Ford Explorer 2006-2010 Service & Repair Manual

Description

The complete factory service and repair manual for the 2006, 2007, 2008, 2009 and 2010 Ford Explorer — 5,337 searchable pages across 80 factory service sections, covering the Explorer, the Explorer Sport Trac and the Mercury Mountaineer in one download.

About the 2006–2010 Explorer

This is the last of the traditional body-on-frame Explorers — the fourth generation, with a live rear axle option, a proper transfer case and the V8 that the front-drive Explorers that followed never offered. They are old enough now that dealer servicing rarely makes financial sense, and common enough that the parts are everywhere, which is exactly the situation a factory manual is for.

Vehicles covered

Ford Explorer, Ford Explorer Sport Trac and Mercury Mountaineer
Model years: 2006, 2007, 2008, 2009, 2010

Engines documented

• 4.0L SOHC V6
• 4.6L V8

Transmission & drivetrain

• 5R55S five-speed automatic transmission
• 6R60 six-speed automatic transmission
• 6R80 six-speed automatic transmission
• Rear-wheel drive and four-wheel drive, with transfer case and axles

What’s inside

80 factory sections covering both engines, all three automatic transmissions, the transfer case, driveline and axles, brakes with anti-lock, steering and suspension, climate control, restraints, emissions, body and closures — and the strongest electrical content of any manual in this range: 476 wiring diagrams, connector end views, more than 3,500 connector references and over 3,400 pinpoint tests.

Common issues this manual helps you tackle

• Transmission harsh shift, lurch and failure — the single largest complaint category for this generation, from hard jolts on the shift to delayed engagement in reverse. The transmission sections cover the valve body and solenoid pack, the servos, the torque converter and full overhaul.
• Radiator leaks and cooling system failure — these radiators are known for leaking from around sixty thousand miles, and the plastic thermostat housing and water pump are close behind. The engine cooling sections document the radiator with its integral transmission cooler, the thermostat housing, the pump and the cooling fan.
• 4.0L SOHC timing chain cassette wear — the plastic guides and hydraulic tensioners on this engine’s triple-chain drive wear out and rattle, and the rear cassette needs the engine out. The engine sections cover the front chain, the jackshaft, both cam drive cassettes and the torque-to-yield fasteners that must be replaced rather than reused.
• Blend door actuator failure — the clicking from behind the dash and the heater stuck on one temperature. The climate control sections document the actuator, the plenum and the calibration procedure.
• Wiper motor output gear failure — recalled on 2006 vehicles after motors were built without grease on the output gear. The wipers and washers sections cover the motor, the gear and the linkage.

Format

Searchable PDF, 5,337 pages. Opens on Windows, Mac, Linux, tablets and phones, and prints cleanly for the bench. English. Instant download after checkout.

Frequently asked questions

Does it cover the Sport Trac?
Yes — the Explorer Sport Trac is documented throughout, as is the Mercury Mountaineer.

Are wiring diagrams included?
Yes, and they are unusually thorough: full diagrams, connector end views and pinpoint tests.

Does it cover the V8?
Yes, the 4.6L V8 and the 4.0L SOHC V6 both have their own sections.

Can I search it?
Yes — the whole manual is searchable text.

Which years does it fit?
2006, 2007, 2008, 2009 and 2010.