2016-2019 Ford Explorer Repair Manual

1) Overview

The Explorer is built for families who want 3-row flexibility, towing/cargo versatility, and available AWD for winter. Best ownership outcomes come from (1) verified recall completion, (2) conservative fluid intervals (engine + PTU + transmission), and (3) quick attention to coolant-related symptoms on V6 models.

Key Specs (typical for 2016–2019 Explorer lineup)

1- Internal Water Pump Failure (3.5L / 3.7L V6)

• • Symptoms: Coolant loss, overheating, sweet smell, milky oil, rough running, temperature warnings.
  • Root Cause: The water pump design on these V6 engines can fail internally; coolant may contaminate oil if not caught early.
  • Fix: Pressure-test + inspect for coolant/oil contamination; replace water pump (often recommended with timing components/seals due to labor overlap); oil flush if contamination occurred.
  • Cost to Fix: $1,500–$3,500 (water pump/timing service) • $4,000–$8,000+ (if engine damage occurred).

2- AWD PTU (Power Transfer Unit) Overheating / Failure (AWD)

• • Symptoms: Burning smell, whining/grinding, vibration, AWD warning, fluid leaks, loss of rear drive.
  • Root Cause: Heat + fluid breakdown in the PTU over time (especially towing, short trips, or heavy loads).
  • Fix: Inspect for leaks and play; service PTU fluid more frequently; replace PTU if noise/metal contamination is confirmed.
  • Cost to Fix: $180–$350 (fluid service) • $1,800–$3,800 (PTU replacement) • $3,500–$6,000+ (if collateral drivetrain damage).

3- Rear Suspension Toe Link Weakness / Fracture Risk (Certain Builds/Regions)

• • Symptoms: Rear clunk, sudden rear steer feeling, instability, abnormal tire wear, alignment won’t hold.
  • Root Cause: Toe link joint/wear and, in worst cases, fracture under certain conditions; Ford issued recalls/programs on toe links for Explorer populations.
  • Fix: Verify recall completion; inspect toe links + knuckles; replace parts per recall/program; perform alignment.
  • Cost to Fix: $0 under recall/program • $600–$1,500 retail (parts + alignment) if out of coverage.

4- Exhaust Odor / Cabin Fume Concerns (Older Coverage Applies)

• • Symptoms: Exhaust smell in cabin, headaches/nausea, odor most noticeable under load or HVAC settings.
  • Root Cause: Possible exhaust sealing/body pressure pathways on some Explorer builds; Ford issued customer satisfaction coverage on certain model years.
  • Fix: Verify eligibility by VIN; inspect exhaust components, seals, and body plugs; perform smoke test if needed.
  • Cost to Fix: $0 if covered • $150–$1,200+ depending on leak source and labor.

5- 6-Speed Automatic Harsh Shifts / Shudder / Delayed Engagement

• • Symptoms: Harsh 2–3/3–4 shifts, flare, delayed drive/reverse, vibration/shudder on acceleration.
  • Root Cause: Fluid degradation, valve body/solenoid wear, torque converter clutch behavior, or calibration-related drivability (varies).
  • Fix: Scan for TCM codes + adaptive data; fluid service if appropriate; update calibration where applicable; repair valve body/TC as confirmed.
  • Cost to Fix: $250–$450 (service) • $900–$2,500 (valve body/solenoids) • $2,500–$5,500+ (converter/major work).

6- Turbo Underboost / Charge Air Leaks (EcoBoost Models)

• • Symptoms: Sluggish power, hiss/whistle under boost, MIL, reduced acceleration.
  • Root Cause: Intercooler/charge pipe couplers, boost control issues, vacuum/actuator leaks, sensor plausibility faults.
  • Fix: Pressure/smoke test charge system; repair leaks; verify wastegate control + sensors; clear and validate.
  • Cost to Fix: $150–$900 (leak repair) • $900–$2,800 (turbo/wastegate related repair).

7- Cooling System Leaks (Hoses/Reservoir/Thermostat)

• • Symptoms: Coolant smell, low coolant warning, overheating, puddles, heater performance drop.
  • Root Cause: Aging hoses/clamps, reservoir cracking, thermostat housing seepage (varies by engine).
  • Fix: Cooling pressure test; replace leaking component(s); refill/bleed properly; recheck after heat cycle.
  • Cost to Fix: $120–$1,200 depending on leak source.

8- Front Suspension Clunks (Sway Bar Links / Struts / Bushings)

• • Symptoms: Clunk over bumps, steering looseness, uneven tire wear, vibration.
  • Root Cause: Worn stabilizer links/bushings, strut mounts, or control arm bushings (wear items).
  • Fix: Inspect front end; replace worn components; alignment after major suspension work.
  • Cost to Fix: $180–$1,600 depending on parts replaced.

9- Brake Pulsation / Warped Rotors (Heavy Vehicle Wear)

• • Symptoms: Steering shake under braking, pedal pulsation, longer stopping feel.
  • Root Cause: Heat spots/rotor variation due to weight, towing, and stop-and-go driving.
  • Fix: Measure rotor runout/thickness; replace rotors/pads as needed; verify caliper slide function.
  • Cost to Fix: $350–$950 per axle (pads + rotors typical).

10- A/C Weak or No Cold Air (Blend Door/Actuator or Refrigerant Leaks)

• • Symptoms: One side warm, intermittent cold air, clicking behind dash, poor cooling at idle.
  • Root Cause: Blend door actuator wear, HVAC control issues, or refrigerant leak/low charge.
  • Fix: Pressure test A/C; UV dye leak check; replace faulty actuator if confirmed; evacuate/recharge to spec.
  • Cost to Fix: $180–$450 (actuator) • $250–$1,400 (leak repair + recharge depending on component).

1- Battery Drain / No-Start After Sitting

• • Symptoms: Dead battery overnight, slow crank, repeated boosts, random module glitches.
  • Root Cause: Aging battery, parasitic draw, or module behavior (some Ford campaigns address module draw concerns on certain vehicles).
  • Fix: Battery + charging test; parasitic draw test; update/reprogram modules where applicable; repair confirmed draw source.
  • Cost to Fix: $180–$350 (battery) • $250–$900+ (diagnosis + repair) • $0 if campaign/recall applies.

2- SYNC / Infotainment Freezes, Reboots, Bluetooth Drops

• • Symptoms: Screen lag, random reboot, no audio, phone won’t pair, navigation glitches.
  • Root Cause: Software instability, corrupted memory/cache, or failing infotainment module (APIM) in some cases.
  • Fix: Master reset + update firmware; verify power/ground; replace/program module if confirmed faulty.
  • Cost to Fix: $0–$150 (update/reset) • $700–$1,800 (module replacement + programming).

3- Backup Camera Intermittent / Black Screen

• • Symptoms: Blue/black screen, delayed image, intermittent display when shifting to Reverse.
  • Root Cause: Camera failure, connector corrosion, harness fatigue, or module comm faults.
  • Fix: Inspect connectors; test video feed; replace camera/harness as needed.
  • Cost to Fix: $180–$750.

4- Door Ajar Warning / Interior Lights Stay On

• • Symptoms: “Door ajar” message, lights won’t turn off, alarm acts up, battery drain.
  • Root Cause: Worn latch sensor/microswitch or latch contamination.
  • Fix: Clean/lube latch (if appropriate); replace latch assembly if sensor failure is confirmed.
  • Cost to Fix: $120–$500 per door.

5- TPMS Light Won’t Clear

• • Symptoms: TPMS warning stays on even after setting pressures.
  • Root Cause: Sensor battery failure, sensor damage, or relearn not completed.
  • Fix: Scan sensor IDs; perform relearn; replace failed sensor(s).
  • Cost to Fix: $60–$120 (relearn/diagnosis) + $60–$140 per sensor installed.

6- Key Fob Not Detected / Remote Range Weak

• • Symptoms: “No key detected,” intermittent start authorization, poor remote range.
  • Root Cause: Weak fob battery, antenna issues, BCM input faults.
  • Fix: Replace fob battery first; scan BCM for codes; test antennas; repair/replace as confirmed.
  • Cost to Fix: $5–$20 (battery) • $200–$900+ (antenna/module repair).

7- Power Liftgate Won’t Close / Reverses

• • Symptoms: Liftgate stops/reverses, won’t cinch, beeps repeatedly.
  • Root Cause: Striker/latch alignment, sensor input, or actuator wear.
  • Fix: Inspect alignment + latch; adjust/replace components as needed; check harness at hinge points.
  • Cost to Fix: $80–$250 (adjustment) • $350–$1,200 (latch/actuator/module).

8- Blind Spot / Parking Sensor Faults (If Equipped)

• • Symptoms: BLIS unavailable message, parking sensors stuck on/off, false alerts.
  • Root Cause: Sensor contamination, bumper impact damage, wiring/connector corrosion.
  • Fix: Clean sensors; scan for DTCs; inspect harness/connectors; replace faulty sensor if confirmed.
  • Cost to Fix: $120–$850 depending on sensor and location.

9- Heated Seat / Climate Seat Not Working (If Equipped)

• • Symptoms: Seat heats briefly then shuts off, one side dead, switch lights but no heat.
  • Root Cause: Heating element break, thermostat/sensor issue, or seat module fault.
  • Fix: Measure element resistance; repair wiring; replace element or module as confirmed.
  • Cost to Fix: $250–$900 per seat (varies by upholstery and labor).

10- Random CAN “U-Codes” / Multiple Warning Lights

• • Symptoms: Multiple warnings at once, intermittent no-start, modules “offline,” erratic gauges.
  • Root Cause: Low voltage events, weak grounds, water intrusion at connectors, or failing module node.
  • Fix: Battery/charging verification first; voltage drop tests on grounds; inspect connectors; isolate CAN fault with scan tool data.
  • Cost to Fix: $150–$1,800+ depending on root cause.

• Honda Pilot (2016–2018) — Dardoor OEM Repair Manual ↗
• Chevrolet Traverse (2018–2020) — Dardoor OEM Repair Manual ↗
• Jeep Grand Cherokee (2014–2018) — Dardoor OEM Repair Manual ↗
• Ford Edge (2015–2018) — Dardoor OEM Repair Manual ↗
• Nissan Murano (2016–2020) — Dardoor OEM Repair Manual ↗

1. Recall — Rear Toe Link Replacement (Explorer affected ranges include 2016–2017 and beyond, depending on campaign): toe link issues can affect rear handling; Ford issued recall campaigns covering rear toe links.
2. Recall 24S02 — A-Pillar Trim Detachment (Explorer 2011–2019): exterior trim may detach while driving (road hazard risk).
3. Recall 25V347 / Ford 25S53 — Door Trim Detachment (2016–2017 Explorer): door/pillar trim can detach; dealer repair is free.
4. Recall 18S35 — Fuel Pressure Sensor / Fuel Leak (Select 2018 Explorers): misassembled sensor may cause fuel leak (fire risk); fuel line assembly replaced.
5. Customer Satisfaction Program 19N05 — Exhaust Odor / CO Concern Coverage (2011–2017 Explorer): Ford offered customer coverage/inspection procedure for peace of mind on affected vehicles.
6. Safety Recall 19S17 / NHTSA 19V435 — Rear Toe Link (Earlier Explorer populations include 2016–2017): updated procedures include testing toe link ball joints/knuckle replacement criteria.
7. Customer Satisfaction Program 21B13 — Rear Toe Links & Knuckles (2017–2019, Detroit & Toronto area): parts collection program/inspection and replacement for specific region-registered vehicles.
8. TSB / Service Highlight — Transmission drivability: harsh shift/shudder complaints usually require scan-data diagnosis before approving valve body or converter work.
9. TSB / Service Highlight — Battery draw complaints: a proper parasitic draw test + module sleep-state verification prevents “parts cannon” repairs.
10. TSB / Service Highlight — Water pump early detection: routine coolant level checks and early leak diagnosis can prevent catastrophic engine damage on V6 models.

Engine Control Module (ECM / PCM) — 10 Common Codes

Transmission Control Module (TCM) — 10 Common Codes

ABS / ESC (Brake System) — 10 Common Codes

SRS Airbag System — 10 Common Codes

Body Control / CAN Communication — 10 Common Codes

1) Is the 2016–2019 Explorer reliable?

Generally solid if maintained, but budget for the 3.5L water pump risk and extra AWD/PTU servicing.

2) Which Explorer engine is the safest long-term bet?

It depends on maintenance and driving style. V6 models need extra attention to coolant health due to internal water pump risk, while 2.3L EcoBoost models benefit from conservative oil intervals and boost-leak monitoring.

3) What’s the most expensive common repair on this generation?

Internal V6 water pump repairs can be costly because of labor overlap with timing components—catching early symptoms matters.

4) Should I service the PTU fluid even if the manual doesn’t emphasize it?

Yes for AWD models—more frequent PTU fluid service is a common preventative strategy to reduce heat-related wear.

5) How do I check if my Explorer has open recalls?

Run your VIN through official recall tools or your Ford dealer. Recalls vary by build date and trim.

6) My Explorer shifts rough—what’s step one?

Scan for powertrain codes and review live data before authorizing transmission parts. A correct diagnosis prevents expensive guesswork.

7) Are toe link issues still relevant for 2018–2019?

Campaigns and regional programs exist for toe links on Explorer populations. Verify by VIN and region.

8) What should a pre-purchase inspection include?

Full module scan, cooling system inspection, AWD/PTU check (if equipped), road test for drivability, and confirmation of completed recalls.

9) What’s an easy habit that prevents big repairs?

Weekly coolant level checks (especially on V6) + early diagnosis of any coolant smell or overheating warning.

10) Are infotainment issues common?

Yes—often software-related; updates resolve many cases.

11) What’s the most expensive repair?

Internal water pump replacement if it leaks internally.

12) Is it safe to drive with coolant loss?

No—stop and diagnose immediately to prevent engine damage.

13) Does towing worsen problems?

Towing increases heat; shorten service intervals accordingly.

Best for Families needing 3-row space, AWD availability, and strong highway comfort.

Watch-outs ⚠️ Treat coolant warnings seriously on V6 engines, service AWD/PTU fluids proactively, and verify recall completion (toe link + trim detachment campaigns vary by VIN).

Bottom line ⭐ A well-maintained 2016–2019 Explorer can be a dependable, comfortable family SUV—just budget smarter for the known high-impact items (water pump/PTU) and insist on a thorough pre-purchase inspection with scan data.