CarComplaints.com Notes: The 2002-2005 Explorer has a very well-established record of expensive transmission failure at under 100k miles. The Explorer has an enclosed transmission which is typically replaced with a rebuilt transmission at a cost of almost $3,000.
Adding insult to injury, the 2002-2005 Explorer also has a massive problem with the rear panel cracking. While it's a minor annoyance compared to transmission failure, ironically the crack usually goes right through the Ford logo.
After ripping my dash apart I discovered that the damper for controlling the hot and cold will not close all the way... It looks to me like the gears in the damper control motor are stripped thus causing the clicking noise.. The down side of this is that the damper motor is pretty close to impossible to get at.. I think Ford should come good for this!!!!!!
Living in Canada this time of year I really need my heater to work!!!!!!
- William A.,
Fredericton, NB, Canada
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Poor quality plastic part breaks.Costs about 40 bucks and everybody wants over $1000 for labor..
- Dan M., Hanover Park, IL, US