Have had numerous problems starting with a lifter stuck in motor at 296 miles, to transmission failure at 15,700 miles. Brakes have squeaked since it was new, overhead console has fallen off twice, satellite radio works when it wants to. Door rubbed on running board, now gas mileage has dropped under 10 miles per gallon. 14 trips to dealership so far and still not all is fixed. *tr
2006 Ford Explorer engine problems
moderate 185 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
185
Recalls
0
Avg fix
$3,100
3fires
1injury
When does it fail?
Of the 185 engine complaints filed for the 2006 Ford Explorer, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 185 engine 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.
Engine accounts for 29% of all owner complaints filed against this vehicle, across 12 categories tracked.
The failure pattern owners describe
Buyer takeaway: Owners report persistent radiator failures (often requiring multiple replacements), engine stalling with no warning, throttle body problems, transmission issues, and catastrophic engine damage across this model year. Many repairs fall outside warranty and cost $500–$1,200+ per incident; some vehicles have required $5,000–$6,700 engine rebuilds. Ford issued a technical service bulletin but has resisted recalls despite widespread complaints.
The 2006 Ford Explorer engine cluster shows a constellation of interconnected failures. Radiator leaks dominate the complaints—owners describe plastic-to-aluminum joint failures as early as 30,000 miles, with some vehicles needing four to seven replacements. Costs run $530 to $1,200 per job. The cooling system troubles cascade: owners report throttle body stalling, uncontrolled acceleration, and hard transmission shifting that often follows radiator failure. Several narratives describe catastrophic engine seizures and blown head gaskets after coolant loss, requiring $5,000–$6,700 engine rebuilds. Spark plugs routinely break during removal, adding $250–$946 per service. Owners consistently note that dealers either claim no problem exists or cannot diagnose until the check engine light illuminates. Ford issued a 2009 technical service bulletin for radiator issues and temperature sensor adjustment but has resisted recall. One owner noted the manufacturer installed a missing thermostat hose clamp (cited in a TSB for faulty coating) only after catastrophic failure. Multiple owners describe feeling unsafe driving these vehicles, particularly at highway speeds when stalling or overheating occurs. The repeated pattern—radiator failure, transmission slip, engine damage—appears well-documented on consumer forums, yet Ford customer service consistently denies awareness of systemic problems.
Same Ford Explorer engine reports on nearby years: 2005 · 2007 · 2008
Failure modes owners describe
Radiator leaks and failures
Radiators fail prematurely, leaking coolant from cracks at the junction between plastic and aluminum sections. Failures occur as early as 30,000 miles and recur repeatedly in the same vehicle. Owners report replacing radiators 3–7 times in some cases.
When: 30,000 to 85,000 miles; often worsens in cold months
Symptoms owners cite: Antifreeze puddles under vehicle; Low coolant levels despite regular maintenance; Temperature gauge spiking to red; Engine overheating; Visible steam from radiator; Radiator overflow tank empty
Repairs/costs cited: $530–$1,200 per radiator replacement; parts backorder noted at dealerships; owners cite NAPA radiators failed in some cases, requiring OEM Ford part; later-design radiators mentioned
Recalls/TSBs owners mention: TSB issued April 2009 for vehicles made before 8/8/2006; TSB recommends temperature computer settings adjustment ($95) for early fan activation; updated radiator designs released; no recall issued; Ford refused reimbursement in most cases
Engine stalling and power loss with throttle body issues
Vehicle loses power and stalls at variable speeds. Wrench light illuminates, hesitation occurs when accelerating. Problem escalates from once every 2–3 weeks to multiple times daily. Dealers cannot diagnose the issue when engine light is off; once light turns on, throttle body components require replacement.
When: Occurs unpredictably at any speed, including 70 mph on highway; frequency increases over time
Symptoms owners cite: Wrench light comes on; Engine jerking and hesitation; Loss of power and stalling; Vehicle must be turned off and restarted to resume normal operation; Engine light stays on for hours to days intermittently; Accelerator hesitates when pressed
Repairs/costs cited: Throttle body components replaced multiple times in some cases; dealers initially claim nothing is wrong despite repeated visits; final diagnosis requires engine light to illuminate; costs not specified in narratives
Recalls/TSBs owners mention: Dealers tell customers nothing is wrong multiple times; corporate contact offers only to have vehicle diagnosed again; no recall; no manufacturer assistance
Cooling system failures leading to engine damage
Radiator or thermostat failures result in coolant loss and engine seizure, blown head gaskets, and warped cylinder heads. In some cases, missing or defective thermostat hose clamps contribute to catastrophic engine failure.
When: 41,000 to 83,000 miles
Symptoms owners cite: Engine dies suddenly without warning lights; Massive smoke from engine bay; Vehicle stalls on highway; Engine seizes or overheats critically; Blown head gaskets; Warped cylinder heads; Cracked pistons
Repairs/costs cited: $5,000–$6,700 for complete engine replacement or major rebuild; thermostat hose clamps with faulty coating noted in TSB; missing clamps identified post-failure
Recalls/TSBs owners mention: TSB issued for thermostat hose clamp replacement due to faulty coating; one owner cited missing clamp as cause; powertrain warranty deemed not applicable to hose clamps by dealership; no recall; manufacturer offered no assistance
Transmission problems related to radiator failure
After radiator failures, transmission develops slipping, hard shifting, jerking, and dragging during gear changes. Some narratives suggest transmission fluid contamination from coolant mixing.
When: Follows radiator failure; occurs after 40,000–100,000 miles
Symptoms owners cite: Transmission slipping, especially around 45 mph; Hard jerking when shifting gears; Transmission drags before shifting; Transmission fluid leaking from cooling line connecting to radiator; Transmission eventually fails after repeated abuse
Repairs/costs cited: Transmission rebuild or replacement required; costs $2,700 for transmission control module replacement in one case; full transmission replacement cost not itemized but described as very expensive; one owner cited 'third transmission' in vehicle
Recalls/TSBs owners mention: No recall; Ford claims no awareness of transmission problems despite web evidence; dealers initially suggest spark plug replacement as Band-Aid; no manufacturer assistance offered
Spark plug breakage and removal difficulty
Spark plugs break off inside the cylinder head during removal attempts. Plugs are two-piece design with high carbon buildup. Removal requires special Ford tool and risks additional engine damage.
When: Occurs at plug replacement intervals; recommended interval dropped from 100,000 to 60,000 miles
Symptoms owners cite: Engine misfire; Difficulty removing plugs; Plugs break during removal; Excessive carbon buildup around plugs
Repairs/costs cited: $250–$946 per plug replacement at dealership; special Ford tool required for removal; if plugs break, $100 additional per broken plug plus machine reboring; shavings from reboring may damage engine; full spark plug service can exceed $1,500
Recalls/TSBs owners mention: Dealership changed recommended interval from 100,000 to 60,000 miles; no recall issued despite known defect
Thermostat housing and upper intake leaks
Yellow antifreeze leaks from thermostat housing and upper intake manifold area. Plastic connections warp in heat. Replacement of thermostat housing, O-rings, and application of silicone sealant do not resolve leaks.
When: Various mileages; recurring issue
Symptoms owners cite: Yellow antifreeze leak visible under vehicle; Leak from thermostat housing area; Plastic material deterioration in heat
Repairs/costs cited: Thermostat housing and O-rings replaced; silicone sealant applied; leaks persist despite repairs; owner suggests metal replacement parts needed for durability in heat
Recalls/TSBs owners mention: No recall; Ford has not acknowledged design defect with plastic connections; no manufacturer assistance
Uncontrolled acceleration and stalling
Vehicle hesitates then rapidly accelerates to 60 mph on its own, or stalls unexpectedly. Drivers must brake to prevent runaway acceleration. Vehicle stalls in traffic or at stop signs; restarts only after delay. Diagnostic tests do not reveal cause.
When: Occurs at various speeds and driving conditions; can happen at idle or during acceleration
Symptoms owners cite: Vehicle hesitates then surges to 60 mph uncontrolled; Stalling at low speeds or complete stops; Stalling during braking; Accelerator becomes difficult to depress; Vehicle lunges forward unexpectedly; Delayed restart after stall
Repairs/costs cited: Diagnostic tests find no error codes; cause undetermined in multiple shop visits; transmission control module replacement cited in one case ($2,700)
Recalls/TSBs owners mention: No recall; dealers cannot identify or resolve issue; manufacturer not made aware in some cases
Engine fire from radiator or electrical failure
Fire originates from engine bay, possibly due to coolant leak igniting or electrical short. Vehicle becomes total loss.
When: 50,000 miles
Symptoms owners cite: Fire emitting from under hood; Fire spreading to windshield and dashboard
Repairs/costs cited: Vehicle destroyed; no repair possible
Recalls/TSBs owners mention: Dealer did not advise on cause; no manufacturer assistance noted
Synthesized from 185 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 8 most recent
Radiator failure. The radiator failed causing the entire engine to overheat. See odi number 10439878. Replaced entire engine and radiator in this vehicle which only has 68,000 miles on it. (costing over $6000). Please issue a recall. *tr
Since purchasing this vehicle new in january 2007 the radiator has been replaced twice. Now, in december 2013 with 114000 miles, the radiator is losing coolant and the engine smells of coolant after driving. Most likely the radiator will have to be replaced for the third time. *tr
We bought the used vehicle in march 2012 with a 30 day warranty. During the first month, noticed engine slipping (usually around 45 MPH). Checked fluids, added coolant and naively thought the problem would go away, and it seemed to for about a month. However, the engine/transmission slippage has gotten much worse since then. We are constantly adding coolant and driving very carefully to avoid…
This 2006 explorer eddie bauer car started making roaring sound when trying to accelerate. Tried backing off the accelerator as much as possible. Thermostat gauge temperature went to hot and displayed red and a/c started blowing cold air. Thermostat then went from hot to cold multiple times. Checked coolant levels and they were fine. The engine and car finally shut down completely…
Tl* the contact owns a 2006 Ford explorer eddie bauer edition. The contact was driving approximately 45 MPH when the check engine warning light illuminated. The contact then realized that the vehicle had overheated as it proceeded to stall. The vehicle was taken to an independent mechanic where they advised her that the radiator and thermostat failed. The vehicle was repaired but the check engine…
Tl* the contact owns a 2006 Ford explorer. The contact stated that the temperature gauge started to increase and the temperature warning lamp illuminated. The vehicle was taken to the dealer who diagnosed that the radiator was leaking and needed to be replaced. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was no longer under warranty. The…
Engine was racing, took it to dealer, they said it was programmable transmission,cost $100 to diagnose and reset program. Ok for a while, started racing again. Took back to dealer, said it is leaky radiator, it was bone dry and it was the engine fan racing not the motor. Just past warranty, never received extended warrant information until just last week,after the fact. Taking it to a different…
Had engine 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 engine problem on the 2006 Ford Explorer?
It's a documented issue but not catastrophic. 185 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 166 complaints that reported odometer mileage, most engine failures cluster between 38,000 and 70,000 miles, with the median around 48,000. A quarter of owners report trouble before 38,000; a quarter make it past 70,000. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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.