Are Ford Explorers made in the USA?
Yes, Ford Explorers are primarily manufactured in the United States. The Ford Explorer is one of Ford's flagship SUV models, and the majority of these vehicles are assembled at Ford's production facilities located within the country.
Where Are Ford Explorers Produced?
The Ford Explorer is primarily produced at Ford's Chicago Assembly Plant in Chicago, Illinois. This facility has been the main production site for the Explorer since its introduction in 1990. In addition to the Chicago plant, Ford also manufactures some Explorers at its Louisville Assembly Plant in Kentucky.
The Chicago Assembly Plant is a large, state-of-the-art facility that employs thousands of workers. It has been a crucial part of Ford's manufacturing operations in the United States for decades, producing not only the Explorer but also other popular Ford models like the Ford Taurus and Ford Flex.
Reasons for U.S. Production
- Proximity to Key Markets: Producing the Explorer in the United States allows Ford to efficiently distribute the vehicles to customers across North America, its primary market.
- Skilled Workforce: Ford's U.S. manufacturing plants employ a highly skilled and experienced workforce, enabling efficient and high-quality production of the Explorer.
- Logistical Advantages: Domestic production minimizes transportation costs and logistics challenges associated with importing vehicles from overseas.
- Compliance with Regulations: Manufacturing the Explorer in the U.S. ensures the vehicle meets all applicable federal and state regulations for sale in the American market.
Overall, the Ford Explorer's U.S. production aligns with Ford's strategy of leveraging its domestic manufacturing capabilities to serve the North American market effectively.
Where are the 2025 Ford Explorers built?
The 2025 Ford Explorer is made at the Chicago Assembly Plant in Chicago, Illinois. This plant is responsible for producing the redesigned model, which features updated styling, technology, and interiors.
- Location: The vehicles are assembled at Ford's facility in Chicago, Illinois.
- Production: The Chicago Assembly Plant manufactures the 2025 Ford Explorer and the Lincoln Aviator.
- Timeline: Production for the 2025 model year is underway, with vehicles starting to arrive at dealerships in the second quarter of 2024.
Which Ford models are made in the USA?
Many Ford vehicles are made in the USA, including the F-150, F-150 Lightning, Ranger, Bronco, Explorer, and Expedition. Other models like the Escape, Super Duty trucks, Mustang, and Transit vans are also assembled in the U.S.
| Vehicle | Location(s) |
|---|---|
| Bronco | Wayne, MI |
| Bronco Sport | Wayne, MI |
| Escape | Louisville, KY |
| E-Transit | Kansas City, KS |
| Expedition | Louisville, KY |
| Explorer | Chicago, IL |
| F-150 | Dearborn, MI; Kansas City, KS |
| F-150 Lightning | Dearborn, MI |
| Mustang | Flat Rock, MI |
| Ranger | Wayne, MI |
| Super Duty | Louisville, KY |
| Transit | Kansas City, KS |
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Is the Ford Explorer built in the US?
The Ford Explorer is one of America's best-selling SUVs, combining comfort, performance, and technology, all assembled at the historic Chicago, IL Assembly Plant.
Which Ford Explorer to stay away from?
Ford Explorer models to avoid include the 2002-2006 models, which are known for serious transmission and engine problems, and the 2020 model year, which had numerous recalls and quality control issues. Other problematic years include the 2016 due to recalls and poor construction, and some early 2021s built in 2020 due to manufacturing issues, although later 2021 models and the 2022 model are generally considered more reliable, despite 2022 receiving some criticism for ride quality and fuel economy.
This video explains why some model years of the Ford Explorer are more problematic than others: 56sAlex The Car DoctorYouTube · Mar 2, 2025
Specific years to avoid
- 2002-2006: The third generation of this model is notoriously unreliable, with widespread complaints about transmissions, engines, and electrical systems.
- 2016: This year had significant quality control issues, including faulty parts, poor assembly, and recalls for recalls for loose control arm bolts, seat belts, and airbags.
- 2020: The first year of the new design had quality control issues, including transmission problems, recalls, and poor fit and finish.
- 2022: While more reliable than earlier years, this model received a lukewarm reception from some reviewers due to a stiff ride, less-than-stellar fuel economy, and a lack of features compared to competitors.
Common issues in other model years
- 5th Generation (2011-2019): While generally more reliable than the third generation, some models experienced issues like premature wear on suspension components and water pump failures on the 3.5L engines.
- 6th Generation (2020-Present): Owners have reported problems such as premature failure of the CV axle boot, issues with the hub disconnect actuator, and rattling exhaust flex pipes.
