FORD/MERCURY: TO PREVENT HARNESS DAMAGE, ON SOME VEHICLES, RESULTING IN CONTACT WITH TIRE OR SUSPENSION COMPONENTS, PROPER ROUTING OF WIRING HARNESS FOR WHEEL SPEED SENSOR IS KEY. 2006-2010 EXPLORER, MOUNTAINEER, EXPLORER SPORT TRAC.
full bulletin at NHTSA ↗2006 Ford Explorer brakes problems
severe 30 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
30
Recalls
0
Avg fix
$450
2crashes
1injury
What stands out
Owners have filed 30 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 17 model years of Ford Explorer in our records for brakes problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS.
full bulletin at NHTSA ↗BRAKE DRAG CONDITION.
full bulletin at NHTSA ↗ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440.
full bulletin at NHTSA ↗ABS LIGHT WITH DTC C1440.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
2006 Explorer owners consistently report cracked ABS tone rings on the rear axle, a pattern that starts showing up around 36,000 miles and continues appearing across the fleet. When it cracks, you get grinding noises, ABS/traction control/wrench lights all lighting up together, and brakes that either grab erratically or fail outright. Replacement costs run $400 to over $1,000. The tone ring material was apparently thinner in early production; Ford later used thicker material, but by then many vehicles had already failed.
Brake pedal problems are widespread: soft pedals that feel spongy, pedals that sink toward the floor, and stopping distances that stretch dangerously long. A few owners had master cylinders replaced—it didn't fix it. Multiple owners describe the brake and gas pedals sitting so close together that an average-sized foot can land on both at once during an emergency stop, which has caused actual collisions. Several owners report the engine revving unexpectedly when approaching a stop or immediately after starting—dealers acknowledge it happens but can't fix it.
There's also the oddball stuff: brakes seizing at highway speed, vehicles continuing to roll after being shifted to Park, and brakes overheating badly after fresh pads and calipers are installed. Across all these issues, dealer diagnostics frequently come back clean or inconclusive, leaving owners frustrated and unsafe.
Same Ford Explorer brakes reports on nearby years: 2005 · 2007
Failure modes owners describe
Cracked ABS tone ring (reluctor ring)
The ABS sensor ring on the rear axle cracks, disabling ABS function and triggering warning lights. When cracked, it typically damages the wheel-speed sensor and prevents proper brake modulation, sometimes causing brakes to seize or grab erratically. Multiple owners report this failure at relatively low mileage.
When: As early as 36,000 miles; reported at 64,000, 80,000, 150,000 miles
Symptoms owners cite: Grinding or metal-on-metal noise from rear wheel area; ABS warning light, wrench light, and traction control light illuminate; Brakes grab, lock, or seize intermittently; Vehicle pulls or jerks when ABS activates; Brake function degraded or absent when tone ring is cracked
Codes mentioned: ABS warning light, Traction control warning light, Service wrench indicator
Repairs/costs cited: Replacement of tone ring and/or wheel-speed sensor required; some dealers replaced entire axle assembly. Costs reported around $423–$1,000+ depending on extent of damage. One owner noted newer tone rings have thicker material than original parts.
Recalls/TSBs owners mention: No recalls mentioned; one owner noted Ford forums indicate this is an ongoing issue among Explorer owners.
Brake pedal soft or sinks to floor with extended stopping distance
Brake pedal feels soft, spongy, or requires pushing to the floor to achieve normal stopping distance. Master cylinder replacement does not resolve the issue in several cases. Problem may be intermittent and difficult for technicians to reproduce.
When: Within first year of ownership (12K–14K miles on used purchase); intermittent throughout vehicle life
Symptoms owners cite: Brake pedal feels soft or requires excessive pressure; Longer than normal stopping distance despite firm pedal pressure; Pedal travels to floor with minimal braking effect; Problem persists or recurs after master cylinder replacement; Difficulty stopping when ABS activates in slippery conditions
Codes mentioned: No diagnostic codes typically set, ABS warning light may illuminate if tone ring is also compromised
Repairs/costs cited: Master cylinder replacement performed on multiple vehicles without resolving the symptom. One owner paid for multiple visits and new brake booster installation without success. Problem remains unresolved in several cases.
Recalls/TSBs owners mention: Dealer acknowledged problem in at least one case but could not provide a fix. One owner reports Ford Motor Company stated they have heard of the problem but have nothing they can do about it.
Brake pedal unintended engagement or vehicle brakes without driver input
Vehicle applies brakes violently or automatically without the driver pressing the brake pedal. Can occur during acceleration or normal driving. In one case, a cracked tone ring was identified as the cause; in others, the root cause was not identified.
When: Intermittent; early mileage reported (3,700 miles); also at higher mileages
Symptoms owners cite: Vehicle stops abruptly or brakes seize without driver input during acceleration; Braking occurs at random intervals while driving; Loss of vehicle control or near-collision risk; ABS, traction control, or wrench lights may illuminate; Grinding noise may accompany braking event
Codes mentioned: ABS warning light, Traction control warning light, Service wrench indicator (in some cases)
Repairs/costs cited: One confirmed case: cracked ABS tone ring identified and repaired ($423.78). Multiple other cases unresolved after dealer diagnostics found no problem; vehicle returned after extended service periods (up to 4 weeks) with no repair completed.
Recalls/TSBs owners mention: No manufacturer response documented in narratives; dealership diagnostics inconclusive.
Engine rev-up at stop or unintended acceleration on startup
Engine RPM spikes to 1200–1500 on its own when approaching a complete stop or immediately after starting the vehicle. Occurs without driver input on the throttle. Multiple owners report this as a widespread issue in 2006 V6 Explorers.
When: From early ownership (3,000 miles); also reported at later mileages; happens on a daily basis for some owners
Symptoms owners cite: Engine revs to 1200–1500 RPM without driver acceleration input; RPM spike occurs just before coming to a complete stop; Engine revs up immediately after ignition, forcing driver to keep foot on brake; Occurs in conjunction with extended stopping distance
Repairs/costs cited: Dealers unable to diagnose or repair. One dealership service manager acknowledged the problem occurs but could not offer a fix. Problem remains unresolved in all reported cases.
Recalls/TSBs owners mention: Ford Motor Company acknowledged via dealership that they are aware of the problem but state there is nothing they can do about it. No recall issued despite owner belief that all 2006 V6 Explorers exhibit the issue.
Brake and gas pedal too close together (design flaw)
Pedal spacing allows a driver of average or modest shoe size to inadvertently place one foot on both the brake and gas pedals simultaneously, causing conflicting inputs. This design flaw has resulted in collisions and property damage when drivers attempt emergency braking.
When: Occurs during braking situations, particularly emergency braking
Symptoms owners cite: Driver foot strikes both brake and gas pedals simultaneously; Engine revs while driver intends to brake, reducing braking effectiveness; Inability to achieve full braking force due to gas input; Collision or property damage as result of dual pedal engagement
Repairs/costs cited: No repair available; design issue. One owner caused damage to three other vehicles and their own due to this pedal layout.
Recalls/TSBs owners mention: No recall or design change mentioned in narratives.
Vehicle continues to roll after being shifted to Park
After shifting to Park, turning off the engine, and removing foot from brake, the vehicle continues to roll as if in Neutral. Occurs intermittently; temporary fix is to shift to another gear and back to Park.
When: Intermittent; 6–7 occurrences over approximately one year
Symptoms owners cite: Vehicle rolls after being shifted to Park and engine turned off; No pattern to occurrence; happens at different locations; Rolling continues until vehicle strikes an obstacle or driver reapplies brake; Transmission and gearbox inspected by dealer with no issues found
Repairs/costs cited: Transmission and gearbox checked by dealer; no problem identified. Temporary fix: shift from Park to another gear and back to Park until vehicle engages properly.
Recalls/TSBs owners mention: Dealer unable to diagnose or repair.
ABS warning lights and sensor faults with warning lights flashing intermittently
ABS, traction control, and wrench warning lights illuminate intermittently on the instrument panel, often in combination. Lights may reset using the dashboard reset button but return periodically. Usually indicates wheel-speed sensor damage or tone ring cracking.
When: Throughout vehicle ownership; some cases intermittent over extended periods
Symptoms owners cite: ABS warning light illuminates intermittently; Traction control warning light comes on; Service wrench light flashes or stays illuminated; Lights reset temporarily using dashboard button, then return; Vehicle drives poorly, especially on gravel or unpaved surfaces
Codes mentioned: ABS warning light, Traction control warning light, Service wrench indicator
Repairs/costs cited: Wheel-speed sensor replacement performed (around $200 reported); however, unless tone ring is also replaced, ABS remains inoperative. Some owners report lights remain on for extended periods without resolution.
Recalls/TSBs owners mention: No official recall mentioned; one owner notes Ford is aware of the cracking problem but has not issued a recall.
Brakes seize or fail to release at highway speed
Brakes suddenly seize or lock up while driving at highway speed, then resume normal operation after vehicle is shut down and restarted. Occurs without warning lights or diagnostic codes in some cases.
When: At highway speeds (40–60 mph); repeated occurrence (five separate occasions in one case)
Symptoms owners cite: Brakes seize or lock suddenly at highway speed; Vehicle loses normal brake operation temporarily; No warning lights illuminated in some cases; Normal function resumes after engine shutdown and restart; Repeated failures on different occasions
Repairs/costs cited: No repairs performed in reported cases; vehicle not diagnosed.
Recalls/TSBs owners mention: Manufacturer notified in at least one case; no action documented.
Brakes overheat and burn after brake service
After new brakes and calipers are installed, brakes become extremely hot and emit a strong burning smell, particularly on longer drives. Issue recurs even after professional installation.
When: Following brake pad and caliper replacement; appears after approximately one hour of driving
Symptoms owners cite: Brakes become extremely hot following installation; Strong burning odor from brake system; Problem occurs on longer drives but not short trips; Recurring issue even after service
Repairs/costs cited: Dealership stated no apparent problem found despite evident overheating and odor.
Recalls/TSBs owners mention: No resolution provided by dealership; owner notes other Explorer owners have reported brake seizing issues.
Synthesized from 30 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had brakes trouble with your 2006 Ford Explorer?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2006 Ford Explorer?
It's a meaningful issue. 30 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 23 complaints that reported odometer mileage, most brakes failures cluster between 39,750 and 86,000 miles, with the median around 65,450. A quarter of owners report trouble before 39,750; a quarter make it past 86,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Ford/Explorer.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.