2006 Ford Explorer electrical problems

Engine dies or stalls without warning while vehicle is in motion, often at highway speeds or in traffic. Loss of all electrical power (dash goes black, radio cuts off, power steering and brake assist fail). Vehicle may restart immediately or require extended time. Some owners report stalling repeatedly over short periods; others report it happens within 3 minutes of startup. One owner reports stalling 3 times on highway in a single year; another reports 6 stalls in 2 months; another reports it happens shortly after rain.

When: Ranges from 5,000 to 150,000 miles. Most frequent complaints occur within first few years of ownership or shortly after purchase. One owner purchased in March 2007 and reported issues through present; another bought in March 2016 and issues began April 2016.

Symptoms owners cite: Engine dies while driving at various speeds (under 40 mph to 55-60 mph, highway speeds); Complete loss of electrical power (dash blacks out, radio cuts off); Loss of power steering (becomes manual); Loss of power brakes; No warning sign, smell, or sound before shutdown; Vehicle may restart immediately or after sitting 7 minutes; Stalling happens repeatedly in short spans (2-3 times in 5-10 minutes); Occasional temporary power loss then regain during driving

Repairs/costs cited: Multiple dealers unable to diagnose or repair. One owner reports vehicle taken to two dealers with 4 different advisors and 11+ repair visits without resolution. One independent mechanic replaced fly-by-wire pedal and throttle body without success. Ford's response has ranged from lack of investigation to refusal to help.

Recalls/TSBs owners mention: No recall issued despite owner contact. Ford Motor Company aware of situation per owner reports but has not issued recall. One owner in 2009 complained to Ford about defective wiring harness; Ford acknowledged issue and offered partial reimbursement for harness replacement only out of warranty.

Wiring harness contains corroded sensors that cause electrical system failure and repeated stalling. One owner's independent mechanic identified 2 corroded sensors within the harness; mechanic stated the entire harness system was defective and stalling would recur. Ford acknowledged the defect and offered harness replacement but only with limited reimbursement out of warranty.

When: Issue discovered in 2009 on vehicle purchased in 2006. Owner experienced stalling repeatedly in last year before complaint.

Symptoms owners cite: Repeated stalling on highways, suburban, and urban roadways; Loss of power and electrical function

Repairs/costs cited: Independent mechanic identified 2 corroded sensors within harness and recommended full wiring harness replacement due to defective harness system. Ford agreed to replace harness but offered only partial reimbursement (majority of cost to owner). Repair cost not specified.

Recalls/TSBs owners mention: Ford confirmed defect via service technicians and area manager of Northeast Dealerships. Ford agreed to replace harness but refused full warranty coverage out-of-warranty, offering only limited reimbursement.

Instrument cluster shorts out or malfunctions, causing multiple symptoms including inability to shift out of park, illumination of multiple warning lights, digital odometer failure, and loss of vehicle control indicators. Dealerships report shortage in cluster or cluster/compass malfunction.

When: Reported at 40,000 miles, 46,000 miles, 107,522 miles, and 21,000 miles depending on failure. One owner had cluster replaced, but shift lever issues continued.

Symptoms owners cite: Unable to shift out of park (can only start in neutral); Multiple warning lights flash (ABS, Wrench, RSC, Check Engine); Digital odometer failure; Gear shift light burned out; Violent left-to-right shaking of vehicle at stops; Loud clicking noises; Passenger side airbag indicator illuminates incorrectly (shows deactivated when passenger present); Shift lever stuck in park (recurring even after repairs)

Repairs/costs cited: One dealership diagnosed ABS tone ring malfunction and cluster/compass malfunction, charged $1,300 for repair. Another dealership quoted $700 for cluster repair. One owner replaced entire dash cluster at dealership and then replaced shift unit (entire unit replacement required; individual bulb/component replacement not available), but shift lever problem persisted. Dealerships have stated these are not covered under warranty despite vehicle being within warranty period (46,000 miles).

Recalls/TSBs owners mention: No recalls issued for cluster failures. Dealerships report failures are not warranty-covered. Ford unable or unwilling to provide replacement instrument cluster components per one complaint.

Transmission sensors fail, transmission rebuilds required, and transmission jerks or locks into specific gears with high engine revving. Vehicle enters limp mode with Wrench light. One owner's vehicle had transmission computer warning flagged in OASIS report before sale but was not repaired.

When: Issues begin within 5 years of purchase. One vehicle (purchased 2010) required sensor replacement, transmission rebuild, and sensor replacement again within 5 years. One CPO vehicle (purchased March 2007) had transmission computer warning on OASIS report that was not addressed before sale.

Symptoms owners cite: Transmission jerks and stays locked in 4th gear; Engine revs very high; Transmission sensor failure (requires replacement); Wrench light illuminates (accompanied by hesitation, brake pulse, and stalling); Vehicle hesitates when TRAC and Wrench lights on; Recurring failures after repair (fixed multiple times, then fails again)

Repairs/costs cited: Transmission sensor replaced (cost not specified). One vehicle required full transmission rebuild. One CPO vehicle had transmission computer work flagged as needed in OASIS report but was sold without this work completed.

Recalls/TSBs owners mention: None documented. One CPO buyer's complaints to dealer and Ford Motor Company were dismissed with statement 'it is my vehicle and to deal with it' and 'CPO means absolutely nothing to the dealers once it is sold.'

ABS and Traction Control warning lights illuminate; brakes lock up or pulse, and vehicle experiences violent shaking. One owner reports brakes locked up and spun car out of control. Symptoms often occur together with other electrical system failures.

When: Reported across various mileages (46,000 miles, 21,000 miles) and years of ownership.

Symptoms owners cite: ABS light illuminates; Traction control (TRAC) light illuminates; Brakes lock up and cause uncontrolled spinning; Brakes pulse/pulse when TRAC/Wrench lights are on; Violent left-to-right shaking at stops; Brake assist (power brakes) loses power

Repairs/costs cited: One dealership identified ABS tone ring as cause of malfunction and replaced it ($1,300 repair cost). Owners report dealer claims related to cluster malfunction and tone ring are connected, though diagnosis remains suspect. One owner's TRAC and Wrench light failures were 'fixed' but then recurred repeatedly.

Recalls/TSBs owners mention: Dealerships state these issues are not covered under warranty. No recalls identified.

Various dashboard warning lights illuminate together or in sequence, often during electrical disturbances or in connection with stalling events. Lights include engine, ABS, Wrench (service), RSC (roll stability control), and skid control indicators.

When: Throughout ownership, reported at various mileages.

Symptoms owners cite: Check Engine light on; ABS light on; Wrench/Service light on; RSC (Roll Stability Control) light on; Skid Control light on; Multiple lights illuminate in sequence or together during stalling event

Repairs/costs cited: Multiple dealer and independent inspections unable to diagnose root cause. Dealership repairs have been temporary; lights return after repair completion.

Power door locks cycle (lock/unlock) unexpectedly while driving. One owner reports doors locking and unlocking repeatedly during electrical episodes that also caused engine stalling and brake failure.

When: Reported during period of broader electrical failures from March 2007 onward.

Symptoms owners cite: Doors unlock and lock while driving; Occurs in connection with engine stalling and brake/power steering loss

AC system fails intermittently. One catastrophic incident involved AC compressor failure followed by fire under dashboard that consumed entire vehicle. Owner heard loud pop when AC engaged, passenger side warmed rapidly, smoke rolled under dash, and flames followed.

When: AC intermittent failure reported during broader electrical issues (March 2007 onward). Fire incident timing not specified but occurred while driving.

Symptoms owners cite: AC intermittently working; Loud pop noise when AC engaged; Heat under dash on passenger side; Smoke under dash; Vehicle fire

Repairs/costs cited: No repair information provided. Fire incident required vehicle to be abandoned.

Engine misses/hesitates during acceleration. Vehicle is equipped with two-piece spark plugs that separate during removal, making them extremely difficult to service. Ford plugs are known to blow out of cylinder heads. Plugs are recommended to 100,000 miles, but are already hard to remove at 60,000 miles.

When: Misfire reported at highway speeds on vehicle with 4.6L V-8 engine.

Symptoms owners cite: Engine misses/hesitates during acceleration on highway

Repairs/costs cited: Spark plug replacement costs upwards of $1,000 for 8 plugs. Plug breakage during removal is common and incurs additional charges. Only Ford can remove plugs without breakage (allegedly). Two-piece plug construction separates on removal.

Recalls/TSBs owners mention: Ford recommends waiting until 100,000 miles for plug replacement, but plugs are difficult to remove and may blow out of head before that interval.

Vehicle fails to start or has difficulty starting. Battery drains unexpectedly. One owner reports vehicle tried to self-start twice, draining battery so low that jump-start was insufficient. Another owner had 5 no-start events within 2 months of purchase.

When: Reported within 2 months of purchase (purchased Dec 2005, no-start by Jan 2006). Self-start battery drain occurred after special service message issued.

Symptoms owners cite: Vehicle fails to start; Vehicle attempts to self-start, draining battery; Battery drained too low for normal jump-start to revive; Vehicle can start in neutral but not in park

Repairs/costs cited: One dealership replaced battery and stated problem would not recur; problem recurred. Self-start issue noted in Ford Special Message #15773.

Recalls/TSBs owners mention: Ford Special Message #15773 issued regarding self-start problem. Dealership aware of message but stated they were 'completely unaware' until owner showed them the message. Dealership unwilling to fix vehicle as per the message.

Vehicle displays Check Charging System warning, indicating alternator or charging circuit failure.

When: Reported after transmission sensor replacement on vehicle with 5 years of ownership.

Symptoms owners cite: Check Charging System warning illuminates; Vehicle will not stay started or stalls

Repairs/costs cited: Owner had sensor replaced, then Check Charging System warning came on. Vehicle refused to stay started even with full throttle input.

Radiator leaks coolant causing vehicle to run hot. Plastic thermostat housing may be cracked. Owner had radiator replaced twice within 5 years.

When: First radiator replacement within 5 years of ownership; second radiator replacement at end of 5-year period; coolant leak recurs after second replacement.

Symptoms owners cite: Coolant leaks; Vehicle runs hot; Check Charging System warning (possibly related to cooling fan draw)

Repairs/costs cited: Two radiator replacements within 5 years. Owner suspects plastic thermostat housing may be cracked.