The 1995 Explorer with 4.0L OHV V6 is a workhorse that'll run forever if you catch the transmission cooler leak early. Miss it, and you're rebuilding both the trans and engine — this is the platform's Achilles heel.
Transmission Oil Cooler Failure Leading to Catastrophic Engine/Trans Damage
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Milky/strawberry-colored transmission fluid or coolant, Trans slipping or delayed engagement after coolant system work, Overheating transmission, White smoke from exhaust and catastrophic engine failure if coolant enters transmission then gets pumped into engine
Fix: The internal trans cooler in the radiator fails, allowing coolant and ATF to mix. Coolant destroys clutch packs; ATF in coolant can circulate into the engine via heater core backflow, wiping bearings. Caught early: external trans cooler install and fluid flush, 3-4 hours. Caught late: transmission rebuild (12-16 hours) plus engine rebuild if coolant contaminated cylinders (25-35 hours). Always bypass the radiator cooler and install external cooler as preventive measure.
Estimated cost: $400-800 if caught early; $4,500-8,000+ for trans and engine rebuild
Symptoms: Rod knock on cold start that quiets when warm, or constant knocking, Excessive oil consumption (1 qt per 500-800 miles), Blue smoke on startup or under load, Low oil pressure at idle when hot, Metal flakes in oil or filter
Fix: This OHV 4.0L has marginal oiling to the #3 and #4 rod bearings; combine with owners who skip oil changes and you get spun bearings or scored cylinder walls. Rings fail from heat cycling. Short block replacement is most common fix (18-24 hours), though full rebuilds with bore/hone run 28-35 hours. Used engines are plentiful but gamble on their history.
Estimated cost: $3,200-5,500 for shop-installed short block; $4,500-7,000 for full rebuild
A4LD/4R55E Transmission Failures
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Harsh 1-2 or 2-3 shifts, or no upshift past 2nd gear, Slipping in 3rd or 4th gear under load, No reverse or delayed reverse engagement, Burnt ATF smell, dark red or brown fluid
Fix: The A4LD (early '95s) and 4R55E are weak transmissions behind the torquey 4.0L, especially if used for towing. Overdrive band adjusters strip, valve bodies clog, and clutch packs burn. Rebuild is 12-16 hours; many shops won't touch A4LD anymore and recommend 4R55E swap. External cooler is mandatory on any rebuilt trans.
Estimated cost: $1,800-3,200 for rebuild; $2,200-3,800 for reman swap with cooler
Ball Joint and Tie Rod End Wear
Common · high severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking over bumps from front suspension, Wandering or loose steering feel, Uneven or cupped tire wear on inside edges, Visible play in wheel when jacked up and rocked
Fix: The Twin Traction Beam front end eats ball joints and tie rod ends, especially if driven on rough roads or with oversized tires. Lower ball joints are press-in (2.5 hours per side), uppers bolt on (1.5 hours per side). Tie rod ends are 1 hour each. NHTSA recalled tie rods on some units; most are worn by now anyway. Do alignment after any front-end work.
Estimated cost: $800-1,400 for all four ball joints; $180-320 for both inner and outer tie rods per side
Rear Liftgate Support Strut Failure
Common · low severity
Symptoms: Liftgate drops suddenly when opened, risk of head injury, Liftgate won't stay open without propping
Fix: Gas struts lose pressure over time and with heat cycling. NHTSA recalled these for safety. Replacement is 0.3 hours, always do both sides. Cheap insurance against a concussion.
Estimated cost: $80-150 for pair installed
Fuel Pump Failure
Occasional · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: No-start with whirring/buzzing from tank but no fuel pressure, Intermittent stalling when fuel level below 1/4 tank, Loss of power under acceleration or at highway speed, Long crank time before engine catches
Fix: In-tank pump wears out, especially if owners run tank low frequently. Requires dropping tank (1.5-2 hours), replacing pump assembly, and dropping tank means inspecting and often replacing rusty straps and filler neck. Fuel filter should've been changed every 30k but rarely was — clogged filter kills pumps early.
Estimated cost: $450-750 including pump assembly and labor
Intake Manifold Gasket Leaks (Vacuum and Coolant)
Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Rough idle, high idle, or stalling, Coolant seepage at front or rear of intake manifold, CEL with lean codes (P0171/P0174) from vacuum leak, Sweet coolant smell in cabin or under hood
Fix: The lower intake plenum gaskets dry out and crack, causing vacuum leaks; coolant crossover gaskets at the front/rear leak externally. Job requires removing upper and lower intake (5-7 hours). Often find corroded throttle body and vacuum tree hoses while you're in there. Don't cheap out on gasket set — use Fel-Pro or OEM.
Estimated cost: $650-1,100 including gaskets and coolant
Owner tips
Bypass the radiator's internal trans cooler and install an external cooler immediately — this single mod prevents the most expensive failure on the platform
Change oil every 3,000-4,000 miles with quality 5W-30; the OHV 4.0L's oiling is marginal and cannot tolerate extended intervals
Inspect ball joints and tie rods every 15,000 miles; the TTB front end hides wear until it's dangerous
Replace fuel filter every 30,000 miles even though Ford says 'lifetime' — clogged filters kill fuel pumps
Check transmission fluid color monthly; any pink-to-milky change means immediate cooler failure response
Buy one under 100k miles with service records showing religious oil changes and proof of external trans cooler install; skip any with unknown history or over 120k — you're buying someone else's deferred overhaul.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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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.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
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.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 09E012000
2009-04-07
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.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
EXTERIOR LIGHTING · 06E026000
2006-03-23
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.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
TIRES:TREAD/BELT · 01X001000
2001-05-22
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.
Consequence: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.
SUSPENSION · 00V402000
2000-11-28 · PE00039
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. UNDER CERTAIN CONDITIONS, A FRONT SWAY BAR LINK CAN FRACTURE.
Consequence: VEHICLE HANDLING COULD BE AFFECTED, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE BOTH THE LEFT AND RIGHT FRONT SWAY BAR LINKS.
TIRES:TREAD/BELT · 00T005000
2000-08-21 · PE00020
TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE TIRE TREAD.
Consequence: IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE ASSISTANCE.
VEHICLE DESCRIPTION: ON CERTAIN SPORT UTILITY VEHICLES, THE HYDRAULIC LIFT CYLINDER BRACKET WELDS COULD FRACTURE.
Consequence: WITH A BROKEN BRACKET WELD, THERE IS A POTENTIAL FOR THE LIFTGATE BRACKET TO GRADUALLY BEND INWARD ALLOWING THE LIFT CYLINDER BALL STUD TO DISENGAGE, UNEXPECTEDLY ALLOWING THE LIFTGATE TO FALL FROM AN OPEN POSITION.
Remedy: DEALERS WILL INSTALL LIFTGATE REINFORCEMENT BRACKETS. DEPENDING UPON THE CONDITION OF THE LIFTGATE SHEET METAL IN THE AREA OF THE BRACKET, DEALERS MAY ALSO INSTALL A LARGER REINFORCEMENT.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. THE CAMPAIGN WILL REINFORCE THE BRACKET ATTACHMENTS OF THE REAR LIFTGATE GAS ASSIST CYLINDERS WHICH COULD PULL AWAY FROM THE INSIDE OF THE LIFTGATE.
Consequence: IF A BRACKET AND GAS ASSIST CYLINDER WERE TO DETACH COMPLETELY FROM THE LIFTGATE AND NO LONGER BEAR AGAINST THE LIFTGATE AS INTENDED, THE REMAINING ASSIST CYLINDER WOULD NOT HOLD THE LIFTGATE IN AN OPEN POSITION. PERSONAL INJURY COULD OCCUR.
Remedy: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 95V052000
1995-03-15
IN SOME OF THE VEHICLES, BRAKE TUBES WERE MISROUTED BETWEEN THE MASTER CYLINDER AND THE HYDRAULIC CONTROL UNIT AND RESULTS IN EXCEEDING THE ALLOWABLE STOPPING DISTANCES AS REQUIRED BY FMVSS NO. 105, "HYDRAULIC BRAKE SYSTEMS." IN ADDITION, SEALS WITHIN THE MASTER CYLINDER COULD BE ABRADED BY THIS CONDITION OVER TIME RESULTING IN AN INTERNAL LEAK AND A FURTHER REDUCTION IN BRAKE PERFORMANCE.
Consequence: CONSEQUENCE OF NON-COMPLIANCE: STOPPING DISTANCES COULD BE LONGER THAN INTENDED RESULTING IN INCREASED POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL REROUTE THE BRAKE TUBES.
STEERING:LINKAGES:TIE ROD ASSEMBLY · 95V053000
1995-03-15
THE INNER TIE ROD ASSEMBLIES WERE IMPROPERLY MANUFACTURED AND CAN FRACTURE CAUSING SHAKING OR SHIMMY AT LOW SPEEDS.
Consequence: THIS CONDITION CAN CAUSE THE WHEEL ON THE SIDE WITH THE BROKEN TIE ROD TO TUCK INWARD OR OUTWARD AND SLIDE RESULTING IN AN INCREASED POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL INSPECT THE INNER TIE RODS AND REPLACE THE SUSPECT TIE RODS.
AIR BAGS:FRONTAL · 95E006002
1995-02-24
THE PASSENGER SIDE AIR BAG HAS AN INFLATOR BODY THAT CRACKED DURING FORMING OF THE CURL THAT RETAINS THE IGNITER PLUG IN THE END OF THE INFLATOR. ALSO THE IGNITER END CAP CAN SEPARATE FROM THE INFLATOR.
Consequence: THE PASSENGER SIDE AIR BAG MAY NOT INFLATE PROPERLY RESULTING IN REDUCED OCCUPANT PROTECTION IN A VEHICLE ACCIDENT. IF THE IGNITER END CAP SEPARATES IN A FRONTAL COLLISION, HOT GASES CAN BE RELEASED AND IGNITE FLAMMABLE MATERIAL OR CAUSE BURN INJURIES.
Remedy: DEALERS WILL REMOVE AND REPLACE THE PASSENGER SIDE AIR BAG MODULE.
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