The 1997-2001 Ford Explorer V8 with a 100% plastic intake manifold is known for engine overheating, even with normal use, and a coolant leak from the front of the manifold. This will often trigger the check engine light and low engine coolant warning light .
The engine coolant leak is from a factory defect, which causes cracking on the front coolant passage of the intake manifold. In a very short time, this leak will lead to engine overheating issues, especially while the vehicle is idling.
Between 1999 and 2001, Ford released an updated version of this engine, known as the 'PI' version with a metal coolant passage on the front of the intake manifold, to prevent future issues.
There is no factory authorized repair for the intake manifold, and replacement is required to correct the engine coolant leak and overheating issues.
A coolant leak may develop from the radiator . Ford has released and updated radiator and powertrain control module (PCM) software update to address this issue. The software update includes revised cooling fan operating parameters. Failure to complete both service procedures may result in repeated radiator failures.
A cosmetic crack may develop on the plastic liftgate trim panel. Ford has released a service procedure to replace the applique without damage the the liftgate glass.
A failed heater blend door or actuator can cause the temperature control for the HVAC system to stop working. A clicking sound from the dash area would commonly indicate an actuator fault. If the heater gets stuck on the hottest setting, the heater blend door may be broken requiring replacement of the heater box to repair the issue.
A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.
The Ford Explorer is known for a rough idle , engine stalling, loss of power, and misfires, accompanied by the check engine light .
The intake manifold O-ring gaskets commonly leak, which creates a large vacuum leak. This vacuum leak causes unmetered air to enter the engine, and the fuel system becomes insufficient to compensate for the large amount of air reaching the engine.
Replacing the intake manifold gaskets corrects this concern.
A ticking noise may develop from the engine due to a cracked exhaust manifold . Damaged exhaust manifolds will require replacement to correct this issue.
4wd vehicles may develop a squealing noise coming from the front wheels when driving below 30 mph. This is generally caused by dry excluder seals, lubricating the seals will commonly correct this concern.
Various problems with the 5-speed automatic transmission were common. These problems can be more common on the 2002 models with build dates before March, 2002. There are many service bulletins describing the diagnoses and repairs, which include fluid leak repairs, transmission software updates, or internal failures requiring a costly repair.
The rear window wiper may not fully contact the rear window. Our technicians tell us that replacing both the wiper blade and wiper arm will generally correct this issue.
The Ford Explorer V8 has known issues with the V8 engine ejecting spark plugs . This will make a tapping or knocking noise, plus the engine will begin to misfire at all speeds. The check engine light will also illuminate.
The threads on the cylinder head of the are too short and soft, allowing pressure from combustion to overwhelm and destroy the threads.
When the spark plug ejects, the cylinder head becomes damaged, necessitating repair of the spark plug port threads, or replacement of the cylinder head and cylinder head gasket.
Ford has recommended a method of repair for the cylinder head that prevents the spark plug from ejecting under future use. Replacement of all spark plugs is not necessary, but an updated spark plug design can help prevent this from happening in the future.
This vehicle is not covered under the TSB, but failure is common.
Drivers may notice the engine idling roughly, hesitation to accelerate, and even engine stalling on the Ford Explorer V8.
The mass air flow sensor (MAF) is prone to fail, and commonly is diagnosed as the faulty component when these issues arise.
When the Check Engine Light illuminates, and the diagnosis is a failed MAF, it will require replacement to correct the issue.
Ensuring the air filter is installed properly, and sealed to the air filter housing, can help prevent MAF sensor issues.
The Ford Explorer with the 4.6L V8 is known for displaying the normal symptoms of a coolant leak, including overheating, especially when the vehicle is idling, the strong smell of coolant from the engine, and illumination of the low engine coolant warning light .
This leak is difficult to locate as it is buried underneath the intake manifold , and only begins to leak coolant onto the ground in advanced stages of disrepair. This leak springs from the heater tube, which allows coolant to flow between the water pump and HVAC heater core .
When the connection for this tube begins to leak, the coolant burns on the hot engine, and produces a sweet smell that is unmistakably engine coolant.
The remedy can be complicated, and will necessitate removal of the intake manifold, heater tube, and possibly the water pump. After removal of these items, the connector may be replaced, or a set of o-rings, depending on the year of the vehicle. Most vehicles, model 2002 and later, will have o-rings, and the water pump will not need to be removed.
The Ford Explorer V8 is known for idling roughly, with a slight whistling noise from the engine compartment. After a short time, this may result in poor fuel mileage, and illumination of the check engine light .
This is caused by a cracked positive crankcase ventilation (PCV) valve hose, which allows a small vacuum leak, and improper evacuation of engine crankcase pressure.
Correction is simple, and requires replacement of the PCV hose. An updated part may be available.
The Ford Explorer V8 is known for intermittent rough idling, which may be accompanied by illumination of the check engine light , and poor fuel mileage.
This may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open, and diagnostic testing must be conducted.
The EGR valve and sensor must be replaced together to correct this concern.
Spark plugs in the Ford Explorer can be very difficult to remove.
Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head .
The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.
There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor for the removal of each broken spark plug.
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