Ford

Explorer (3rd)

2002-2005 · Midsize SUV ยท 3 engines
Best Engine โŒ Avoid (1.3)
6,471 NHTSA Complaints
14 Recalls
95 Fire Reports
291 Crash Reports
Includes data from: EXPLOREREXPLORER SPORT
View all 4 generations of the Ford Explorer → ๐Ÿ“‹ Inspection checklist

NHTSA Safety Ratings About NHTSA ratings

Overall Not Rated
Frontal Crash
โ€”
Side Crash
โ€”
Rollover
3/5 (22.8% risk)
ESC: Optional FCW: No LDW: No
Overall Not Rated
Frontal Crash
โ€”
Side Crash
โ€”
Rollover
3/5
ESC: Optional FCW: No LDW: No
Overall Not Rated
Frontal Crash
โ€”
Side Crash
โ€”
Rollover
2/5
ESC: No FCW: No LDW: No
Overall Not Rated
Frontal Crash
โ€”
Side Crash
โ€”
Rollover
3/5
ESC: Optional FCW: No LDW: No
Overall Not Rated
Frontal Crash
โ€”
Side Crash
โ€”
Rollover
2/5
ESC: No FCW: No LDW: No

Engine Reliability Ratings

Ford Explorer Unidentified Engine

โŒ Avoid (1.0)
2,393 complaints 598.2 per year
37 fire reports 5 fatalities
View details

Complaint Breakdown

transmission
939
body
482
suspension
266
other
193
engine
165

Known Issues

Transmission Issues (939 complaints)
Body/Trim Issues (482 complaints)
Suspension Issues (266 complaints)
Show 7 additional engine variants with limited data
These engines appear in fewer than 10 owner complaints and aren't included in the main ratings above. Low counts can mean a genuinely clean record, but they can also reflect VIN-decode anomalies in NHTSA data. Treat as informational, not as a confident rating.

5.9-I6-Diesel

5.9L 6-cyl / 210 hp
โœ… Recommended (4.6)
2 complaints 2.0 per year Diesel
View details

Complaint Breakdown

electrical
1
wheels tires
1

Known Issues

Electrical System Issues (1 complaints)
Wheels & Tires Issues (1 complaints)

Ti-VCT

3.5L 6-cyl / 290 hp
โœ… Recommended (5.0)
1 complaint 1.0 per year Gasoline
View details

Complaint Breakdown

electrical
1

Known Issues

Electrical System Issues (1 complaints)

3.8-V6-Gas

3.8L 6-cyl / 140 hp
โœ… Recommended (5.0)
1 complaint 1.0 per year Gasoline
View details

7.3T-V8-Diesel

7.3L 8-cyl Turbo / 215 hp
โœ… Recommended (3.5)
1 complaint 1.0 per year Diesel
1 fire report
View details

Complaint Breakdown

engine
1

Known Issues

Engine Issues (1 complaints)

5.4T-V8-Gas

5.4L 8-cyl Turbo / 380 hp
โœ… Recommended (5.0)
1 complaint 1.0 per year Gasoline
View details

Vehicle-Level Issues

These issues affect the Ford Explorer regardless of engine variant.

Transmission Issues (2,453 complaints)
transmission critical
Body/Trim Issues (1,564 complaints)
body critical
Suspension Issues (550 complaints)
suspension critical
Engine Issues (477 complaints)
engine critical
Cooling System Issues (202 complaints)
cooling critical

Recalls (14)

09V399000Oct 12, 2009serious
Vehicle Speed Control

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.

09E025000Nov 4, 2009serious
Exterior Lighting

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.

09E012000Jul 3, 2009serious
Exterior Lighting

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.

07E104000Nov 11, 2007serious
Visibility

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."

07V336000Mar 7, 2007serious
Vehicle Speed Control

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.

06E049000May 23, 2006serious
Exterior Lighting

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.

06E026000Mar 22, 2006serious
Exterior Lighting

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.

06V114000Oct 3, 2006serious
Seats

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.

04V442000Sep 12, 2004cosmetic
Structure

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.

03V094000Jul 2, 2003serious
Structure

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.

03V281000May 7, 2003serious
Seats

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.

01V171000May 23, 2001serious
Tires

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.

01X001000May 21, 2001critical
Tires

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.

01I010000Oct 3, 2001cosmetic
Visibility

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.

Alternatives in Midsize SUV

Frequently Asked Questions

What are the most common 2002-2005 Ford Explorer problems?

The 2002-2005 Ford Explorer has accumulated 6,471 NHTSA complaints. The most frequently reported problem areas are Transmission, Body/Trim, Suspension. As with any used vehicle, an inspection before buying and a vehicle history report are recommended.

Which Ford Explorer engine is most reliable?

The 2002-2005 Ford Explorer was offered with 10 engine options. Based on NHTSA complaint data, the 4.6L 8-cyl has the lowest complaint density and is considered the most reliable choice for buyers.

Is the 2002-2005 Ford Explorer a good used car?

The 2002-2005 Ford Explorer can be a sound used car depending on trim, mileage, and maintenance history. With 6,471 total NHTSA complaints on record, prospective buyers should review the known problem areas and check for open recalls before buying.

How many NHTSA complaints does the 2002-2005 Ford Explorer have?

The 2002-2005 Ford Explorer has 6,471 complaints filed with NHTSA as of our latest data pull. Complaint counts reflect owner-reported issues and do not necessarily indicate defects or safety risks on their own.

What recalls affect the 2002-2005 Ford Explorer?

There are 14 NHTSA recalls affecting some 2002-2005 Ford Explorer vehicles. Recall status varies by VIN โ€” check the NHTSA recall database at recalls.nhtsa.dot.gov with your specific VIN to confirm which campaigns apply.

What should I check before buying a used Ford Explorer?

Before buying a used Ford Explorer, verify all open recalls are completed via the NHTSA VIN lookup tool. Pay particular attention to Transmission, Body/Trim, Suspension, which are the most commonly reported problem areas. Request maintenance records, have an independent mechanic inspect the vehicle, and run a vehicle history report to check for prior accidents or 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. 6,471 complaints analyzed. Data confidence: high. Last updated: 2026-05-23.

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