary service' repairs (reprogram A/C, replace rear drain valves, reseal the rear of the body, TSBs incl. 19-2346, CSP 17N03 for Police units) for concerned owners. If you smell exhaust, get the campaign repairs done and check for cracked exhaust manifolds and unsealed body seams.
3.5L water pump failure, internal, chain-driven (also 3.5L EcoBoost)
majorThe Cyclone 3.5L V6's water pump is inside the engine, driven by the timing chain. When its seal fails, coolant can leak into the crankcase and mix with oil, wrecking bearings before the driver notices; even a caught-early failure requires timing-cover-off surgery. Dealer repairs commonly run $2,000–$4,500, and a pump that dumps coolant into the oil can total the engine ($6,000–$9,500). A class action (Roe v. Ford) covering 2007–2020 Duratec/Cyclone vehicles was dismissed in January 2024 after a confidential settlement. There is no recall. Watch for coolant loss with no visible leak, sweet smell, or a weep hole drip at the front of the engine; failures cluster around 80k–150k miles.
Rear suspension toe link fracture (recalls)
majorA cross-axis ball joint in the rear suspension can seize, stressing the rear toe link until it fractures, which causes sudden loss of steering control. Ford recalled 2013–2017 Explorers in July 2021 (NHTSA 21V-537, Ford 21S32, ~775k vehicles) to inspect and replace the cross-axis ball joint and toe link, and expanded the campaign to 412,774 2017–2019 Explorers in a follow-up recall announced in late 2025. Clunks or knocking from the rear over bumps are the warning sign. Check your VIN. This is a free fix and a genuine safety issue.
Power transfer unit (PTU) leaks and failure (AWD models)
moderateThe PTU that sends power to the rear axle on AWD Explorers runs less than a quart of fluid next to a hot exhaust, the fluid cooks, seals leak (commonly the rear output shaft seal), and the unit eventually whines, grinds, or seizes. Ford lists no service interval, which owners and independent techs widely blame for the failures. Changing the 75W-140 fluid every 30k–60k dramatically extends life. Replacement PTUs run $800–$1,400 for the part plus $800–$1,500 labor.
A-pillar trim can fly off (recall)
minorThe A-pillar exterior trim pieces flanking the windshield can detach at speed if their retention clips were not fully engaged at assembly, creating a road hazard. Ford recalled 1.89 million 2011–2019 Explorers in January 2024 (NHTSA 24V-031, Ford 24S02). Dealers inspect and replace the trim free. Cosmetic-level severity for the driver, but do the free fix.
MyFord Touch / SYNC infotainment freezes
minor2012–2015 cars with MyFord Touch are notorious for frozen screens, reboot loops, and lost Bluetooth pairings; the system was a lawsuit magnet industry-wide. Software updates (up to SYNC 3.10) help, and 2016+ models with SYNC 3 are far better. A master reset (or pulling the battery cable for a few minutes) clears most one-off freezes.
Problems listed here are compiled from NHTSA complaints, recalls, technical service bulletins, and widely documented owner reports for the 2012–2019 Ford Explorer. Not every vehicle will experience these issues.
Which Ford Explorer model years does this cover?
These problems and recalls specifications apply to every Ford Explorer built from 2012 through 2019 — the U502 (5th generation), mid-size 3-row crossover suv (unibody, fwd/awd). Nothing in this specification changes between those model years. Pick your year for the engines it offered, what changed that year, and the problems recorded against it.
What changed during the 2012–2019 Ford Explorer
- 20122.0L EcoBoost joins as an FWD-only economy option (no tow package)
- 2013Explorer Sport added: 365-hp 3.5L EcoBoost, AWD, 352mm brakes, 20-in wheels
- 2014Essentially unchanged: a few new exterior colors added; Limited trim gains standard heated second-row seats
- 2015Essentially unchanged: Limited trim adds an available adaptive cruise control option, with second-row heated seats offered as an option lineup-wide
- 2016Major facelift: new front/rear styling, 280-hp 2.3L EcoBoost replaces the 2.0L, Platinum trim (3.5L EcoBoost) added, SYNC 3 arrives mid-cycle; low-beam bulb changes to H11
- 2018–2019Minor updates; carryover mechanicals in the final years before the RWD-platform redesign
2012–2019 Ford Explorer problems and recalls: common questions
What are the most common problems with the 2012–2019 Ford Explorer?
- The recurring ones are: exhaust odor / carbon monoxide in cabin (the 'co saga'); 3.5l water pump failure, internal, chain-driven (also 3.5l ecoboost); rear suspension toe link fracture (recalls); power transfer unit (ptu) leaks and failure (awd models); a-pillar trim can fly off (recall). Each is detailed above with symptoms, affected years, and typical cost.
Which 2012–2019 Ford Explorer years should you avoid?
- The years to be most careful with are those affected by exhaust odor / carbon monoxide in cabin (the 'co saga') (2011–2017 (complaints continue through 2019)) and 3.5l water pump failure, internal, chain-driven (also 3.5l ecoboost) (2012–2019 (all 3.5L engines, NA and EcoBoost)) and rear suspension toe link fracture (recalls) (2013–2019 (worst in road-salt states)). A documented problem is not automatically a reason to walk away. Service records showing the repair was done change the picture entirely.
Are there recalls on the 2012–2019 Ford Explorer?
- 4 of the issues listed carry a recall or technical service bulletin: NHTSA PE16-008 / EA17-002 (closed Jan 2023, no recall); Ford TSB 19-2346; CSP 17N03 (Police Interceptor) (exhaust odor / carbon monoxide in cabin (the 'co saga')), No recall; Roe v. Ford class action dismissed Jan 2024 after settlement (3.5l water pump failure, internal, chain-driven (also 3.5l ecoboost)), NHTSA 21V-537 (Ford 21S32); expanded to 2017–2019 in late 2025 (412,774 vehicles) (rear suspension toe link fracture (recalls)), NHTSA 24V-031 (Ford 24S02) (a-pillar trim can fly off (recall)). Recall work is free at a franchised dealer regardless of age or mileage. Check your VIN on the NHTSA site to see what is outstanding.
How much do 2012–2019 Ford Explorer repairs typically cost?
- Typical figures for the issues above: exhaust odor / carbon monoxide in cabin (the 'co saga'), Free under Ford's complimentary service program; $500–$1,500 if paying for manifold or sealing work independently; 3.5l water pump failure, internal, chain-driven (also 3.5l ecoboost), $2,000–$4,500 (pump, done proactively); $6,000+ if the engine ingests coolant; rear suspension toe link fracture (recalls), Free under recall; $400–$900 per side if paying out of pocket; power transfer unit (ptu) leaks and failure (awd models), $100–$200 fluid service (preventive); $1,500–$3,000 for PTU replacement.
Sources
- Ford. What is the recommended engine oil for my vehicle? (oil/filter lookup)
- NHTSA EA17-002 ODI resume, Explorer exhaust odor engineering analysis
- NHTSA recall 21V-537 (Ford 21S32), rear suspension toe link
- NHTSA recall 24V-031 (Ford 24S02), A-pillar trim detachment
- Ford Authority / CarComplaints, 3.5L water pump class action dismissed after settlement
- Ford.com parts, Motorcraft BXT-65-850 Group 65 battery fitment
- Ford.com parts, Motorcraft SP-546 spark plug (gap 0.045)
- Ford.com parts, Motorcraft FP-70 cabin air filter (CV6Z-19N619-A)
- fueleconomy.gov, 2013 and 2017 Ford Explorer EPA ratings
- WiperBladesUSA, 2016 Explorer wiper sizes 26/22/11