Ford Explorer Problems: Common Issues and Repair Costs
The Ford Explorer is a spacious, powerful SUV known for strong performance and hybrid options. It’s a popular family and towing vehicle, especially in plug-in hybrid (PHEV) form. While well-built overall, the Explorer does suffer from several recurring issues. This guide breaks down the most common Ford Explorer problems and provides real-world UK repair cost estimates.
1. Hybrid Battery and Charging System Problems (PHEV Models)
Problem: Plug-in hybrid models often show charging faults, failed charge cycles or a warning on the dashboard like “Electric Drive System Malfunction.”
Causes:
- Faulty onboard charger
- Software bugs in the battery management system
- Sensor problems in the cooling system
Typical Repair Costs:
- Charger control module: £800 to £1,200
- High-voltage battery coolant pump: £400 to £600
- Software reprogramming: £100 to £200
- Full battery replacement (very rare): £6,000 to £8,000
Tip: Book regular dealer updates and act fast on warning messages.
2. Transmission Faults (10-Speed Automatic)
Problem: Drivers report hard gear changes, hesitation between shifts, and occasional transmission error codes.
Causes:
- Shift actuator wear
- Transmission fluid issues
- Software errors in the control module
Repair Costs:
- Gearbox fluid change: £200 to £300
- Valve body or solenoid repair: £500 to £900
- Full rebuild or replacement: £2,500 to £3,500
Tip: Change gearbox fluid every 40,000 to 50,000 miles to prevent major failure.
3. Brake System and ABS Problems
Problem: Spongy brake pedal, inconsistent stopping power, or ABS warning lights.
Causes:
- Worn brake booster
- Faulty ABS module or sensor
- Dirty or old brake fluid
Repair Costs:
- ABS sensor: £100 to £180
- Brake booster: £400 to £600
- ABS control unit: £800 to £1,200
- Brake fluid flush: £80 to £120
Tip: If you feel brake performance drop, check both mechanical parts and electrical sensors.
4. Suspension and Steering Wear
Problem: Knocking noises from under the car, vague steering feel or uneven tyre wear.
Causes:
- Worn suspension arms or bushings
- Faulty shock absorbers
- Loose or worn steering rack
Repair Costs:
- Control arms: £300 to £450 (both sides)
- Front shocks: £250 to £400
- Steering rack: £700 to £1,000
- Wheel alignment: £60 to £90
Tip: Listen for clunks and address them early to avoid extra tyre wear.
5. Infotainment System and Electrical Faults
Problem: SYNC screen freezing, Bluetooth disconnecting, camera issues and random electrical errors.
Causes:
- Outdated SYNC firmware
- Faulty parking sensors
- Weak keyless entry module
Repair Costs:
- SYNC screen or unit: £500 to £900
- Parking sensor: £100 to £200
- Keyless module: £150 to £300
- Software update: £60 to £120
Tip: Always request software updates during regular servicing.
6. Turbocharger and Engine Cooling Faults (2.3 EcoBoost)
Problem: Loss of power, engine overheating or poor fuel economy in petrol turbo models.
Causes:
- Boost control actuator failure
- Coolant leak
- Blocked intercooler
Repair Costs:
- Turbo actuator: £250 to £400
- Full turbo replacement: £1,000 to £1,600
- Coolant pipe or seal repair: £100 to £350
Tip: Look for early signs like reduced acceleration or rising engine temp.
Summary of Common Ford Explorer Repair Costs (UK)
| Area | Cost Range (UK) |
|---|---|
| Hybrid charging system | £100 to £1,200+ |
| Full hybrid battery replacement | £6,000 to £8,000 |
| Automatic transmission faults | £200 to £3,500 |
| Brake and ABS repairs | £80 to £1,200 |
| Suspension and steering work | £60 to £1,000 |
| SYNC and electrical faults | £60 to £900 |
| Turbo and engine cooling | £100 to £1,600 |
Annual Maintenance Costs (UK)
| Task | Cost Estimate |
|---|---|
| Oil and filter change | £140 to £200 |
| Full annual service | £250 to £350 |
| Brake pads and discs (front) | £180 to £250 |
| MOT with minor repairs | £60 to £300 |
| 12v battery replacement (PHEV) | £120 to £180 |
Key Tips for Explorer Owners
- Update your hybrid and SYNC software regularly
- Don’t ignore early gear change hesitation
- Service the transmission on time to avoid expensive failure
- Check for coolant leaks, especially in EcoBoost engines
- Book a suspension check yearly to avoid steering wear
Final Thoughts
The Ford Explorer is capable and feature-rich, but it’s not without its faults. The most common problems in the UK involve the transmission, hybrid charging system, brakes, and infotainment glitches. Regular updates and early attention to symptoms can prevent major costs. If you’re buying a used Explorer, always check the service records and make sure all recall and software work has been done.
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