Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The 2005 Ford Explorer one of our worst vehicles on record. "Avoid like the plague" is putting it lightly.

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.


definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
44,467 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2005 Ford Explorer fuel system problems

fuel system problem

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2005 Ford Explorer Owner Comments

problem #6

Apr 092011

Explorer 4WD 6-cyl

  • 51,000 miles


2005 Ford Explorer - everytime I fill the gas tank full - the fuel gauge sticks and goes down to empty.

- Wa, WA, USA

problem #5

Sep 212009


  • 59,000 miles
We fill the truck up. The next day the gauge shows full. Great for a long distance trip.

- Dubuque, IA, USA

problem #4

Dec 202008


  • 35,000 miles
2005 Ford Explorer fuel sensor failure.

- Fort Pierce, FL, USA

problem #3

Mar 062008


  • 52,000 miles


When I fill my gas tank, occasionally the arrow does not go to full. I also have an electronic notification on my dashboard that tells me how many miles I have left to drive before I am on empty. This also does not change. This has happened no more than five times and takes a day or two for gauge to read full.

- Aliquippa, PA, USA

problem #2

May 042008


  • 32,800 miles
2005 Ford Explorer - fuel pump failure while driving vehicle shuts off and also fuel gauge reads E then emission light comes on. This is a safety hazard and a known defect. My vehicle had this to happen at 32,800 miles and I almost was involved in a major highway accident. By my chacks Ford is aware but is not concerned should be a recall.

- Buffalo, NY, USA

problem #1

Oct 252007

Explorer 4WD 6-cyl

  • Automatic transmission
  • 37,000 miles
The fuel gauge suddenly drops to empty even when the fuel tank is full. I have a 2005 Ford Explorer that had this repaired under warranty because it happened before 36000 miles. My husband has a 2005 Ford Explorer that we just bought in April 2007. His just hit 37,000 miles and this has happened to him as well. It also happened in my coworker's 2003 Ford Explorer. There is a recall on the 2002 Ford Explorer with V6 engine covering this exact same problem. However the 2005S are not in the recall and should be.

- Batavia, NY, USA

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