The 2019 Explorer is the last year of the fifth-generation platform (2011-2019), carrying forward well-documented transmission and drivetrain issues that plagued this entire generation. The 3.5L EcoBoost variant has serious engine longevity concerns, while all models suffer from PTU and transmission cooler failures.
Power Transfer Unit (PTU) Failure on AWD Models
Common · high severityTypical onset: 60,000-100,000 mi
Symptoms: Grinding or whining noise from front differential area, Metal shavings in PTU fluid, AWD malfunction warning light, Binding sensation during tight turns
Fix: PTU rebuild or replacement required. The unit shares fluid circuit with transmission and frequently runs low on fluid due to inadequate service intervals. Requires 3-4 hours labor for R&R, plus fluid service for transmission. Ford revised the service interval but damage is often done by the time owners find out.
Estimated cost: $1,800-3,200
Transmission Oil Cooler Internal Failure (6F50/6F55 Trans)
Common · high severityTypical onset: 70,000-120,000 mi
Symptoms: Transmission slipping or harsh shifts, Coolant mixing with transmission fluid (strawberry milkshake fluid), Engine overheating, Transmission overheating warning, White smoke from exhaust
Fix: Internal cooler in the radiator fails, allowing coolant and ATF to cross-contaminate. Requires radiator replacement, complete transmission fluid flush (often multiple times), and frequently full transmission replacement if contamination circulated too long. This is a 6-8 hour job minimum if trans needs replacement. Catching it early with fluid checks is critical.
Estimated cost: $800-1,200 for cooler/flush only; $3,500-5,500 if transmission damaged
3.5L EcoBoost Carbon Buildup and Engine Failure
Occasional · high severityTypical onset: 80,000-130,000 mi
Symptoms: Misfires and rough idle, Loss of power under load, Excessive oil consumption (1 qt per 1,000 mi or worse), Knocking or ticking noises, Check engine light with misfire codes
Fix: Direct injection causes severe carbon buildup on intake valves. Combined with timing chain tensioner wear and inadequate oil change intervals, these engines can suffer catastrophic failure including spun bearings, broken pistons, and scored cylinder walls. Walnut blastingvalves runs $400-700, but many engines need full rebuilds or short block replacement at 15-20 hours labor.
Estimated cost: $600-900 for carbon cleaning; $6,000-9,000 for engine rebuild/replacement
Rear Shock Absorber and Suspension Bushing Failure
Common · medium severityTypical onset: 50,000-90,000 mi
Symptoms: Clunking noise over bumps from rear, Excessive body roll in turns, Uneven tire wear on rear, Floating or bouncy ride quality
Fix: Rear shocks wear prematurely, and the rear lower control arm bushings tear. Ford issued a recall for rear suspension components but not all failure modes are covered. Replacing both rear shocks and lower control arm bushings takes 3-4 hours. Use quality aftermarket shocks, OEM units have same short lifespan.
Estimated cost: $800-1,400
Front Driveshaft Center Support Bearing Failure (AWD)
Occasional · medium severityTypical onset: 60,000-100,000 mi
Symptoms: Vibration at highway speeds, Clunking when accelerating from a stop, Squeaking or grinding noise from underneath vehicle center
Fix: The two-piece front driveshaft's center support bearing fails, causing vibration and noise. Requires driveshaft removal and either bearing replacement or full driveshaft replacement. 2-3 hours labor. This often gets misdiagnosed as transmission or PTU issues initially.
Estimated cost: $500-900
Door Ajar Warning and Latch Failures
Common · low severitySymptoms: Door ajar warning with all doors closed, Interior lights staying on, Doors not latching securely, Power sliding door malfunctions on Limited/Platinum
Fix: Door latch assemblies fail internally, causing false warnings or actual latching problems. Affects all doors but driver and rear hatch most common. Each latch replacement is 0.5-1.0 hour labor. Ford had multiple TSBs but no comprehensive recall. Replace failed latches individually as they occur.
Estimated cost: $200-400 per latch
Water Pump Failure (3.5L Engines)
Occasional · high severityTypical onset: 80,000-120,000 mi
Symptoms: Coolant leak from front of engine, Whining or grinding noise from accessory drive, Engine overheating, Coolant level dropping
Fix: Water pump fails with little warning. On 3.5L engines (both NA and EcoBoost), this requires removing the timing cover and is an 8-10 hour job. Always replace timing chains, guides, and tensioners at the same time since you're in there. This is preventive maintenance territory at 100k miles.
Estimated cost: $1,800-2,800
Hard pass unless you find a unicorn with documented PTU services and you're getting a 3.5L naturally aspirated or 2.3L EcoBoost — the 2020+ redesign is a much better platform.
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.