Five Ford Explorer Engine Problems You Must Fix

A strange sound when you start the engine. A shift that doesn’t feel right. A check engine light that is flashing then disappears; these issues may seem minor at first, but they are early warnings of major engine trouble.

At Cowden Automotive in San Francisco, we know exactly what goes wrong with Ford Explorers because we repair these SUVs every day. Timing chains fail, head gaskets leak, and throttle bodies shut down without warning. These problems don’t just affect performance—they can destroy your engine if ignored.

Is your Explorer showing signs of trouble? These are the five most common failures and how to prevent them.

Timing Chain Rattle Leads To Complete Engine Failure (1997-2010)
If you own a 1997-2010 Ford Explorer with the 4.0L SOHC V6, listen closely when you start the engine. If you hear a metallic rattling sound, your timing chain guides are breaking down. Ford used plastic guides that wear out quickly, causing the timing chain to loosen. If the chain jumps timing, it can bend valves, crack pistons, and destroy the cylinder head.

Solution: A timing chain replacement requires engine removal in some cases, but catching it early prevents a full engine rebuild. If you hear a rattle at startup, get it checked immediately before it turns into a much bigger repair.

Transmission Failure Creates Excessive Engine Strain (2002-2005)
Ford Explorers built between 2002 and 2005 are notorious for transmission problems. Drivers report slipping gears, delayed engagement, and sudden loss of power. A failing transmission forces the engine to compensate, leading to overheating, higher RPMs, and premature engine failure. If left unfixed, metal fragments from a worn-out transmission can circulate through the engine, damaging internal components.

Solution: Regular fluid changes can extend transmission life, but once it starts slipping, a rebuild is often necessary. Catching transmission problems early prevents excessive wear on your engine and avoids costly repairs.

Head Gasket Failure Causes Coolant Leaks And Overheating (2006-2010)
Ford Explorers equipped with the 4.6L V8 engine from 2006 to 2010 are known for head gasket failures. If your vehicle loses coolant without visible leaks, overheats, or produces white smoke from the exhaust, the head gasket may be failing. This issue happens because the aluminum cylinder heads warp under high temperatures, allowing coolant to leak into the combustion chamber. If ignored, it can lead to catastrophic engine failure.

Solution: Watch for early warning signs such as unexplained coolant loss or an engine running hotter than normal. Fixing a head gasket early can prevent a much more expensive engine replacement.

Throttle Body Failure Shuts Down Acceleration (2011-2016)
Ford replaced traditional throttle cables with electronic throttle bodies in 2011-2016 Explorers, but these systems have a major flaw. Drivers report sudden loss of power, hesitation, and vehicles going into limp mode without warning. The problem comes from a failing throttle position sensor, which prevents the engine from responding to accelerator input.

Solution: A malfunctioning throttle body must be replaced to restore full power and prevent unsafe driving conditions. If your Explorer suddenly loses acceleration or hesitates, don’t wait for it to happen in heavy traffic.

Carbon Build-Up Reduces Power And Efficiency (2016-Present)
Some drivers experience transmission problems, such as rough shifting, hesitation, or fluid leaks.

Solution: Modern Ford Explorers with 2.3L and 3.5L EcoBoost engines use direct fuel injection, which improves efficiency but creates a hidden problem. Over time, carbon deposits form on the intake valves, restricting airflow and causing poor acceleration, rough idling, and misfires. Since fuel never touches the valves, this buildup worsens over time and reduces engine performance.

Don’t Let A Small Problem Become A Major Breakdown
Ford Explorers are tough, but no vehicle is indestructible. Engine problems start small, but ignoring them leads to expensive repairs. Whether it’s a timing chain rattle, a slipping transmission, or a sudden loss of power, waiting too long can mean the difference between a repair and a full engine replacement.

At Cowden Automotive in San Francisco, we fix these problems before they turn into disasters. Don’t wait for your Explorer to leave you stranded. Call (415) 777-9858 today and schedule an inspection.