Inside our test sample, we found no rattles or squeaks but lots of trim that was loose if not quite falling off. Applying pressure to the gauge pod, the A-pillar trim, and various dash and door panels, we found that our Ford Explorer Sport Trac wasn't assembled with the same degree of care as previous Honda Ridgeline test trucks. Still, fits were flush and gaps were tight, so maybe this is a moot point.

On the outside, our test Explorer Sport Trac's assembly quality could have stood improvement. There was a major alignment issue between the front fascia/grille and the chrome garnish on the hood. Door gaps were inconsistent from side to side, the rubber molding fit sloppily on each side at the B-pillars, the plastic trim on top of the bed and on the rear bumper was loose and easy to pull off, and both the hood and tailgate were misaligned. Panel gaps weren't particularly tight on this thing, either.