Explorer (3rd)
Data covers 2 NHTSA model names
Reliability Score
Complaints by Engine Code
4.0-V6-Gas
4.0L 6-cyl / 207 hpView details
Complaint Breakdown
Ford Explorer Unidentified Engine
View details
Complaint Breakdown
4.6-V8-Gas
4.6L 8-cyl / 225 hpView details
Complaint Breakdown
Show 7 additional engine variants with limited data
5.0-V8-Gas
5.0L 8-cyl / 215 hpView details
Complaint Breakdown
5.9-I6-Diesel
5.9L 6-cyl / 210 hpView details
Complaint Breakdown
5.4-V8-Gas
5.4L 8-cyl / 255 hpView details
Complaint Breakdown
Ti-VCT
3.5L 6-cyl / 290 hpView details
Complaint Breakdown
3.8-V6-Gas
3.8L 6-cyl / 140 hpView details
Complaint Breakdown
7.3T-V8-Diesel
7.3L 8-cyl Turbo / 215 hpView details
Complaint Breakdown
5.4T-V8-Gas
5.4L 8-cyl Turbo / 380 hpView details
Complaint Breakdown
Owner Complaints by System
Complaints owners filed with NHTSA about the Ford Explorer, counted across every engine. A complaint can name more than one system.
What to check on a used 2002-2005 Ford Explorer
On a used 2002-2005 Ford Explorer, the systems with the most NHTSA owner complaints are the transmission and drivetrain (2,425), the body and structure (1,553) and the suspension (539). Each one has an inspection step below, with counts as of 2026-10-12. A complaint is an owner report, not a confirmed defect, and counts rise with sales.
- Accelerate gently through every gear, then once at full throttle. Shift into Reverse and back to Drive.Costly repair. NHTSA has 2,425 owner complaints on the 2002-2005 Ford Explorer about the transmission and drivetrain, all engines combined.
- Open and close every door, the hood and the trunk or hatch. Check the latches, the seals and the gaps between panels.Minor. NHTSA has 1,553 owner complaints on the 2002-2005 Ford Explorer about the body and structure.
- Drive over a speed bump and a rough patch at 15 to 20 mph with the radio off.Safety. NHTSA has 539 owner complaints on the 2002-2005 Ford Explorer about the suspension.
- Start the engine cold and listen for the first 30 seconds, then again at idle once it is warm.Costly repair. NHTSA has 461 owner complaints on the 2002-2005 Ford Explorer about the engine, all engines combined.
- With the engine cold, check the coolant level and color, then watch the temperature gauge on the drive.Costly repair. NHTSA has 331 owner complaints on the 2002-2005 Ford Explorer about the cooling system, all engines combined.
Recalls (14)
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Show 9 older recalls
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT FRACTURES, THE SEAT BACK MAY RECLINE UNTIL IT MAKES CONTACT WITH AN OBJECT BEHIND THE SEAT, SUCH AS THE SECOND ROW SEAT CUSHION.
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT, THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT FRACTURES AND DOES NOT JAM IN THE SEAT BACK FRAME, THE SEAT BACK MAY RECLINE UNTIL IT MAKES CONTACT WITH AN OBJECT BEHIND THE SEAT, SUCH AS THE SECOND ROW SEAT CUSHION.
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE RIGHT SIDE TIRES MAY HAVE HORIZONTAL CUTS ON THE EDGE OF THE TREAD THAT COULD HAVE OCCURRED DURING VEHICLE ASSEMBLY.
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 2002 FORD EXPLORER AND MERCURY MONTAINEER SPORT UTILITY VEHICLES. THE BRACKETS CONNECTING THE LEFT CYLINDERS TO EACH SIDE OF THE LIFTGATE GLASS COULD ROTATE OUT OF POSITION IF EITHER THE URETHANE BOND OR TORQUE ARE NOT SUFFICIENT.
NHTSA Safety Ratings About NHTSA ratings
Alternatives in Midsize SUV
Frequently Asked Questions
What are the most common 2002-2005 Ford Explorer complaints?
Owners have filed 6,347 complaints with NHTSA about the 2002-2005 Ford Explorer. The systems they name most often are the transmission, the body and trim and the suspension.
Is the 2002-2005 Ford Explorer a good used car?
That depends on the model year, the mileage and the maintenance history of the car in front of you. Owners have filed 6,347 complaints with NHTSA about the 2002-2005 Ford Explorer. Check which systems they name most often and whether a recall is still open on that car.
How many NHTSA complaints does the 2002-2005 Ford Explorer have?
NHTSA has 6,347 owner complaints on file for the 2002-2005 Ford Explorer as of the latest data pull. A complaint is an owner's report, not a confirmed defect, and counts rise with sales.
What recalls affect the 2002-2005 Ford Explorer?
NHTSA lists 14 recalls covering some 2002-2005 Ford Explorer vehicles. Which ones apply depends on the VIN: enter it at nhtsa.gov/recalls to see the open campaigns on a specific car.
What should I check before buying a used Ford Explorer?
Run the VIN through NHTSA's recall lookup and confirm every open recall has been done. Look hardest at the transmission, the body and trim and the suspension, the systems owners complain about most. Ask for maintenance records, have an independent mechanic inspect the car and run a vehicle history report for prior accidents and title issues.
What are the NHTSA crash test ratings for the Explorer?
The 2004 Ford Explorer received an overall N/A-star safety rating from NHTSA. Frontal crash: N/A stars. Side crash: N/A stars. Rollover: 3 stars (22.8% rollover probability). Electronic Stability Control: Optional. Forward Collision Warning: No. Lane Departure Warning: No. These ratings are based on standardized crash tests conducted by the National Highway Traffic Safety Administration.
Data from NHTSA federal complaints database. 6,347 complaints analyzed. Data confidence: high. Last updated: 2026-10-12.