Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only camshaft/camshaft roller follower(s) requiring replacement, replace all of the camshaft roller followers on both banks/cylinder heads with part number 3L3Z-6564-A, not just the faulty roller follower(s). When replacing the camshaft roller followers, refer to Workshop Manual (WSM), Section 303-01.
full bulletin at NHTSA ↗2007 Ford Explorer Sport Trac engine problems
severe 17 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$3,100
1crash
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
FORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE HARD STARTS AND ENGINE IDLE RPM FLUCTUATION AND EXHIBIT DIAGNOSTIC TROUBLE CODES (DTCS) P0505, P0506, P2111 AND P2112.
full bulletin at NHTSA ↗FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.
full bulletin at NHTSA ↗FORD/MERCURY/LINCOLN: VEHICLES MAY EXHIBIT ONE OR MORE OF THE FOLLOWING SYMPTOMS: DRIVE AWAY HESITATION, LOSS OF RPM ON DECELERATION, DIFFICULTY STARTING, AND/OR IDLE RPM LESS THAN DESIRED. THE F53 MOTORHOME CHASSIS IS INCLUDED.
full bulletin at NHTSA ↗MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P202 - 4.6L 3V.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Radiator leaks dominate these complaints. The aluminum core develops seam failures or the plastic lower tank cracks, with coolant pooling and dripping. Owners at 40,000–60,000 miles face $500+ replacement costs, and at least one owner had the new radiator fail again within 20,000 miles. Ford issued a TSB blaming improper fan control programming but only offered radiator swap and reprogram as a fix—no recall.
Spark plugs are another recurring headache. Ford installed fragile HT-1 ceramic plugs that crack during removal, requiring special tools and costly labor to extract debris. Quoted repair costs run $300 per plug, and multiple plugs breaking per replacement is common.
Plastic intake manifolds crack from overheating, causing persistent coolant leaks even after radiator and thermostat work. Thermostat malfunctions cause temperature gauge spikes without warning lights. PCM failures trigger intermittent stalling under all conditions, one at just 56,000 miles. Engine stalling during deceleration is reported repeatedly with loss of power steering and brakes—a genuine safety concern dealers cannot duplicate or fix. Exhaust manifold bolts snap at 65,000 miles; owners found 25+ similar cases and estimate $3,000+ in repair costs. Surface rust appears in engine compartments and under seats at extremely low mileage; Ford dealers call this normal.
Failure modes owners describe
Radiator coolant leaks
Aluminum radiator core develops leaks at seams or the plastic lower tank, causing coolant to pool and drip. Owners report multiple leaks in the same radiator. Service managers noted this is a recurring issue across multiple vehicles of this model.
When: 40,000–59,000 miles; some as early as around 8,000–10,000 miles
Symptoms owners cite: Coolant pooling at radiator bottom; Visible dripping under vehicle; Engine overheating; Temperature gauge rising
Repairs/costs cited: Radiator replacement: $500–$583 (parts only); some owners also report $1,000+ in total repair costs when repeat replacements occur. One owner had radiator fail again at 59K miles after initial replacement at 38.5K miles.
Recalls/TSBs owners mention: TSB issued for radiator coolant leaks; Ford attributed root cause to fan control programming—fan not running when needed or for adequate duration, causing radiator overheat. Programming update and radiator replacement offered as fix. No recall issued.
Plastic intake manifold cracking
Plastic intake on the manifold cracks from overheating when exposed to heat from metal manifold, causing coolant leaks. Owners report Ford is aware of the problem but has not corrected it.
When: Mileage not specified
Symptoms owners cite: Coolant leak from intake manifold; Persistent leaking despite radiator replacement
Repairs/costs cited: Over $1,000 spent on repairs; owners report continued leaking even after thermostat reprogramming attempt.
Recalls/TSBs owners mention: Ford offered thermostat reprogramming as a solution but owners report it did not resolve the problem.
Spark plug brittle fracture and removal difficulty
HT-1 ceramic spark plugs break during replacement attempts, especially when removed. Plugs develop stress cracks. Replacement requires special tools and extended labor time, making repair prohibitively expensive.
When: During routine or diagnostic maintenance; mileage not specified
Symptoms owners cite: Engine misfire (cylinder 7 noted in one complaint); Engine skip under load; Spark plugs breaking when removed
Repairs/costs cited: Ford service charges $300 per plug replacement quoted in one narrative; owners must pay extra labor for removal of broken plug debris. Special tool required.
Recalls/TSBs owners mention: None; owners report Ford is aware of the problem but charges customers extra to handle the failures.
PCM (powertrain control module) internal failure
Internal PCM failure causes intermittent engine shutdown under all driving conditions. One owner diagnosed this at 56,000 miles on a vehicle with very low mileage at time of failure. Failure is described by dealer as design defect; replacement PCM was on backorder.
When: 56,000 miles (low mileage for failure)
Symptoms owners cite: Engine shuts off intermittently while driving; Occurs under all conditions (stop-and-go, highway); No warning lights
Repairs/costs cited: $1,546.41 for replacement PCM (part sourced and shipped by owner); owner had to locate part themselves as dealership had it on backorder.
Recalls/TSBs owners mention: Dealer acknowledged internal PCM failure due to design defect; new redesigned PCM was on backorder at time of complaint.
Engine stalling during deceleration or stop
Engine shuts off intermittently when slowing for turns, stops, or braking. Loss of power steering and power brakes creates safety hazard. Dealers unable to duplicate or repair the problem. Multiple owners in Sport Trac club report the same issue.
When: Mileage not specified
Symptoms owners cite: Engine shut-off during deceleration; Loss of power steering; Loss of power brakes; Intermittent stalling, especially during braking
Repairs/costs cited: Dealers report unable to diagnose or repair; problem cannot be duplicated.
Recalls/TSBs owners mention: No effective response; dealers unable to address.
Thermostat malfunction
Thermostat fails to control engine temperature properly, causing extreme heat and unsafe driving conditions. Temperature gauge spikes without warning lights. One owner at 85,000 miles reported malfunction with AC also functioning sporadically.
When: 85,000 miles (one documented case); also reported without mileage in other narratives
Symptoms owners cite: Temperature gauge rises without warning indicator; Engine runs loud; Extreme heat in vehicle; AC functions sporadically during hot weather; Engine overheating
Repairs/costs cited: Not specified; owner reported vehicle unsafe to drive due to extreme heat.
Recalls/TSBs owners mention: Manufacturer advised no related recall; TSB issued per one narrative but did not resolve underlying issue for some owners.
Exhaust manifold bolt fracture
Passenger-side exhaust manifold bolts break, described as a known problem Ford has avoided recalling. Owner research found 25+ cases of 4.6 V8 Explorer Sport Trac owners reporting the same failure.
When: 65,000 miles (documented case)
Symptoms owners cite: Broken exhaust manifold bolts
Repairs/costs cited: Ford charges over $3,000 to repair; owner describes this as a faulty design affecting the majority of these vehicles.
Recalls/TSBs owners mention: No recall issued despite apparent pattern; Ford charges full repair cost.
Surface rust in engine compartment and underbody
Rust appears inside engine compartment, on drive shaft mechanism, and under all seats at very low mileage (360–700 miles). Dealer attributed to corrosive environment and normal occurrence for new Ford vehicles.
When: Failure at 360 miles, reported at 700 miles
Symptoms owners cite: Visible rust in engine compartment; Rust on drive shaft mechanism; Rust under all vehicle seats
Repairs/costs cited: Dealer suggested wiping with towel; no repair recommended.
Recalls/TSBs owners mention: Dealer stated this is normal and due to corrosive environment.
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2007 Ford Explorer Sport Trac?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2007 Ford Explorer Sport Trac?
It's a meaningful issue. 17 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 15 complaints that reported odometer mileage, most engine failures cluster between 40,000 and 89,000 miles, with the median around 65,000. A quarter of owners report trouble before 40,000; a quarter make it past 89,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2007/Ford/Explorer Sport Trac.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.