The 2012 Explorer (5th-gen platform debut) brought independent rear suspension and unibody construction, but early production units suffer from catastrophic engine failures, persistent PTU leaks, and transmission cooling issues that can destroy the 6F50/6F55 automatic.
3.5L V6 Cylinder Wall Scoring / Piston Ring Failure
Occasional · high severity
Typical onset: 60,000-120,000 mi
Symptoms: Excessive oil consumption (quart every 500-1000 miles), White/blue smoke on cold start, Loss of compression, Rough idle and misfire codes, Metal debris in oil
Fix: Early 3.5L Duratec engines had inadequate cylinder wall plating that wears prematurely. Requires complete engine rebuild or replacement. 30-45 labor hours for removal, machining, and reinstallation. Many opt for remanufactured long blocks.
Estimated cost: $6,500-12,000
2.0L EcoBoost Carbon Buildup and Coolant Intrusion
Common · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: Rough idle and hesitation, White smoke from exhaust, Coolant loss with no visible leaks, P0301-P0304 misfire codes, Loss of power under load
Fix: Direct injection causes valve carbon buildup requiring walnut blasting every 60-80k miles (4-6 hours). Coolant intrusion through cracked cylinder head or failed block requires head gasket replacement or complete engine overhaul (20-35 hours).
Estimated cost: $800-1,200 for carbon cleaning; $4,000-8,000 for head gasket/internal repairs
Power Transfer Unit (PTU) Fluid Leak and Failure
Common · high severity
Typical onset: 50,000-90,000 mi
Symptoms: Fluid dripping from center of vehicle, Grinding or whining noise from front differential area, Burning smell, AWD malfunction warning, Complete loss of AWD function
Fix: PTU seal fails, runs dry, and destroys internal bearings and gears. Ford updated the unit multiple times but early ones are problematic. Requires PTU replacement (4-6 hours). Critical: PTU has no dipstick and no maintenance schedule—many run dry without owner knowledge.
Estimated cost: $1,800-3,200
Transmission Oil Cooler Line Corrosion / Coolant Contamination
Common · high severity
Typical onset: 70,000-110,000 mi
Symptoms: Transmission slipping or shuddering, Coolant in transmission (strawberry milkshake fluid), Transmission overheating, Hard shifts or delayed engagement, Complete transmission failure
Fix: Internal transmission cooler corrodes, mixing coolant and ATF. Destroys transmission internals requiring complete rebuild or replacement (12-18 hours). Also requires cooling system flush. Ford extended warranty on some VINs via TSB 19-2315.
Estimated cost: $3,500-6,500
Rear Suspension Lower Control Arm Bushing Failure
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunking noise over bumps from rear, Excessive rear tire wear (camber issues), Wandering or unstable handling, Visible cracked or separated rubber bushings
Fix: Independent rear suspension uses multi-link design with rubber bushings that deteriorate prematurely. Typically requires both lower control arms. 3-4 hours per side plus alignment (1 hour).
Estimated cost: $800-1,400
Electric Power Steering Motor and Column Failures
Occasional · high severity
Symptoms: Complete loss of power steering assist, Steering wheel becomes extremely heavy, Warning message 'Power Steering Assist Fault', Intermittent assist (comes and goes), Grinding noise from steering column
Fix: EPAS motor or column control module fails, often without warning. Multiple recalls issued (14S32, 18V-362). Requires steering column or motor assembly replacement (3-5 hours). Safety-critical—vehicle is drivable but requires significant effort to steer.
Estimated cost: $1,200-2,400
Transmission Mount Collapse
Common · low severity
Typical onset: 50,000-90,000 mi
Symptoms: Clunk on acceleration or deceleration, Excessive vibration at idle in Drive, Visible transmission movement in engine bay, Harsh shift feel
Fix: Hydraulic transmission mount deteriorates and collapses. Simple replacement but often diagnosed incorrectly as transmission problem. 1.5-2 hours labor.
Estimated cost: $250-450
Owner tips
Change PTU fluid every 30,000 miles even though Ford says 'lifetime'—use Motorcraft or equivalent 75W-140
Inspect transmission fluid at every oil change for discoloration (coolant contamination)—catch it early
For 2.0L EcoBoost: walnut blast valves every 60-80k miles to prevent carbon-related issues
Avoid 3.5L V6 engines built before mid-2013 production if possible—later builds have improved cylinder coating
Check for open recalls on your VIN, especially steering and PTU-related campaigns
Skip the 2012 unless it has complete engine and PTU service records—2015+ models resolved most catastrophic issues and are significantly more reliable used buys.
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 Motor Company (Ford) is recalling certain 2011-2019 Explorer vehicles. The A-pillar trim retention clips may not be properly engaged, allowing the trim to detach.
Consequence: A detached trim piece can fall off the vehicle, becoming a road hazard and increasing the risk of a crash.
Remedy: Dealers will inspect and replace the A-pillar trim as necessary, free of charge. Owner notification letters were mailed on July 18, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S02.
SUSPENSION:REAR · 21V746000
2021-09-22
Ford Motor Company (Ford) is recalling certain 2011-2013 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota,
Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. These vehicles may be equipped with a cross-axis ball joint (CABJ) replacement part that could seize, and result in a fracture of the outboard section of the rear suspension toe link.
Consequence: A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.
Remedy: Dealer will inspect for the presence of a CABJ. If a CABJ of any design is found, the dealer will inspect the tightness of the CABJ, and replace the CABJ, knuckle, and/or toe link as necessary, free of charge. Interim notification letters were mailed November 10, 2021. Owner notification letters were mailed on March 17, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S43.
SUSPENSION:REAR · 19V435000
2019-06-10
Ford Motor Company (Ford) is recalling certain 2011-2017 Explorer vehicles. The rear suspension toe links may fracture due to stress on the rear suspension.
Consequence: A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.
Remedy: Ford will notify owners, and dealers will replace the rear suspension toe links, and inspect both rear toe link ball joints, replacing the rear wheel knuckle(s), if necessary, free of charge. The recall began June 26, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S17.
WHEELS:HUB · 17E048000
2017-08-28
Ford Motor Company (Ford) is recalling certain Wheel Hub Bearing assemblies, part number HB5Z-1104-C, incorrectly listed as being for installation on the rear axles of 2011-2017 Ford Explorer 4X2 vehicles. These bearings assemblies were manufactured without a self retention feature, possibly resulting in the separation of the wheel or wheel end.
Consequence: A loss of the wheel or wheel end can increase the risk of a crash.
Remedy: Ford will notify the distributors of the hubs specifying that they are to only be used on drive axles. It is believed that none of the hubs were purchased from Ford dealers for the incorrect application. Owners may contact Ford customer service at 1-866-436-7332.
STRUCTURE:BODY:DOOR · 15V171000
2015-03-24
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Explorer vehicles. In the affected vehicles, the interior door handle return spring may unseat, resulting in interior door handle that does not return to the fully stowed position after actuation.
Consequence: If the interior door handle return spring is unseated, the door may unlatch in the event of a side impact crash, increasing the risk of personal injury.
Remedy: Ford will notify owners, and dealers will inspect all four of the interior door handles and either repair or replace them, free of charge. The recall began on July 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S11.
STEERING:ELECTRIC POWER ASSIST SYSTEM · 14V286000
2014-05-29 · PE12017
Ford Motor Company (Ford) is recalling certain model year 2011-2013 Ford Explorer vehicles manufactured May 17, 2010, through February 28, 2012. The affected vehicles may experience an intermittent connection in the electric power steering gear, which can cause a loss of the motor position sensor signal resulting in a shut down of the power steering assist.
Consequence: If the vehicle experiences a loss of power steering assist it will require extra steering effort at lower speeds, increasing the risk of a vehicle crash.
Remedy: Ford will notify owners, and dealers will update the Power Steering Control Module (PSCM) software, free of charge. If a vehicle shows a history of a loss of motor position sensor signal when the vehicle is brought in for the recall remedy, its steering rack assembly will be replaced, free of charge. The recall began on July 23, 2014. Owners may contact Ford customer service at 1-800-392-3673. Ford's number for this recall is 14S06.
STEERING · 14E001000
2014-01-06
Ford Motor Company (Ford) is recalling certain replacement steering gears installed on model year 2011-2012 Explorers as service parts in September 2013 and January 2014. The affected gears may lock, preventing the driver from being able to steer the vehicle.
Consequence: The inability to steer the vehicle increases the risk of a crash.
Remedy: Ford will notify owners and dealers will replace the suspect steering gears with new steering gears, free of charge. The recall began on January 29, 2014. Customers may contact Ford at 1-800-392-3673. Ford's number for this recall is 13S14.
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