Ford Explorer Sport
3.5L twin-turbo V6 EcoBoost. 365 hp in the Explorer Sport. Massive torque, dual turbochargers. Timing chain problems with the Gen 1 design (single chain for both banks) — Ford switched to two separate chains in 2017. Cam phasers start rattling around 50,000 miles. Same internal water pump as the naturally aspirated variant.
Hidden athlete
365 hp twin-turbo V6 in the Explorer Sport — a wolf in family clothing. Brutal torque, great sound, AWD standard. Cam phasers and timing chain are the Achilles heel.
Engine Weaknesses 4
Gen 1 design (2011-2016) uses a single chain for both cylinder banks — excessive stress leads to stretch. Ford switched to two separate chains in 2017. Particularly common with extended oil change intervals.
Symptoms: Rattle on cold start, rough running, P0016/P0017 codes, power loss at high RPM.
The four cam phasers on the 3.5L EcoBoost wear out starting around 50,000 miles. Cold start rattle grows progressively louder. Ford CSP-21N03 extended warranty for 2017-2020 models. Dealer repair costs up to $6,800.
Symptoms: Diesel-like rattle at cold idle, fades after warmup. Check engine light, reduced engine power.
Same problem as the naturally aspirated 3.5L: the internally mounted water pump can leak coolant into engine oil when the seal fails. Slightly less common on the EcoBoost due to higher thermal loads, but with identical catastrophic consequences.
Symptoms: Coolant loss without visible leak, milky oil, chain rattle on cold start.
Turbocharger bearings can develop leaks, allowing oil into the intake tract. Blue smoke on throttle, increased oil consumption. Repair becomes expensive when both sides fail simultaneously.
Symptoms: Blue exhaust smoke on acceleration, increased oil consumption, oil residue on turbo housing, power loss.
Vehicle Weaknesses 7
Major safety issue: the rear suspension toe link can fracture, causing loss of vehicle control. Multiple NHTSA investigations, 413,000 vehicles recalled (26V101). Cross-axis ball joint seizure puts excessive stress on the toe link until it breaks.
The electric power steering can fail intermittently — steering suddenly becomes heavy. NHTSA recall 14V286000 for 2011-2013 models. Software update and potential steering gear assembly replacement as the fix.
Cracked exhaust manifolds allow fumes into the engine bay and through the HVAC into the cabin. Worst under hard acceleration with recirculation mode on. NHTSA investigated 1.3 million vehicles. Ford TSB 16-0166, Customer Service Program CSP-17N03.
Ford recalls 412,774 Explorers model years 2017-2019 — rear toe links can fracture. NHTSA recall 26V101 / Ford 26S08. Cross-axis ball joint seizure causes excessive stress. Dealers replace with reinforced toe links at no cost.
The aluminum hood corrodes under the paint — iron particles from manufacturing attack the aluminum. Blistering and peeling along the hood edges. Particularly affects 2013-2016 models. Ford TSB 17-0062, but no official recall.
The blend door actuator behind the dashboard fails frequently — rhythmic clicking and incorrect temperature distribution result. Part itself is cheap ($70), but labor costs are high if the dashboard must be removed.
Liftgate motor or gas strut fails — tailgate no longer opens automatically or drops down. Common wear item starting around 50,000 miles.