Ford Explorer (5th Gen) Buyer's Guide: Internal Water Pump Failure and More (2015-2022)
Ford · Explorer · 5th gen · 2015–2022
Buying a 2015–2022 Ford Explorer? Known issues include 3.5L water pump failure, PTU failure on AWD models, transmission harsh shifting, and A/C evaporator failure. Read our clinical used buyer's guide.
Mirko4 min read
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The 2015–2022 Ford Explorer (5th generation) is a common used SUV, but its 3.5L V6 carries a documented risk of internal water pump failure that can destroy the engine without warning. This generation spans two distinct phases—pre-refresh (2016–2019 U625) and refreshed (2020+ U625) on the same architecture—and is offered with three engines: a 3.5L Ti-VCT V6, a 3.5L EcoBoost V6, and a 2.3L EcoBoost I4 (2020+). While the Explorer offers ample space and towing capacity, several high-cost failure points make a pre-purchase inspection non-negotiable.
Generation Overview
Production ran from 2015 through 2022 with a mid-cycle refresh for 2020. The pre-refresh models (2016–2019) are built on the U625 platform and feature a 3.5L Ti-VCT V6 as the base engine, a 3.5L EcoBoost V6 on Sport and Platinum trims, and a 6-speed automatic transmission. The 2020 refresh added revised front and rear styling, a reworked interior, and introduced a 2.3L EcoBoost I4 engine to replace the base V6 on some trims, along with an available 10-speed automatic and standard Co-Pilot360 safety suite. The architecture remained 5th-gen throughout; no major structure changes occurred. Key variants: Base, XLT, Limited, Sport, and Platinum.
Known Issues
Water Pump Failure (3.5L V6)
The water pump is driven internally by the timing chain and cannot be accessed without major engine teardown. When the pump seal fails, coolant leaks into the engine oil, contaminating the lubrication system and often leading to catastrophic engine failure. This affects all 3.5L Ti-VCT and 3.5L EcoBoost engines from 2015 through 2022. Severity: Critical — repair costs range from $2,500 to $4,000+. Watch for low coolant level with no external leak, milky oil on the dipstick, or engine overheating.
PTU Failure (AWD Models)
The Power Transfer Unit (PTU) on all-wheel-drive variants is undersized and poorly ventilated. It leaks fluid, overheats, and the internal gears can fail, causing loss of drive to the rear wheels and loud whining noises. This is common across all AWD trims, regardless of year. Severity: High — replacement costs $1,500–$2,500. Listen for a whining sound from the front driveline that rises with speed; check for fluid drips under the center of the vehicle.
6-Speed Transmission Harsh Shifting
Pre-refresh models (2015–2019) equipped with the 6F50/6F55 six-speed automatic frequently exhibit hard shifts, hesitation, or delayed engagement, especially between 2nd and 3rd gear or when shifting into reverse. This is a known software and hardware issue that can be partially addressed with fluid changes and reprogramming. Severity: Medium — repair costs vary from $300 for a flush to $3,000+ for a rebuild. Test drive the vehicle and note any abrupt or jerky shifts.
A/C Evaporator Failure
The A/C evaporator core is prone to developing small leaks, resulting in loss of refrigerant and weak cooling. Because the evaporator is buried deep in the dashboard, replacement requires extensive labor (typically 6–8 hours). Severity: Medium — repair costs $1,200–$2,000. Look for poor A/C performance, musty odor from vents, or the need for frequent refrigerant recharge.
Rear Suspension Subframe Bushing Deterioration
The rear subframe bushings degrade prematurely, causing clunking noises from the rear suspension, imprecise handling, and uneven tire wear. This affects all trims but is more pronounced in higher-mileage examples. Severity: Medium — replacement costs $600–$1,200. Listen for a metallic clunk when going over bumps or during acceleration/deceleration.
Sub-Variant Issues
3.5L EcoBoost Turbocharger Issues (Sport/Platinum)
On Sport and Platinum trims, the 3.5L EcoBoost engine is susceptible to turbocharger wastegate rattle, oil leaks from turbo feed lines, and intercooler condensation causing misfires under cold damp conditions. Severity: Medium — turbo replacement costs $2,000–$3,000 per side. If you're looking at a Sport or Platinum, this adds another layer of risk beyond the water pump and PTU.
2.3L EcoBoost Carbon Buildup (2020+)
The 2.3L EcoBoost I4 is a direct-injection engine prone to intake valve carbon buildup, which can cause rough idle, reduced power, and misfires over time. Severity: Medium — walnut blasting costs $500–$800. Watch for hesitation during acceleration or irregular idle.
FAQ
What are the most common problems with the Ford Explorer (5th Gen) (2015-2022)?
Internal water pump failure on the 3.5L V6 is the most serious and most reported issue, since the pump is driven by the timing chain and its failure can contaminate the engine oil. PTU failure on AWD models and 6-speed transmission harsh shifting are the next most common concerns.
Is the Ford Explorer (5th Gen) (2015-2022) reliable?
It requires attention to the cooling system specifically. Internal water pump failure is a known, expensive issue since it's integrated into the engine rather than externally serviceable, making verification of coolant condition and service history important before buying.
Are there Ford Explorer (5th Gen) years to avoid?
Water pump failure reports span both the 2015 launch year and later production through 2022, so it isn't isolated to a specific window — a cooling system inspection matters more than picking a particular year.