Problems · by component

2005 Ford Explorer structure problems

164 owner complaints to NHTSA about the 2005 Ford Explorer cite structure, 29% of all 568 complaints for this model year.

Complaints
164
29% of all complaints
Crashes
0
Reported by owners
Fires
0
Reported by owners
Injuries
2
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“The contact owns a 2005 Ford Explorer. The contact stated that there was a crack on the top panel of the rear liftgate. The contact was concerned that the rear liftgate would fracture if she opened the liftgate. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 120,000.”
Owner complaint to NHTSAFiled Sep 1, 2022StructureODI 11482456
“THE FAN BLADES HAD MANY BIG CRACKS IN THE PLASTIC BLADES,THE DRIVER DOOR THE BODY IS CRACKED BY TOP OF DOOR HING BACK DOOR IS THE SAME, THE PAINT IS PEALING AND STARTING TO RUST ON TOP.THE PLASTIC THERMOSTAT CRACKED.”
Owner complaint to NHTSAFiled Nov 30, 2020Structure, EngineODI 11377168
“THE FRONT, DRIVER'S SIDE, TIRE CAME APART AND CAUSED CONSIDERABLE DAMAGE TO MY VEHICLE'S BODY AND POSSIBLY OTHER DAMAGES NOT SEEN. I NEED TO TAKE THE VEHICLE TO A MECHANIC FOR AN INSPECTION TO SEE IF THERE ARE OTHER DAMAGES. THE TIRE IS A GOOD YEAR EAGLE RS-A. THE DOT # IS 4B08 DLWR 3701. TIRE SIZE P235/70R16. I WAS DRIVING ON INTERSTATE I-75 WHEN THE TIRE CAME APART. IT WAS TERRIBLY SCARY. I DID NOT REALIZE WHAT HAD HAPPENED AND THOUGHT THE VEHICLE WAS FALLING APART. I PULLED ONTO THE EMERGENCY LANE AND REALIZED THE TIRE HAD COME APART. THE RUBBER COMING OFF THE TIRE CAUSED QUITE A BIT OF BODY DAMAGE. THE VISIBLE DAMAGES INCLUDE DAMAGES TO THE DRIVER'S SIDE HEAD LIGHT, RUBBER RIPPED OUT THE DRIVER'S SIDE BLINKER, MOLDING UNDER THE DRIVER'S DOOR WAS RIPPED OUT, PAINT DAMAGE, TIRE WELL DAMAGE AND LOOSENING OF OTHER MOLDING ON DRIVER'S SIDE. A MECHANIC WILL HAVE TO INSPECT FOR UNSEEN DAMAGES.”
Owner complaint to NHTSAFiled Dec 21, 2018Structure, Wheels, Unknown or otherODI 11162956
“2005 FORD EXPLORER. FRAME IS ROTTING ALONG THE WELDS. NOT UP AND DOWN. LENGTH WISE RUNNING WITH THE FRAME. OBVIOUSLY A FACTORY WELD ISSUE AND A BIG ISSUE AT THAT AS THE ISSUE COULD HAVE THE FRAME FAIL AND ENTIRE HUB/AXLE/WHEEL ASSEMBLY RIP RIGHT OFF THE VEHICLE. THIS IS ALSO A VERY COMMON ISSUE WITH FORD'S IN GENERAL FROM 02-2005. AS YOU ALREADY KNOW I'M SURE. THIS VEHICLE WAS WELL MAINTAINED AND TAKEN CARE OF AND THE FRAME ISSUE HAS MADE AN OTHERWISE GREAT RUNNING LOW MILEAGE VEHICLE WORTHLESS. NOT TO MENTION HAD THE ISSUE NOT BEEN FOUND VERY DANGEROUS! PLEASE GET THESE DEATH TRAPS OFF THE ROAD!! HAVE PICTURES BUT THE FILES ARE TO LARGE TO SEND. THANKS.”
Owner complaint to NHTSAFiled Apr 9, 2018StructureODI 11084224
“THE BACK LIFT GATE PANEL CRACKED ON THE BACK OF OUR FORD EXPLORER AND WHEN WE WENT TO SHUT THE LIFT GATE THE WHOLE BACK WINDOW SHATTERED. FORD WON'T REPLACE IT BECAUSE THEY SAY ITS NOT A SAFETY ISSUE AND OUR YEAR OF OUR FORD WAS NOT APART OF THE RECALL OF THESE PANELS BEING CRACKED. PLEASE BE AWARE THAT IF YOU HAVE ONE OF THESE CRACKS THAT THE BACK WINDOW CAN SHATTER WHEN CLOSING THE LIFT GATE.”
Owner complaint to NHTSAFiled Aug 31, 2017StructureODI 11020756
“WE HAVE A 2005 FORD EXPLORER AND THE BACK LIFT GATE PANEL WAS CRACKED RIGHT BY THE FORD SYMBOL. WHEN WE WENT TO OPEN THE BACK LIFT GATE AND THE PANEL WHERE IT WAS CRACKED BROKE IN HALF AND SHATTERED THE WHOLE BACK WINDOW AND INJURED US. FORD WANTS TO CHARGE ME $140.00 TO JUST LOOK AT IT. COME ON FORD DO WHAT'S RIGHT! BEWARE IF YOU HAVE A CRACKED PANEL ON YOUR FORD! IT CAN BREAK IN HALF AND THE GLASS CAN SHATTER.”
Owner complaint to NHTSAFiled Aug 30, 2017StructureODI 11020618

Showing 6 of 164 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 7, 2026NHTSA vehicle page

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.