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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.

6.5

fairly significant
Typical Repair Cost:
$450
Average Mileage:
82,250 miles
Total Complaints:
268 complaints

Most Common Solutions:

  1. Ford should recall based on 2002-2005 complaints (124 reports)
  2. Ford should fix it if reported,being it's a known defect!!! (75 reports)
  3. not sure (36 reports)
  4. part needs to be replaced (14 reports)
  5. replace (10 reports)
  6. re-initiate the charity repair solution (4 reports)
2005 Ford Explorer body / paint problems

body / paint problem

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2005 Ford Explorer Owner Comments (Page 9 of 14)

« Read the previous 20 complaints

problem #108

Dec 142010

Explorer

  • Automatic transmission
  • 120,000 miles

A D V E R T I S E M E N T S

I contacted Ford when I discovered that the lift gate just below the back window cracked and this was their response "I sincerely understand the frustration that this experience has brought you.

We have reviewed the situation, and unfortunately, there are no warranties, Field Service Actions/Customer Satisfaction Programs on your vehicle that would provide assistance for this repair.

However, we do suggest that the repair be done by a Ford/Lincoln-Mercury dealership where the technicians are trained to put your vehicle back into factory specifications, and any parts replaced will come with a 12 months/12,000 miles warranty. Please be advised that a diagnostic fee may be charged. If additional assistance is required, we suggest that you contact the Customer Relationship/Service Manager. They will further assist in facilitating your service/repair needs. Moreover, your vehicle is not involved in any recalls or customer satisfaction programs."

This is a load of crap! Since my lift gate cracked, I started watching and I have over 40 license plate numbers of other Ford products with the same defect. How can they say there isn't a problem?!?!? I am in the process of writing the president and CEO of Ford to see if maybe then we (everyone with this problem) can get Ford to accept responsibility and do the right thing: fix them!

- lorryh, Cypress, TX, US

problem #107

Jan 012011

Explorer XLT 4.0L

  • Automatic transmission
  • 76,000 miles

After the winter I went to the back of the Explorer to open the rear window and noticed that the rear panel had cracked all the way through.

- Kurt G., Moline, IL, US

problem #106

Dec 042007

Explorer

  • Automatic transmission
  • 35,000 miles

I was annoyed that there began a crack right about the left side of the emblem on the back of my explorer. The crack grew because it wasn't under warranty. Today driving I had a woman pull me over with the same exact problem on her explorer. She said she had the crack repaired when the car was under warranty however it's back and the dealer says no warranty no repair unless you want to pay $400 to repair the crack again. Ford needs to make this right it doesn't take a mastermind to realize this is a clear cause of FACTORY DEFECT aka BAD DESIGN

- Jeannie V., Porter Ranch, CA, US

problem #105

May 152010

Explorer Eddie Bauer 4.6L

  • Automatic transmission
  • 54,000 miles

A D V E R T I S E M E N T S

sent ford email about problem. they said i should take it to an authorized dealer for repair,not to be covered by ford under warranty or expense. dah!!!!. if they wont cover there mistake/poor design why should i pay for this. so i guess when i go car shopping it wont be a ford on my mind.K I A now offers a 100000 mi warranty/lifetime warranty where brothernlaw bought his new sorrento. ridgerunner n ms

- David E., Collins, MS, US

problem #104

Jan 152011

Explorer XLS V6

  • Automatic transmission
  • 70,000 miles

We only had 2 payments left when we noticed the crack after a cold weekend. Then we started noticing other Explorers in our area with the identical crack and that's what prompted me to google this. Then I found this site with so many other people having the same problem. I will say overall it's been a good vehicle and we've not had many problems but I'm very disappoiinted that Ford won't take responsiblility for this since it is clearly a design flaw. If we have the liftgate replaced it will most likely do the same thing so I'm not sure what to do at this point. We don't want water damage to the interior or the wiring in the liftgate but I'm afraid to even use the liftgate at this point.

My husband wanst to just put some silicone in the crack but the resale value will now be greatly reduced. Bummer!!

- anitasc, Campobello, SC, US

problem #103

Feb 032011

Explorer Eddie Bauer V8

  • Automatic transmission
  • 102,000 miles

This problem is a typical problem with Ford. The cost to relace is Approx. $700.00 Ford will not help with the cost of the replacement

- Craig W., Columbia, SC, US

problem #102

Jan 152011

Explorer 4.6L

  • Automatic transmission
  • 72,000 miles

A D V E R T I S E M E N T S

We have two 2005 explorers in our family. Both have crack in the same place.

- matt_hannan2000, Mooresville, NC, US

problem #101

Nov 262010

Explorer XLT 6 cyl

  • Automatic transmission
  • 120,000 miles

Called Ford dealership for information on repair and was told it would be over $500 to fix it and that it was basically an engineering design flaw...what?!?!? Apparently they are not concerned that the back door panel can just crack in half without even moving the vehicle, since they made it this way for a number of model years; apparently they also don't care much about their quality reputation....I've only had this car for 4 months and have already had four repairs (and the previous owner had rebuilt the tranny before I bought it). I hardly drive it and there's always a new problem with it every time I do...my first and last Ford...

- Lisa N., Charlottesville, VA, US

problem #100

Dec 032010

Explorer Eddie Bauer 4.6L V8

  • Automatic transmission
  • 72,435 miles

I have the same complaint as others. I am a long time Ford customer. I have owned both cars and trucks. This is a defect that Ford should FIX at no cost to us owners.

- David M., Demopolis, AL, US

problem #99

Dec 292010

Explorer Eddie Bauer V6

  • Automatic transmission
  • 63,000 miles

I just noticed this crack under the window on the back hatch yesterday afternoon. My GARAGE kept explorer apparently is not safe from this defect like so many other explorers. My hubby went to ford and they openly acknowledged the defect, but didn't offer any help. Fixing it at the dealership will be 1K. OUCH. I am so disappointed with ford and I'll be buying other American brands from here on out.

- Barbara P., Mckinney, TX, US

problem #98

Dec 012010

Explorer XLT 6

  • Automatic transmission
  • 55,000 miles

A D V E R T I S E M E N T S

Crack on the right side of Ford Emblem on the back hatch panel. I've noticed about 5 Explorers with the same problem. One had 1/2 the panel completely off. Concerned that it could be a hazard if it flies off while driving. Could possibly be rusting underneath the panel. Ford should repair this problem at no cost to the consumer. This is definitely a flaw in the design.

- Sandra K., Huntington Beach, CA, US

problem #97

Feb 012011

Explorer XLS V6

  • Automatic transmission
  • 88,000 miles

click to see larger images

cracked panel below the rear window

This 1/16th in. crack appeared below the rear window of the exterior rear hatch panel. It is located on a piece of plastic trim where the Ford logo is attached. I got to looking at other Explorers and have seen the same crack on many of them. I'm not planning on paying to fix this. I believe this is a defect and Ford should issue a recall for this defect. I was pondering on whether to try to fill the crack with silicone and paint it but I suppose it would reappear again the first time the hatch is shut after mending it. This problem should fixed by Ford at no cost to the owner.

- Warren L., Ovilla, TX, US

problem #96

Feb 252011

Explorer XLT SPT/NBX /Trac 4.0L V6 Fi

  • Automatic transmission
  • 120,000 miles

click to see larger images

cracked panel below the rear window

I HAVE A 2005 FORD EXPLORER AND NOTICED THAT THE REAR HATCH HAS A CRACK IN IT TO THE LEFT MIDDLE OF THE FORD EMBLEM, THE VEHICLE HAS ONLY 120,000 MILES ON IT AND I THINK THIS IS A DEFECT IN WORKMANSHIP WHICH FORD SHOULD COVER, BUT THEY WILL NOT PAY FOR REPAIRS OF IT AT ALL. FURTHER MORE I WILL NOT BUY ANOTHER FORD VEHICLE AS THE COMPANY DOES NOT STAND BEHIND THEIR PRODUCTS AT ALL. SHAME ON FORD AND THEIR CHEAP CONSTRUCTION OF MATERIALS.

- whtchokalatte7, plano, TX, US

problem #95

Dec 152010

Explorer

  • Automatic transmission
  • 100,000 miles

If Ford knows that this is a problem with their product I can't imagine them not fixing it. It is appalling that Ford hasn't addressed this issue. It might not be a safely concern but I take pride in my car and having this huge crack in the back is a eyesore. It is very clear that us the consumers aren't causing it. Ford needs to fix this.

- Wendy S., Bonham, TX, US

problem #94

Jan 012007

Explorer XLT V6

  • Automatic transmission
  • 80,000 miles

Add me to the list. I've got the crack. Aesthetic and safety issue.

- bjerome, Edmond, OK, US

problem #93

Dec 012010

Explorer XLT V8

  • Automatic transmission
  • 125,000 miles

2005 Ford Explorer XLT V8 - Cracked Panel Below Rear Window

Ford needs to buck up, recall and repair this obvious design flaw. The crack in the panel of my vehicle is approximately 1/8" to 1/4" inch wide and growing -- it is definitely a safety issue. Ford's negligence and refusal to take responsibility for this issue is inexcusable! This is the third Ford vehicle that I have purchased -- in today's world you can't afford to lose another customer -- make it right Ford!!

- kittywho, Bishop, CA, US

problem #92

Dec 012010

Explorer

  • Automatic transmission
  • 85,000 miles

My mothers explorer has the crack. car is in great shape and an extended warranty was purchased and still good when this was noticed. back hatch hadn't been opened in at least a week when this appeared. the Ford dealership says this is not covered under warranty. will try to find the facebook groups and join. It is unacceptable for a vehicle to crack when not touched and it not be considered a defect.

- Torie R., Lampasas, TX, US

problem #91

Feb 102011

Explorer XLT 4.0L

  • Automatic transmission
  • 150,000 miles

click to see larger images

cracked panel below the rear window

I had no idea what happened but when I contacted my insurance company they told me it is a Ford defect and Ford should fix it, the dealer said it's out of warranty so I am on my own. Well I understand replacing tires, brakes, belts, etc. they are supposed to wear out, but part of the vehicle body is NOT supposed to crack open like an egg! I would love to know if Ford will accept any responsibility for this!

- Diane D., Sanford, NC, US

problem #90

Jul 092009

Explorer XLS V6

  • Automatic transmission
  • 69,543 miles

Had a crack to the right of the emblem; I repaired it with Fiberglass and mating. Repainted the panel and it looked like new. Within two weeks I had a new crack to left of the emblem.

The panel does not expand at the sale rate as the glass. This problem is a FORD engineering screw up and should be replaced with a panel of different material by FORD.

I have been a Ford owner for over 40 years and be switching to a different brand.

- geocad, Boynton Beach, FL, US

problem #89

Dec 312010

Explorer EX V6

  • Automatic transmission
  • 69,490 miles

To whom it may concern:

I am currently a 2005 Ford Explorer owner. I have taken great pride in owing my Ford, until now. I tell everyone, "Buy Ford" that’s the American way! Ford has been around for a very long time. Everyone knows Ford, right? What everyone does not know is some of the hassles Ford owners have to go thru to get something defected, CORRECTED. Why should we, Ford buyers, have to go thru such extreme to get an issue resolved? Aside from purchasing a new home, purchasing a car is the second highest investment a person does. So, if we are trusting you, and investing thousands upon thousands of money for your product, why can’t you give us the same respect, and correct issues that arise?

My 2005 Ford Explorer is one of many with the rear back panel crack next to the “FORD” emblem. Such an eye-sore and so disappointed every time I see it. I mean, don’t you advertise your slogan each and every day “QUALITY IS JOB ONE”, “BUILT FORD TOUGH”? Are you serious? Built tough for what? Now, I can see if it were just a “few” issues with this crack, but as you can see by some of the comments I have pasted in this email, there are over 400 complaints with this ONE issue? I live in Texas, and in the past week, I have taken 6 different pictures of Ford Explorer owners, with the same crack on back panel. That is just ONE week ONE town. So, I am sure if I didn’t have to work and earn a paycheck, TO PAY FOR MY LOVELY FORD EXPLORER, I would have a lot more pictures. I just wonder how you feel knowing that right now, there are at least over 400 people driving your Ford, trusting you, that are so dissatisfied, that most of them will most likely NOT buy another Ford again. I am sure there are more than 400, because the models range from 2002-2006 with this defect, and don’t forget those that recently went and bought a Ford, that the crack has not “appeared yet”, because trust me, it will. I warned a co-worker of mine about not buying this used 2002 Ford Explorer, just for the simple fact of this crack, and she didn’t listen of course, and 2 months after she spent $6,000 of her hard earned money, walaaa…..cracked panel in back! Go figure! She took to dealership, and it was going to cost her another $600 to fix the panel. Go figure again!

I know for a fact this is not the first time you have heard of this, and it is such an insult to us, Ford buyers, that you would ignore this, and not offer to fix something that clearly is a manufacture issue. It does not make one feel good to spend all our money, and still be dissatisfied and unhappy. We might as well buy a Toyota for that matter. At least they seem to WANT to fix the issues, and own up to it.

It is my wish, and hope for all Ford Explorer owners to be able to take their vehicle that they WILLINGING purchased from you, when we could have clearly gone elsewhere, to the shop, and this issue is resolved. Most of us love to show off our vehicles, and at this point, it just is not a pretty site, with a 7 inch crack in the back. We are scared to even go wash it, water seems to find its way in the back trunk too, and please do not suggest “sealant” because that does not work either. Please, Please take in consideration of the people who are begging you to recall this, and make us happy, the way we all make you happy when you receive your paycheck every month. Remember, if it wasn’t for us, the buyers, you would not be where you are today.

I will be printing out all 400 complaints, at home, and each week I will send them to the CEO, Chairman, and Secretary of CEO, my Congressman, my newspaper, whoever I need to get in touch with, to get this message across. I will pull a Shaw shank Redemption, and continue to flood fax machines, emails, post offices, everyone I can, until SOMEONE listens, and realizes that this needs to be corrected. Just like I CHOSE to buy a Ford, I will CHOOSE to stand by in what I believe in. Another one of your slogans is “Ford has a better idea”, well I have an even better idea, “RECALL THE REAR BACK PANEL ON ALL 2002-2006 FORD EXPLORERS”

Thank you. Until next week………. Robert G. Killeen Texas

- Robert G., Killeen, TX, US

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