Exhaust Odor / Carbon Monoxide Intrusion

The 2011 through 2017 Explorer became the subject of a six-year NHTSA investigation after thousands of owners, including several police departments, reported exhaust odors entering the cabin. Investigators traced the highest readings to sealing gaps from police upfitting, to rear-end collision damage, and to cracked exhaust manifolds on some units.

Ford responded with a free field service campaign covering exhaust manifold inspection, gasket and drain valve sealing, and a climate control reprogram for more fresh air. Any Explorer from these years with a persistent exhaust smell deserves the same inspection. We check the manifold and rear seals, and confirm whether the campaign has been performed.

Power Steering Assist Failure

Certain 2011 through 2013 Explorers built with an early production run of the electric power steering gear can lose the motor position sensor signal, shutting down power steering assist without warning. Ford issued a formal recall covering the affected build window.

Drivers experiencing this report a sudden increase in steering effort at low speed, often accompanied by a dashboard chime. The remedy is either a software update to the power steering control module or a full steering rack replacement. We confirm recall eligibility by VIN before diagnosing further.

EcoBoost Timing Chain Stretch

First-generation 3.5-liter EcoBoost Explorers, built through 2016, feature a documented timing chain design that can stretch over time. Because the water pump also sits inside the timing case, a chain problem often shows up alongside cooling symptoms rather than on its own.

The clearest early warning is a rattle for a few seconds on cold start, sometimes progressing to rough idle or misfires as the chain stretches further. Left unaddressed, a badly stretched chain can jump timing and bend valves. We inspect the chain, tensioner, and cam timing components before recommending repair.

Internal Water Pump Failure

The 3.5-liter V6 used across the Explorer lineup places the water pump inside the engine, driven off the timing chain rather than mounted externally. When the internal seal fails, coolant has a direct path into the crankcase, and a small weep hole meant to signal early leakage often clogs before doing its job.

Watch for coolant loss with no visible external leak, a milky film on the oil dipstick, or an overheating warning with no obvious cause. This is not a job to postpone, as coolant-contaminated oil can quickly damage bearings. We pressure test the system and inspect the internal pump before contamination spreads.

Rear Axle Driveshaft Disconnect

Certain 2020 through 2022 Explorers built on the redesigned platform were recalled after Ford found the rear axle's horizontal mounting bolt can fatigue and snap. When it breaks, the driveshaft can disconnect, cutting off drive power and allowing the vehicle to roll if the parking brake isn't engaged.

NHTSA opened a formal investigation before Ford issued the recall, and dealers replace the mounting hardware at no cost. A related bulletin also covers drive shafts prone to fracturing along a weld seam on 2020 AWD models. We check recall status by VIN first, since this is a safety-critical repair covered under warranty.