Ford Explorer Extended Warranty
The Ford Explorer is America's top-selling midsize SUV and an iconic three-row family vehicle. It's large, capable, and feature-packed — but 5th-generation Explorers (2011–2019) in particular developed a reputation for reliability problems across their transmission, Power Transfer Unit, and EcoBoost turbo systems. Here's what Explorer owners need to know.
Quick Answer
The Ford Explorer is a capable family SUV, but transmission failures ($3,500–$6,500), Power Transfer Unit (PTU) failure ($1,500–$2,800), EcoBoost turbo issues ($1,800–$3,500), and timing chain problems ($2,000–$3,500) are well-documented and expensive. Athena covers all of these with a flat $100 deductible.
Key Takeaways
- 1PTU (Power Transfer Unit) failure is the Explorer's most widespread and preventable repair — $1,500–$2,800.
- 2The 6F35/6F50 transmission on 5th-gen Explorers has documented reliability issues; replacement costs $3,500–$6,500.
- 3EcoBoost turbocharger replacement on 2.0L and 3.5L models runs $1,800–$3,500.
- 4Timing chain rattle on the 2.0L EcoBoost is a documented early failure — repair costs $2,000–$3,500.
- 5Athena covers Explorers under all four plan tiers with a $100 deductible.
- 6Covered repairs can be done at any licensed shop, including Ford dealerships.
Common Ford Explorer Failure Points
The Explorer's size and feature list come with mechanical complexity — and several systems are known to cause expensive repairs:
Power Transfer Unit (PTU) — Preventable but Common
The PTU is a small gearbox in the Explorer's AWD system that transfers power from the front to the rear wheels. Despite requiring fluid changes every 30,000 miles, Ford did not include this in the Explorer's recommended maintenance schedule — and many owners never changed it. By 80,000–120,000 miles, neglected PTUs develop internal bearing failure. PTU rebuild or replacement costs $1,500 to $2,800.
PTU failure is one of the most preventable — and most common — Explorer repair issues. Consumer forums are filled with Explorer owners who were unaware their PTU needed fluid service until it began making grinding noises. Extended warranty coverage means this $2,000+ repair costs just $100 out of pocket.
Transmission (6F35 / 6F50)
The 5th-generation Explorer's 6-speed transmissions have documented reliability concerns: harsh shifts, shudder during light acceleration, and premature wear — particularly on 2011–2015 models. Full transmission rebuild or replacement costs $3,500 to $6,500 depending on the variant and extent of damage.
EcoBoost Turbocharger
Explorer trims with the 2.0L or 3.5L EcoBoost engine rely on turbochargers that can develop boost leaks, actuator failure, and bearing wear. Turbocharger replacement costs $1,800 to $3,500 depending on the engine variant.
Timing Chain (2.0L EcoBoost)
The 2.0L EcoBoost engine has a documented timing chain rattle issue on early-production 5th-generation Explorers. Timing chain and phaser replacement is a significant repair — costing $2,000 to $3,500 — that addresses this known failure point.
What Athena's Coverage Pays For
Every major Explorer failure point is covered across Athena's plans:
- Powertrain Plus: Engine internals, transmission, transfer case, drive axle
- Enhanced Powertrain: Adds turbocharger, A/C, and electrical coverage
- Deluxe Coverage: Adds PTU/AWD system, suspension, cooling, and steering
- New Car Coverage: Near-complete mechanical and electrical protection
You pay just $100 per visit. Athena pays the repair shop directly — Ford dealer or independent mechanic.
Explorer Eligibility for Coverage
Most Ford Explorers qualify for Athena Auto Protection if they have:
- A clean title (no salvage or rebuilt titles)
- Under 150,000 miles at enrollment
- No pre-existing mechanical failures at enrollment
Coverage activates after a 30-day and 1,000-mile waiting period.
Sources & Methodology
Last Updated: March 2026
RepairPal: Ford Explorer repair cost estimates and reliability data (2024–2025)
NHTSA: Ford Explorer transmission and PTU complaint records (2011–2019)
Consumer Reports: Ford Explorer reliability ratings and owner satisfaction (2023–2025)
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