The Ford Explorer is an SUV that’s currently in its 6th generation. Find out the top 5 1995 to 2003 Ford Explorer problems owners run into with the 2nd generation.
2nd Generation Ford Explorer Problems (1995 to 2003)
1. Blend Door Failing
Symptoms of a Bad Blend Door
- The heat stays on when directed otherwise
Causes of a Bad Blend Door
The blend door goes into the heater box and opens and closes for hot and cold temperatures. The tubing in the heater box can crack and open, and the blend door can remain in the heat position.
How to Fix a Blend Door
You’ll need to remove the dash and heater box to replace the blend door. This job can take around 8 hours.
2. Timing Chain Cassettes/Guides Failing
Symptoms of Problems with the Timing Chain in the 95 to 03 Ford Explorer
- Chattering noise from the timing chain area
Causes of Problems with the Timing Chain Guides
The timing chain cassette is a piece of metal with a plastic covering. It keeps the timing chain taut from the top camshaft to the crankshaft. The plastic can brittle and break.
How to Fix Problems with the Timing Chain Guides
You’ll want to fix this problem as soon as possible. The timing chain will break if this problem is not fixed.
3. Transmission Problems
Symptoms of Problems with the Transmission in the 95 to 03 Ford Explorer
- Fluid leaking from the transmission
- Shuddering transmission
- Lack of transmission shifting
Causes of Transmission Problems
The transmission is known to leak.
How to Fix Problems with the Transmission
If the transmission is leaking, inspect the pan and replace it and the seal if needed.
4. Upper Intake Manifold Gasket Leaking
Symptoms of a Bad Upper Intake Manifold Gasket
- Check engine light
- Vacuum leak sound
- Roughh engine idle especially when cold
Causes of a Bad Upper Intake Manifold Gasket
The aluminum upper intake gasket between the upper and lower intake can pop out and leak.
How to Fix a Bad Upper Intake Manifold Gasket
Look for a gasket protruding from the upper and lower intake manifold gasket, which is a sign it needs to be fixed.
5. Plastic Intake
Symptoms of Problems with the Plastic Intake in the 2nd Gen Ford Explorer
- Engine seize
- Temperature gauge reads for overheating
- Coolant leaking from the plastic intake
Causes of Issues with the Plastic Intake
The plastic intake can crack and leak coolant. You may be driving at a higher speed, like on the highway, and the engine could seize if you don’t notice the engine overheating.
How to Fix a Bad Intake
Replace the old intake with an updated one that has a crossover aluminum pipe.