Problem Reports and Reliability: Ford Explorer 2020-2026

The sixth generation of the Ford Explorer had one of the most turbulent launches in the industry, with 30 recalls in its very first year. The situation is improving progressively, but buyers should remain vigilant. The Explorer is not a model we recommend, given the sheer number of problems and recalls across its model years.

Key Issues

• Exhaust gas intrusion (ST 2020–2021) — real health risk from carbon monoxide exposure
• Automatic transmission — the most reported defect, with jerky shifts and abrupt downshifts; 5 separate recalls
• Unintended movement while parked — 250,000+ vehicles affected, fix contested by the National Highway Traffic Safety Administration (NHTSA)
• Rearview camera — 700,000+ vehicles, 6 recalls, a recurring problem difficult to resolve permanently
• Valve failure (3.0L) — 90,000 vehicles recalled in 2024, risk of catastrophic engine damage
• Power steering, panoramic sunroof, infotainment — multiple documented failures

Technical Overview

The 2020-2026 Ford Explorer marks a major architectural shift for Ford: the move from a front-wheel-drive platform to a rear-wheel-drive (RWD) layout. It is worth noting that all-wheel drive comes standard on most trims. Available in Canada with a turbocharged 2.3L four-cylinder as the base engine and a twin-turbo 3.0L V6 for the ST variant, all versions are paired with a 10-speed automatic transmission. The 2025 model introduces a new infotainment system based on Android Automotive, a first for Ford.

Exhaust Gas Intrusion into the Cabin

This is the most concerning issue affecting this generation, primarily involving 2020 and 2021 Explorer ST models equipped with the 3.0L engine. Cracks in the catalytic converter and defective welds on the exhaust manifold allow gases to seep into the cabin. Owners report a burning smell during hard acceleration — the risk of carbon monoxide exposure is real and serious. Ford issued a recall calling for replacement of the catalytic converter and a reprogramming of the engine control module.

10R60 Automatic Transmission Problems

The 10-speed automatic transmission is the most reported defect, accounting for roughly one-third of all NHTSA complaints for the 2020 model year. Symptoms include harsh gear changes, sudden downshifts, and clunking noises. Its adaptation to the SUV format caused persistent calibration issues.

Unintended Movement While Parked

Over 250,000 vehicles from model years 2020 through 2022 were recalled for a risk of rolling while parked, even with the parking brake engaged. The driveshaft can disconnect, rendering the parking brake ineffective. The NHTSA has also questioned the adequacy of the fix proposed by Ford.

Rearview Camera and 360° View System

Over 700,000 vehicles are affected by six separate recalls. Owners report blurry or pixelated images, or a blue screen when reversing. Some have had their camera replaced up to three times without a lasting fix.

3.0L EcoBoost Intake Valve Failure

In August 2024, approximately 90,000 vehicles — including 2021 and 2022 Explorer ST models — were recalled for intake valves prone to fracturing, which can cause a sudden loss of power or catastrophic engine damage. This issue also affects the Lincoln Aviator. For anyone purchasing a used Explorer ST, verifying the status of this recall is essential.

Power Steering and Other Issues

Several owners report complete power steering failures, as well as vibrations and cracking noises from the steering column. Additional issues include: panoramic sunroof leaks that can cause electrical short circuits, and an unstable infotainment system with black screens, Apple CarPlay disconnections, and frequent freezes.

What owners are reporting

Other problems reported by owners include water leaks in the tailgate and third row, excessive oil consumption on 4-cylinder and 6-cylinder engines, and other issues related to overall assembly quality.

Verdict by Model Year

For buyers interested in a used model, the sixth-generation Ford Explorer has a concerning reliability history.

The 2020 and 2021 model years are particularly problematic, and Consumer Reports rates all models from 2020 through 2023 as “less reliable than the category average.” While the 2024 and 2025 versions are significantly more refined, the generation’s track record is hard to ignore. Given this history, buyers are better served by more proven and better-rated alternatives such as the Toyota Highlander or Honda Pilot, which offer far greater long-term peace of mind.