2016 Ford Explorer Service and Repair Manual

This 2016 Ford Explorer UB (U502 NA) Service and Repair Manual Covers

Engine and Drivetrain

• Procedures for 2.3L EcoBoost I4, 3.5L Cyclone V6, and 3.5L EcoBoost V6 engines.
• Direct fuel injection and sequential multiport electronic fuel injection diagnostics.
• Twin-scroll turbocharger and wastegate actuator system servicing.
• Emissions and exhaust system repairs, including catalytic converters.
• Overhaul for the 6-speed SelectShift automatic (6F35/6F50/6F55) transmissions.
• Intelligent AWD, Power Transfer Unit (PTU), Terrain Management System, and rear axle service.

Chassis and Suspension

• Front MacPherson strut suspension repair procedures.
• Rear multi-link independent suspension servicing.
• Electric power-assisted steering (EPAS) steering rack assembly and alignment.
• Wheel alignment specifications.
• Wheel bearing and hub replacement.
• Control arm, ball joint, and stabilizer bar troubleshooting.

Braking Systems

• ABS diagnostics.
• Brake master cylinder, vacuum booster, and hydraulic system service.
• AdvanceTrac with Roll Stability Control (RSC) diagnostics.
• Mechanical and electronic parking brake adjustments.
• Pad, rotor, and caliper replacement.

Electrical and Wiring

• Factory wiring diagrams and grounding schematics.
• 12V battery, smart charging, and high-output alternator diagnostics.
• BCM (Body Control Module) programming.
• Fuse box configurations (engine bay and passenger compartment).
• LED headlamps, fog lamps, and signature lighting diagnostics.
• SYNC 2 or SYNC 3 infotainment system and digital instrument cluster troubleshooting.

Air Conditioning and HVAC

• Tri-zone automatic climate control diagnostics.
• Blower motor and blend door actuator replacement.
• R-134a refrigerant capacities and system pressure servicing.
• Compressor clutch and heater core troubleshooting.

Body and Interior

• Interior trim, center console, and PowerFold third-row seat removal.
• Active grille shutter repair.
• Keyless entry, SecuriCode keypad, and remote start diagnostics.
• Hands-free foot-activated power liftgate adjustments.
• Airbag, side curtains, and occupant restraint system service.

Diagnostics and Troubleshooting

• DTC lookup workflows.
• Ford IDS scan tool procedures.
• Component voltage and resistance testing specifications.
• Troubleshooting step workflows for drivability issues.
• Control module flashing and parameter identification (PID) logging.

Common Error Codes Covered

This manual provides diagnostic and repair procedures for thousands of manufacturer-specific fault codes, including:

Engine Codes

• P0300 – Cylinder Misfire Detected
• P0420 – Catalyst Efficiency Below Threshold
• P0299 – Turbocharger Underboost (EcoBoost models)
• P0012 – Intake Camshaft Position Timing Over-Retarded
• P0128 – Coolant Thermostat Error

Transmission Codes

• P0715 – Speed Sensor Circuit Malfunction
• P0751 – Shift Solenoid Performance
• P0741 – Torque Converter Clutch Circuit Performance

ABS and Chassis Codes

• C0020 – ABS Pump Motor Circuit
• C0031 – Front Wheel Speed Sensor
• C1001 – Co-Pilot360 / Vision System Camera Blind

Network Communication Codes

• U0100 – Lost Communication With PCM
• U0140 – Lost Communication With BCM

Body Control Codes

• B10A2 – Crash Input Sensor Fault
• B11D8 – Restraints Module Configuration Error

And thousands of additional diagnostic codes, test procedures, wiring diagrams, and repair instructions.

• Professional automotive workshops
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Vehicle owners performing DIY repairs
• Automotive training institutions