Three problems related to manifold/header/muffler/tail pipe have been reported for the 2007 Ford Explorer Sport Trac. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2007 Ford Explorer Sport Trac based on all problems reported for the 2007 Explorer Sport Trac.
Passenger side exhaust manifold bolts have broken at 65k miles. After researching this seems to be a known problem Ford has avoided recalling. I easily found 25 plus cases of explorer sporttrac owners with the 4. 6 v8 reporting this exact problem. Ford charges over 3k to fix what seems to be a faulty design that happens on the majority of these vehicles.
The truck has been leaking coolant. The mechanic finally found the problem. The intake on the manifold is plastic. It gets overheated on the metal manifold and cracks which causes coolant to leak. We've spent over $1000 getting repairs. Still leaks due to that one faulty part. Everything I've read indicates that Ford is aware of the problem but has taken no steps to correct it. They did claim that reprogramming the thermostat settings was all it needed but that is not true.
I had misfires on cylinder 7, tried to replace plugs had four break in manifold, found that speciality tool had to be bought to replace plugs that break, also found that Ford service was well aware of problems with plugs and they charge extra to remove and replace broken plugs. Ford engineered a faulty product and because the ntsb has not slapped their hands they will not make any amends to their customers for replacement of plugs. Something should be done to make them replace the plugs for a non defective part.