Where is the Ford Explorer manufactured?
The Ford Explorer is manufactured in the United States, primarily at Ford's Chicago Assembly Plant in Chicago, Illinois. This location serves as the main production site for the Explorer in recent model years.
In this article, we outline where the Explorer is built, why that site is used, and how production fits into Ford's broader manufacturing network. We’ll also touch on how manufacturing origins can be relevant to buyers and markets around the world.
Primary production site in the United States
The Chicago Assembly Plant in Chicago, Illinois, is the central hub for assembling the Ford Explorer for the North American market. As a multi-model facility, it handles the production of several Ford SUVs, with the Explorer being a key line in its output. The plant’s role reflects Ford’s strategy of concentrating popular, high-demand models at a single, well-equipped site to optimize supply and quality control.
Why this site matters
Location matters for supply chains, labor efficiency, and regional demand. By concentrating Explorer production at Chicago, Ford can streamline parts sourcing, scheduling, and engineering updates across the model line that shares underlying architecture with other SUVs.
Global production context and market variations
Ford markets the Explorer beyond the United States, and production arrangements can vary by year and region. The Chicago Assembly Plant serves as the primary production site for the U.S. and many North American models, while some international sales may rely on regional production arrangements. Buyers should note that the vehicle’s country of origin is sometimes listed on the window sticker or VIN, reflecting where its assembly occurred.
What buyers should check
If you’re purchasing an Explorer outside the United States or evaluating a used vehicle, verify the vehicle’s manufacturing origin on its documentation. Current U.S.-market Explorers are produced in Chicago, but regional variants or special editions in different markets may come from other plants depending on the year and model configuration.
Summary: The Ford Explorer’s primary manufacturing home for the U.S. market is the Chicago Assembly Plant in Chicago, Illinois, making it the central site in Ford’s North American SUV lineup. While Chicago handles the main production, Ford’s global operations mean regional variations can occur, so checking the VIN/window sticker provides the most precise confirmation for any given vehicle.
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.
Is the Ford Explorer made in the USA?
Yes, Ford Explorers are made in America, specifically at the Chicago Assembly Plant in Illinois. The Chicago plant is a historic facility that has been producing Ford and Lincoln vehicles for many years and is a key part of Ford's domestic manufacturing operations.
- Location: The Explorer is assembled at the Chicago Assembly Plant, located on the South Side of Chicago.
- Supporting American Jobs: The plant's production supports American jobs and contributes to the local and national economy.
- Part of a larger domestic strategy: The Chicago Assembly Plant is just one of several Ford facilities in the United States that are part of the company's strategy to produce a significant number of vehicles domestically.
What Fords are built in China?
Ford produces a range of vehicles in China, including both models specifically for the Chinese market and some that are exported to other regions, such as the Lincoln Nautilus and potentially the Ford Edge L. Key examples of Ford vehicles made in China include the Equator, Equator Sport, Edge, Territory, Explorer, Bronco New Energy, and the Lincoln Aviator and Nautilus. Production is handled through joint ventures like Changan Ford and JMC-Ford.
Models made in China
- Ford Equator: A mid-size, three-row SUV made by JMC-Ford.
- Ford Equator Sport: A compact SUV developed and manufactured by JMC-Ford, also exported as the next-generation Ford Territory.
- Ford Edge: A mid-size crossover manufactured by Changan Ford.
- Ford Territory: A compact SUV produced by JMC-Ford.
- Ford Explorer: A D-segment/mid-size crossover made by Changan Ford.
- Ford Bronco New Energy: An electric version of the Bronco, specifically for the Chinese market and assembled by JMC.
- Ford Mustang Mach-E: The all-electric SUV is produced at Changan Ford facilities.
- Ford Edge L: A spacious, seven-seat hybrid SUV specifically built for the Chinese market and manufactured at the Changan Ford Hangzhou plant.
- Lincoln Nautilus: This luxury SUV is manufactured in China and exported to the United States.
- Lincoln Aviator: Another luxury SUV produced in China at the Changan Ford facility.
- Lincoln Corsair: A luxury compact SUV that is also made in China for the Chinese market.
- Ford Ranger: The pickup truck is being domestically produced in China for the local market.
Where are 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.
