Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
Complete failure of the powertrain electrical harness. Heat degradation to wire insulation has exposed all conductors. Several other owner operators have experienced the same issue wherein the Dealer has attempted repair of existing trouble codes, by replacing sensors, modules and components. Problems range from vehicle shut-off at speed, vehicle fires, no-start and failed PCM modules due to short to power or short to ground. Based on my findings, this specifically impacts vehicles ranging from 2006-2010, Ford Explorer or Mercury Mountaineer with the 4.0L SOHC engine.
While driving we turned on the ac and we herd a big pop. Then the passengers leg got warm. Then we felt around it kept getting hotter. It followed the dash then smoke rolled off under the dash. I threw it in park we jumped out the flames consumed the vehicle. We were on a road.
2006 Ford Explorer eddie baurer- within 12 hours of purchasing the car, the starter caught on fire, car was out of service 1 week. Transmission hesitated from a cold start especiallly bad when pulling out into traffic. Engine roared at times, sounded like a jet taking off. Dealer said this was normal, it was the engine fan ???? Car lurched forward when starting on several occasions. At first service dept agreed there was a problem with 8 cylinder transmission and that they were no fixes but then the Ford rep got involved and suddenly they couldn't find any problems with the car. They suggested that our only recouse was to go thru the lemon law which we did. It was a long drawn out process but after 6 months of dealing with the situation, the lemon arbitration rulled in our favor and Ford was required to buy back the Explorer. …
Driving on a highway I-95 in florida. The vehicle started to miss as we accelerated. We took the car into a Ford dealer service for plug replacement. This auto has a 4.6 litre v-8 engine. We were amazed to find that it will cost upwards of $1000.00 to replace 8 spark plugs. That cost esculates if any plugs are broken. The plugs are two piece construction and separate on removal. Only Ford can remove the plugs and more will be charged for any broken. It is impossible to remove these plugs without breakage. Ford recommends not changing the plugs until 100,000 miles. By that time you are out of guaranty and if they are hard to come out at 60,000 miles imagine if they are left in. These plugs are known to blow out of the head and I am sure there are many accidents. I am a disabled veteran 83 years old and a mechanical engineer. …
I bought a 2006 Explorer in 2010 and in 5 years I have had a sensor that's goes inside the transmission replaced, then transmission rebuilted, and the radiator replaced twice. Now that it's paid off leaking coolant again making it run hot. Now it saying check the charging system and stop on me on the freeway and now won't stay started. Thought I was doing everything right with the maintenance of the truck but it keeps breaking down. Also the wrench thing is on and won't stay started even while pressing the gas pedal to the floor all after I just had another sensor replaced. And besides the radiator leaking again that plastic thing they call a thermostat housing May be cracked. I feel I'm spending more money repairing things on this truck in 5 years that most people spend on a new car. If I had seen all the problems this model year was having would have went a different brand.
We recently bought our truck in March 2016 and since about April of 2016 the truck continuously shuts off, in traffic, on the highway, on residential roads..pretty much any and every where, it happens while driving and while idling. All power is lost including power steering. Sometimes it will shut off 2/3 times in a 5-10 minute span will driving. It has cut off on me twice while driving through intersections while I had my children in the car with me almost resulting in accidents both times. Sometimes while driving it loses power then suddenly regains power back and will continue to drive. This is an all round dangerous and potentially deadly situation! After doing some research it seems as if this is a very common problem with these vehicles. I've contacted Ford myself and so far they haven't issued a recall and are aware of this situation. Please help!!
Car shuts off while driving. This has happened about 6 times in the last two months. Always at speeds under 40 MPH and always within 3 minutes of turning the car on. There's never any warning or smell or sound. Dash goes black, radio cuts off, power steering fails, and I have to coast to the side of the road. Obviously this is very frightening and I've been very lucky that it has not yet happened at lights or turns. My car guy is really good and he's at a loss. He thinks maybe it's a security system malfunction. I drive with children in the car and I can't afford a to buy a new car. I'm not sure what my other options are.
My 2006 Explorer has recently started shifting hard and sometimes will not shift into gear right away. When I pull up to a stop light or become stationary it will try to die and sometimes will. And will also not go into gear unless I give it a lot of gas and then it takes a minute to pick up complete speed. I have already had to replace multiple things on this vehicle and am seeing that others have been having the same trouble. Ford do the right thing and recall this vehicle. Also my interior lights have gone out and is not the fuse or bulbs.
Tl* the contact owns a 2006 Ford Explorer. The contact stated that various warning indicators flashed and the vehicle stalled several times. The vehicle was taken to an independent mechanic where the fly by wire pedal and the throttle body were replaced, but the failure continued. The vehicle was not taken to a dealer for diagnostic testing. The manufacturer was notified of the failure and did not assist. The approximate failure mileage was 150,000.
Tl* the contact owns a 2006 Ford Explorer. The contact stated that the passenger side air bag indicator illuminated, which indicated that it was deactivated even when a passenger was in the front seat. The vehicle was taken to a dealer, but was not diagnosed or repaired. The manufacturer was not notified. The failure mileage was 107,522.
Electrical complaints in other Explorer years
Frequently asked questions
How common are electrical problems on the 2006 Ford Explorer?
NHTSA has 39 complaints about the electrical system of the 2006 Ford Explorer, 6% of the model year's 630 complaints. The component named most often is instrument cluster/panel (5 mentions).
Is there a recall for 2006 Ford Explorer electrical problems?
No. NHTSA lists no electrical system recall for the 2006 Ford Explorer, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2006 Ford Explorer electrical problems start?
Half of the complaints with a recorded mileage happened before about 60,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.