2015 Ford Explorer problems: every known failure
All 9 documented failure points for this exact year — what goes wrong, when,
what it costs, and how to spot it on a test drive. Free, from Milo's research on this model.
9known failure points
1768NHTSA owner complaints
9safety recalls
$5,000worst-case single repair
A comfortable, spacious family hauler with a steering rack that wants to retire early and a PTU that eats itself — buy the right one cheap, or don't buy at all.
Every documented failure, earliest first
Ordered by the mileage the problem typically appears. VERY HIGH
confidence means it's tied to a documented NHTSA recall, and 5 of these are rated Critical.
40k–80k mi● Critical$0–$800VERY HIGH
Rear suspension toe link fracture (subject to multiple NHTSA recalls, especially in salt-belt states)
How to catch it: Run the VIN on NHTSA and the Ford recall portal before purchase — confirm all three toe-link recalls are closed, especially if the truck lived in CT/IL/MI/OH/PA/etc.
Source: documented (NHTSA recall)
50k–100k mi● Plan$50–$700MODERATE
3.5L EcoBoost intercooler condensation causing misfires and stumbling under boost in humid weather
How to catch it: Install the well-known intercooler drain mod (small hole and check valve in the low spot) or an aftermarket bar-and-plate intercooler — cheap, permanent fix.
Source: multi-source pattern (AI synthesis)
50k–90k mi● Plan$400–$800MODERATE
3.5L EcoBoost carbon buildup on intake valves (direct injection with no port injectors)
How to catch it: Add a catch can and run a can of CRC GDI intake valve cleaner every 15k — it slows carbon accumulation dramatically.
Source: multi-source pattern (AI synthesis)
60k–90k mi● Critical$1,500–$2,500HIGH
Electric power steering (EPAS) rack failure — sudden loss of assist, often with no code
How to catch it: Scan for any steering-related DTCs pre-purchase and check TSB history — a reman rack from a reputable rebuilder is roughly half the Ford price if you catch it early.
Source: owner-reported (282 NHTSA complaints)
60k–100k mi● Critical$300–$1,200MODERATE
Exhaust manifold-to-cabin CO leak (the 'exhaust smell' complaint that spawned the Police Interceptor lawsuit and Ford customer satisfaction program 19N03)
How to catch it: Verify 19N03 CSP work was done, seal the rear quarter/liftgate drain holes with butyl tape, and buy a $20 CO detector to keep in the cabin.
Source: multi-source pattern (AI synthesis)
70k–110k mi● Critical$150–$3,000VERY HIGH
Power Transfer Unit (PTU) fluid degradation and bearing failure on AWD models — Ford originally called it 'lifetime fluid'
How to catch it: Change the PTU fluid every 30k with Motorcraft XL-12 — it's a 30-minute job with a suction pump and it can add 100k of life to a $2,500 part.
Source: documented (NHTSA recall)
70k–120k mi● Plan$150–$600MODERATE
Rear liftgate/window water intrusion soaking the rear cargo area and rusting the spare tire well
How to catch it: Lift the spare tire cover on the test drive — a wet or rusty tub is a big-time negotiation lever and confirms the leak.
Source: multi-source pattern (AI synthesis)
80k–120k mi● Critical$1,800–$3,000MODERATE
Water pump failure — internal on 3.5L NA and 3.5L EcoBoost, coolant enters the oil pan
How to catch it: Pull the oil cap and dipstick on any pre-purchase — milky residue or a low coolant reservoir with no external leak is a walk-away sign.
Source: multi-source pattern (AI synthesis)
90k–150k mi● Plan$300–$5,000MODERATE
6F55 6-speed automatic harsh shifts / solenoid pack issues
How to catch it: Do a drain-and-fill (not flush) with Mercon LV every 30–40k; Ford's 'lifetime' spec is fiction on a heavy 3-row.
Source: multi-source pattern (AI synthesis)
Buying one of these?
Knowing what breaks is half of it.
Milo's full report gives you the other half — for your exact car:
- A line-by-line negotiation script
- The pre-purchase inspection checklist
- VIN-specific open recalls
- What it's really worth right now
- Your next 15,000 miles, forecast
- Hidden features & money-savers
Get the full 2015 Ford Explorer report →
First report free · then $10
Findings blend documented NHTSA recalls and complaints with patterns
synthesized from owner communities. Confidence is labeled on every item; an inference is
never presented as documented fact. Always inspect the specific vehicle and verify open
recalls by VIN before buying.