The contact owns a 2015 Ford Explorer. The contact stated that while driving his vehicle at approximately 50 MPH, the check engine light illuminated, and he smelled as if something was burning. The contact stated that he then pulled over and waited until the smoke cleared before driving the vehicle again. The contact stated that he then took his vehicle to get serviced for an oil change as he…
2015 Ford Explorer engine problems
severe 204 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
204
Recalls
0
Avg fix
$3,100
1crash
1fire
11injuries
When does it fail?
Of the 204 engine complaints filed for the 2015 Ford Explorer, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 204 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 19 model years of Ford Explorer in our records for engine problems, this one ranks #3 by owner-complaint volume.
The failure pattern owners describe
Buyer takeaway: The 2015 Explorer has serious, widespread exhaust fume intrusion into the cabin during highway driving and acceleration, documented by owners at dangerous carbon monoxide levels, plus a known internal water pump failure that can wreck the engine—neither reliably fixed by dealers or covered by Ford after warranty expires. Avoid this model unless inspected by an independent mechanic with a CO detector and documented service history for cabin sealing and engine work.
The 2015 Ford Explorer engine failures cluster into two distinct problems.
Exhaust fumes entering the cabin is by far the dominant complaint. Owners report strong exhaust and sulfur odors seeping into the vehicle during hard acceleration, highway merging, uphill driving, or under load—and it persists regardless of whether air conditioning recirculation is on or off. Multiple owners measured carbon monoxide levels using home detectors, documenting readings of 5–64 ppm during drives, with some hitting 81–183 ppm. Symptoms include headaches, nausea, dizziness, vomiting, vision problems, and fatigue severe enough to impair driving and affect work. One police officer fainted and crashed; Austin PD installed CO detectors in their Explorers. Dealers have attempted TSB 14-0130 (cabin sealing), exhaust system replacement, muffler replacement, body resealing, EGR valve repair, and evaporator core replacement—repeatedly on some vehicles—without lasting fixes. Ford initially denied the problem existed, then blamed mildew or driver behavior. At least one recall program (17N03) was issued but appears limited in scope.
Internal water pump failure is the secondary issue. Owners report coolant leaks starting as early as 46,000 miles, traced to the water pump sealed inside the engine block. In some cases, coolant and metal particles contaminate the oil, risking catastrophic engine failure with no warning. Repair costs run $2,300–$2,800. Owners note the part was supposedly "upgraded" based on part number suffix, but failure persists.
One owner also reported sudden power loss and rough running at highway speed that resolved after restart.
Same Ford Explorer engine reports on nearby years: 2013 · 2014 · 2016 · 2017 · 2018
Failure modes owners describe
Exhaust fumes entering cabin
Carbon monoxide and exhaust gases leak into the passenger compartment, especially during acceleration, highway merging, uphill driving, or sustained engine load. Odor ranges from sulfur/rotten egg to burnt hair/burning oil. Occurs with or without air conditioning recirculation active.
When: Since near-new; worse under hard/sustained acceleration and higher speeds/RPMs (typically >2,800 rpm); recurs throughout ownership
Symptoms owners cite: Strong exhaust/sulfur/burnt hair odor in cabin; Headaches; Nausea and vomiting; Dizziness and lightheadedness; Drowsiness and fatigue; Blurred vision; Watering eyes and coughing; Difficulty concentrating; Carbon monoxide detector readings of 5–64 ppm (some up to 183 ppm)
Repairs/costs cited: Dealers attempted TSB 14-0130 (cabin sealing/rear underbody sealing), exhaust system replacement, muffler replacement with 'bad welds', body seam resealing, EGR purge valve repair, evaporator core replacement, reprogramming electronic modules, and tailgate gasket replacement. Multiple repeat visits (some 3+ times) without permanent fix. Repairs often free under warranty or TSB, but out-of-warranty repairs quoted $1,800–$3,000 and not guaranteed.
Recalls/TSBs owners mention: Ford recall program 17N03 (based on TSB16-0165, expiring December 31, 2019) issued for some vehicles. Police Interceptor Utility covered. Civilian vehicles often excluded from recall VINs. Ford initially denied carbon monoxide was present, blamed mildew, or told owners their driving habits caused the issue. Some dealers told owners to take vehicle on longer trips to 'dry out' evaporator. Field engineers on-site were unable or unwilling to replicate smell during test drives.
Internal water pump failure
Water pump sealed inside the engine block develops internal leaks, allowing coolant to escape and contaminate the engine oil and oil pan. Can lead to catastrophic engine failure with metal particle contamination if not caught early.
When: 46,000–114,000 miles; typically early/mid-life of vehicle with no advance warning
Symptoms owners cite: Coolant leak visible under vehicle or in driveway; Low coolant reservoir level; Engine overheating risk if leak progresses unchecked
Repairs/costs cited: Requires replacement of internal water pump assembly. Cost $2,300–$2,800. One owner noted part number upgraded with 'B' suffix, but failures continue. Repair typically takes 5–7 days.
Recalls/TSBs owners mention: No recall mentioned. Ford warranty covers repair on vehicles within 3–5 years. Extended warranty programs may deny coverage if not included. Owners report no manufacturer assistance or buy-back offers. One collision center and insurer claimed this is 'wear and tear' despite lawsuit filed in Massachusetts over design defect.
Total engine failure from water pump and coolant contamination
Water pump failure causes coolant to enter engine block and mix with oil, leading to total engine failure. One owner reported this as a known design flaw affecting 2011–2020 models with no recall issued despite multiple victims.
When: Mileage not always specified; can occur suddenly during normal operation or traffic
Symptoms owners cite: Total engine failure with no advance warning; No instrument panel warning before failure; Vehicle comes to complete stop or standstill
Repairs/costs cited: Requires full engine replacement or rebuilt engine installation. One owner paid $7,000+ out of pocket for rebuilt engine. No manufacturer assistance offered despite multiple complaints.
Recalls/TSBs owners mention: No recall issued. Ford denied responsibility. Owners had to bear replacement costs entirely. One owner extensively corresponded with Ford and dealership to no avail.
Power loss and stalling
Engine loses power suddenly during highway driving; transmission acts as if in neutral despite being in drive; RPM drops to idle. Vehicle restarts after pulling over and waiting.
When: One incident reported at 70 mph uphill at night; another at highway speeds in general; recurred 3+ times for one owner
Symptoms owners cite: Complete loss of forward motion and power; Transmission feels in neutral when in drive; RPM drops to idle; Engine runs rough then shuts down; Vehicle restarts without issue after brief pause
Codes mentioned: Service Terrain System Management warning with wrench icon (one complaint)
Repairs/costs cited: Alternator and battery replaced in one case; no diagnosis confirmed the root cause. One owner reported it as possible turbocharger cooling line weakness.
Recalls/TSBs owners mention: Dealership unable to diagnose or replicate failure on multiple visits. No codes showed up in system. Manufacturer suggested warranty extension but did not follow up. One incident classified as out-of-warranty with no lemon law relief.
Synthesized from 204 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
Water pump was leaking. Got warning indicating the coolant levels were low. Filled up coolant and was empty a couple weeks later. Was 14 hours of labor to fix. Mechanic said they get ford explorers with the same issue about 2 times per week. Should be a recall.
On my 2015 Ford explorer xlt, the water pump which is encased inside the cyclone/duratec engine, broke and leaked coolant which was mixed with the oil, tge oil pan and the oil pump causing complete engine failure. There was no advance warning and Ford has not issued a recall although a number of models have been affected. This caused me to have to replace my engine at my expense. Ford motor…
Tl* the contact owns a 2015 Ford explorer. While driving various speeds, the contact felt nauseous, sleepy, and had headaches. There were no warning indicators illuminated in the vehicle. The vehicle was taken to future Ford Lincoln (650 automall dr, roseville, ca 95661, (888) 656-7577) and was serviced per Ford reference number: 17n03 regarding the carbon monoxide concern. The dealer repaired…
Had engine trouble with your 2015 Ford Explorer?
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 2015 Ford Explorer?
It's a meaningful issue. 204 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 140 complaints that reported odometer mileage, most engine failures cluster between 24,400 and 90,000 miles, with the median around 43,643. A quarter of owners report trouble before 24,400; a quarter make it past 90,000. 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/2015/Ford/Explorer.
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.