The 2007 Explorer marks the last year of the fourth-gen platform before a major redesign. Both engine options have significant weaknesses: the 4.0L SOHC V6 is known for catastrophic timing chain cassette failures, while the 4.6L V8 suffers spark plug ejection and head gasket issues. Transmission cooler failures are endemic across all configurations.
4.0L SOHC Timing Chain Cassette Failure
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Rattling noise on cold start that disappears after warm-up, Check engine light with cam/crank correlation codes, Sudden catastrophic engine failure with metal shavings in oil, Loss of power or rough running
Fix: The plastic timing chain cassettes disintegrate, sending debris through the engine. By the time symptoms appear, internal damage is often done. Requires complete timing chain replacement with updated metal guides (8-12 hours labor), but many engines need full rebuilds or replacement due to bearing/cylinder damage from debris. This is THE killer for the 4.0L SOHC.
Estimated cost: $2,500-$8,000
Transmission Oil Cooler Line Failure and Cross-Contamination
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Transmission fluid in coolant (strawberry milkshake appearance), Engine coolant in transmission, Transmission slipping or erratic shifting, Overheating transmission or engine
Fix: The internal transmission cooler inside the radiator develops leaks, allowing coolant and ATF to mix. This destroys both the transmission and can damage the engine. Requires radiator replacement, complete transmission flush and filter (sometimes full transmission replacement if damage occurred), coolant system flush, and all cooler lines (6-10 hours labor if caught early, 15-25 hours if transmission is damaged).
Estimated cost: $1,200-$5,500
4.6L V8 Spark Plug Ejection and Thread Damage
Occasional · high severity
Typical onset: 60,000-120,000 mi
Symptoms: Sudden loud popping or hissing sound from engine, Misfire on one cylinder, Loss of compression on affected cylinder, Spark plug blows out of head entirely
Fix: The 2-valve 4.6L has insufficient thread engagement for spark plugs, and they can strip out or eject completely under combustion pressure. Time-Sert or Helicoil thread repair is possible if caught early (3-5 hours per plug), but often requires cylinder head removal for proper repair (8-12 hours). Using factory torque specs and anti-seize is critical during plug changes.
Estimated cost: $800-$3,000
Rear Axle Seal and Bearing Failure
Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Gear oil leaking from rear wheel area, Howling or grinding noise from rear axle during acceleration, Vibration at highway speeds, Clunking when changing from forward to reverse
Fix: Rear axle seals leak, contaminate brakes, and if ignored lead to bearing failure. Seal replacement is straightforward (2-3 hours per side), but bearing failure requires axle shaft replacement and sometimes differential work (5-8 hours). The 8.8-inch rear end is robust, but maintenance matters.
Estimated cost: $400-$1,800
Lower Control Arm Ball Joint Failure
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking over bumps from front end, Wandering or loose steering feel, Uneven tire wear on inside edge, Visible play when prying on tire at 6 and 12 o'clock
Fix: The ball joints are pressed into the lower control arms and wear out. Ford doesn't sell ball joints separately, so you're replacing entire control arms. Front alignment required after replacement (3-4 hours labor for both sides plus alignment).
Estimated cost: $600-$1,000
Overhead Console and Rear Liftgate Release Switch Failure
Occasional · low severity
Symptoms: Overhead compass/temperature display blank or garbled, Rear liftgate won't release from interior button, Dome lights intermittent or stuck on, HomeLink garage opener stops working
Fix: The overhead console module fails due to poor solder joints on the circuit board. The liftgate release switch also commonly fails. Console replacement or repair (1 hour labor), switch replacement is separate (0.5 hour). Annoyance factor high, but not a breakdown issue.
Estimated cost: $200-$500
Owner tips
If buying a 4.0L V6, insist on proof of timing chain replacement with updated metal guides or walk away — this is a ticking time bomb
Check radiator coolant for ANY discoloration or oily residue, and pull transmission dipstick to verify ATF is clean red, not pink or brown
On the 4.6L V8, use ONLY Motorcraft plugs torqued to exact spec (27 ft-lbs, no more) with nickel anti-seize, and replace every 60k miles
Inspect rear axle breather tube for clogging — pressure buildup accelerates seal failure
Budget $1,500-2,000 annually for deferred maintenance if buying high-mileage (over 100k)
Hard pass on the 4.0L V6 unless timing chains are proven done; the 4.6L V8 is marginally better but still a money pit after 100k miles — better options exist in this price range.
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; verify clearance with engine cover
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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.
STEERING · 07V181000
2007-04-25
ON CERTAIN SPORT UTILITY VEHICLES, THE TWO BOLTS THAT ATTACH THE STEERING GEAR ASSEMBLY TO THE FRAME MAY HAVE BEEN OVER-TIGHTENED. THIS CONDITION COULD RESULT IN ONE OR BOTH OF THE BOLTS FRACTURING, CAUSING THE STEERING GEAR TO BECOME LOOSE.
Consequence: THIS CONDITION COULD CAUSE "CLUNKING" NOISE WHEN STEERING AS WELL AS DECREASED STEERING EFFECTIVENESS POTENTIALLY RESULTING IN A CRASH.
Remedy: DEALERS WILL REPLACE BOTH THE STEERING GEAR ASSEMBLY MOUNTING BOLTS AND NUTS FREE OF CHARGE. THE RECALL BEGAN ON APRIL 27, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
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 2007 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.