The 2006 Explorer (U251 platform) is plagued by catastrophic 4.0L SOHC V6 timing chain failures and transmission issues, making it one of Ford's riskier mid-2000s SUVs. The 4.6L V8 is more reliable but harder to find.
4.0L SOHC V6 Timing Chain Cassette Failure
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Rattling noise on cold start that may disappear when warm, Check engine light with cam/crank correlation codes (P0340, P0341), Sudden loss of power or complete engine failure if chain jumps timing, Metal shavings in oil from cassette guides disintegrating
Fix: Replace both timing chain cassettes, guides, tensioners, and cam phasers. Requires front engine disassembly. 12-16 labor hours. Often discovers additional damage requiring head work or full engine replacement if driven after failure.
Estimated cost: $2,800-5,500
5R55S/W Transmission Cooler Line and Internal Failure
Common · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Harsh or delayed shifts between 2nd and 3rd gear, Transmission slipping under load or on hills, Transmission fluid leaking from cooler lines at radiator, Burnt transmission fluid smell, Limp mode with wrench light on dash
Fix: Cooler line failures alone are 2-3 hours and $300-600. Internal failures (solenoid pack, clutches, or valve body) require rebuild or replacement. R&R transmission is 8-10 hours plus rebuild costs.
Estimated cost: $2,200-4,200
Rear Axle Pinion Seal and Bearing Failure
Occasional · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: Gear oil dripping from front of rear differential, Howling or whining noise from rear end that increases with speed, Clunking when shifting from drive to reverse, Vibration at highway speeds
Fix: Pinion seal replacement is 2-3 hours. If bearing is damaged, requires full differential disassembly and setup (6-8 hours). Often discovered too late after running low on fluid damages ring and pinion.
Estimated cost: $450-1,800
Lower Control Arm and Ball Joint Wear
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking over bumps from front suspension, Wandering or loose steering feel, Uneven tire wear on inside or outside edges, Excessive play in wheel when checking at 12 and 6 o'clock
Fix: Ball joints are pressed into control arms; most shops replace entire lower control arm assemblies. 3-4 hours for both sides including alignment. Worn ball joints can separate causing loss of control.
Estimated cost: $600-1,100
4.0L V6 Cylinder Head Cracking
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust on startup, Rough idle or misfires on specific cylinders, Coolant in oil (milky appearance on dipstick), Overheating despite new thermostat and water pump
Fix: Cylinder heads on 4.0L SOHC are prone to cracking between valves. Requires head removal, magnaflux testing, and replacement if cracked. 14-18 hours for both heads. Often discovered during timing chain job.
Estimated cost: $3,200-5,800
Rear Liftgate Latch and Hinge Failure
Occasional · low severity
Symptoms: Liftgate won't latch or requires slamming multiple times, Liftgate pops open while driving, Power liftgate operates erratically or not at all, Sagging liftgate on one side, Warning light on dash indicating liftgate ajar
Fix: Latch mechanism replacement is 1-2 hours. Hinge reinforcement or replacement adds 2-3 hours per side. Common issue from heavy liftgate design stressing mounting points.
Estimated cost: $300-900
Owner tips
Change transmission fluid every 30k miles with Mercon V—5R55 transmissions are sensitive to old fluid
Inspect timing chain tensioners at every oil change on 4.0L V6; listen for cold-start rattle and address immediately
Use Motorcraft oil filters only on 4.0L SOHC—aftermarket filters have caused oil starvation issues
Check rear differential fluid level every 15k miles; pinion seal leaks are slow and easy to miss
If buying used, get pre-purchase inspection focused on timing chain noise and transmission shift quality
Avoid the 4.0L V6 models unless timing chains and transmission have been recently replaced with documentation—otherwise you're buying someone else's upcoming $5,000+ problem; 4.6L V8 versions are acceptable if properly maintained but still carry transmission risk.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: Standard top post battery; some models may use BCI Group 86
As an Amazon Associate, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.
Every control module on the 2006-2010 Ford Explorer — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
📍 Behind instrument panel, driver side left of steering column
🔧 Ford IDS with VCM II
⚠️ Integrated fuse/relay box with body control. Configuration programming required for options (remote start, alarm, perimeter lighting, etc.). As-built data critical.
Transfer Case Control Module (TCCM)1.8 hr R&Rdealer / factory tool +0.3 hr4WD models with electronic shift (ControlTrac II)▸ programming details
📍 Inside cabin, under center console near transmission tunnel
🔧 Ford IDS with VCM II
⚠️ Controls electric shift motor on transfer case. Configuration programming recommended for proper operation. Terrain Management System on higher trims requires additional calibration.
📍 Under passenger seat, integrated with seat frame
🔧 Ford IDS with VCM II
⚠️ Weight sensor for passenger airbag suppression. Calibration required after replacement. Critical safety system; must verify proper operation with IDS.
📍 Inside cabin, under center console behind climate controls
🔧 Ford IDS with VCM II
⚠️ VIN programming required. Adaptive learning resets after replacement; may take 20-30 miles to relearn shift quality. New six-speed transmission for 2006.
📍 Under center console, below radio/climate control stack
🔧 Ford IDS with VCM II
⚠️ Crash data stored; must clear codes and reset crash flag with IDS after deployment. Configuration for seat occupancy sensors and side airbags required.
📍 Engine compartment, driver side frame rail near master cylinder
🔧 Ford IDS with VCM II
⚠️ Integrated hydraulic control unit. AdvanceTrac standard; includes yaw sensor and steering angle sensor inputs. Configuration programming required. Bleeding procedure required after replacement.
⚠️ Odometer programming required to transfer mileage. VIN and configuration must be programmed. PATS transceiver integrated in cluster. Message center configuration required.
📍 Behind center instrument panel, above transmission tunnel
🔧 Ford IDS with VCM
⚠️ Translates between HS-CAN, MS-CAN, and other network protocols. VIN programming required. Critical for inter-module communication; failure causes multiple system faults.
Air Suspension Control Module (ASCM)1.0 hr R&Raftermarket tool +0.3 hrRear air suspension option▸ programming details
📍 Rear cargo area, driver side quarter panel behind trim
🔧 Ford IDS or aftermarket scan tool
⚠️ Controls rear air springs and compressor. Height sensor calibration required. Air suspension switch in cargo area must be ON for diagnostics.
⚠️ Controls ultrasonic sensors in rear bumper. No programming required. Standard on many trims.
Audio Control Module (ACM)0.8 hr R&Rrelearn only +0.2 hr
📍 Behind center stack, integrated with radio head unit
🔧 Clock and presets manual reset
⚠️ Premium sound systems have external amplifier under passenger seat. Navigation-equipped models have DVD drive and GPS antenna. Radio code may be required after battery disconnect.
⚠️ Controls seat position memory and heating. Memory settings stored in module; lost on replacement. No programming required but settings must be manually re-entered.
Lighting Control Module (LCM)0.7 hr R&Rno codingWith automatic headlights or HID headlights
📍 Behind instrument panel, integrated with headlight switch assembly
⚠️ Controls automatic headlight operation and HID ballast functions. No programming required. Some functions controlled by SJB on base models.
Trailer Tow Module (TTM)0.7 hr R&Rno codingWith factory trailer tow package
📍 Behind rear bumper, driver side near hitch receiver
⚠️ Provides trailer lamp diagnostics and relay control. Integrated trailer brake controller available as separate option.
⚠️ Not a separate module; function split between PCM and IC. Key programming requires IDS. Two programmed keys needed to add additional keys via self-learn procedure. Keyless entry/start available on higher trims.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
MARATHON IS RECALLING CERTAIN SEAT COVERS, BRAND SUPERHIDES WITH PART NUMBERS 593, 594, 578, 960, 228, 228-09, 267-08, 333, 625, AND 630, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE SEAT COVERS ARE MADE OF HEAVIER THREAD AND ARE NOT COMPATIBLE WITH SEATS CONTAINING SIDE AIRBAGS. THE HEAVIER SEAT COVER COULD INTERFERE WITH FULL DEPLOYMENT OF THE AIRBAG IN THE EVENT OF A CRASH.
Consequence: AN IMPROPERLY DEPLOYED AIRBAG COULD RESULT IN SERIOUS INJURY.
Remedy: MARATHON WILL NOTIFY OWNERS OF RECORD AND REPLACE THE SEAT COVER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 14, 2010. OWNERS MAY CONTACT MARATHON AT 1-800-735-2769.
VISIBILITY:GLASS, SIDE/REAR · 07E104000
2007-12-11
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
EXTERIOR LIGHTING · 06E049000
2006-05-24
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2006 Ford Explorer 4.0L V6 SOHC and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.