This is Ford's own service information for the sixth generation Explorer, the U625 that arrived for 2020 on a new rear wheel drive platform. It runs to 15,467 pages in a single searchable PDF and is organised by Ford's own section numbering, 152 numbered sections in all.

The 2020 redesign changed almost everything underneath. The Explorer went back to a longitudinal, rear drive layout, gained a ten speed automatic and picked up a hybrid for the first time. Every one of those systems is documented here in the same detail Ford gives a dealer technician.

Read this before buying so you know exactly what you are getting. One thing worth knowing up front: this set holds no wiring schematics. What it does hold is the diagnostic half in full, with more than six thousand pinpoint test references, 1,289 diagnostic trouble codes and over forty thousand connector references with pin-out tables giving pin, circuit, gauge and qualifier. If circuit drawings are specifically what you need, this book on its own will not give you them. Everything else about the car is here.

Which vehicles this manual fits

• Fits: Ford Explorer, sixth generation U625, in rear wheel drive and all wheel drive form. Ford's separate Police Equipment section is included
• Covers years: 2022, 2021, 2020
• Engine options: the 2.3L EcoBoost four cylinder, the 3.0L EcoBoost twin turbo V6 fitted to the ST, the naturally aspirated 3.3L Duratec V6, and the 3.3L hybrid. All four are documented separately, each with its own engine, cooling, fuel charging, ignition, starting, emission control, intake and electronic controls sections
• Hybrid: the electric motor, electric powertrain cooling, electric powertrain control, the high voltage battery with its mounting and cables, and the voltage converter and inverter all have sections of their own
• Gearbox: the 10R60 and 10R80 ten speed automatics, with transmission, transfer case and power transfer unit coverage plus external controls and cooling
• Driveline: transfer case, four wheel drive systems, driveshaft, front and rear drive axles and differentials, and the front drive halfshafts
• Suspension: separate front suspension sections for rear wheel drive and all wheel drive, rear suspension, wheels and tyres, and the tyre pressure monitoring system
• Diagnostics: 6,157 pinpoint test references, 1,289 distinct trouble codes and 44,167 connector references
• Wiring: no circuit schematics. Connector pin-out tables, connector numbers and module diagnosis are present throughout
• Language: English
• Pages: 15,467 in one PDF
• File type: PDF, 714 MB

Inside this manual

Ford splits its service information into numbered sections. Below is what this set holds, listed the way the book itself organises it. Where a system differs by engine or by drivetrain, Ford writes a separate section for each, and all of those separate sections are present.

Each system section follows the same shape Ford uses in its dealer material: specifications first, then description and operation, then the diagnosis routine, then removal and installation with torque figures. That is why the page count runs so high for one vehicle.

Sample pages from this manual

Three pages lifted straight out of the file, unedited, so you can judge the level for yourself:

What you can repair with it

Diagnosis is where this set earns its keep. Pinpoint tests are called on 6,157 times, there are 1,289 distinct trouble codes charted, and connectors are referenced 44,167 times with the pin, circuit, wire gauge and qualifier set out in a table beside the test step. A pinpoint test tells you which terminal to back-probe, what the meter should read, and which branch to take from each answer, so a fault gets cornered instead of guessed at.

The 2020 redesign put the Explorer on a rear drive architecture, and the driveline sections were rewritten to match. You get the power transfer unit, transfer case, four wheel drive control, both halfshaft sets and both differentials, alongside separate front suspension sections for the rear drive and all wheel drive cars because the geometry differs between them.

Four powerplants are documented independently: the 2.3L EcoBoost, the 3.0L EcoBoost twin turbo that sits in the ST, the naturally aspirated 3.3L Duratec V6, and the 3.3L hybrid. Independently means what it says. Cooling, ignition, starting, emission control, evaporative emissions, intake, fuel charging and electronic engine controls all appear four times over, once per engine, so nothing you read has been averaged across a range.

Hybrid work is fully supported. The pack is built from pouch cells delivering roughly 300 volts DC, and the manual walks the high voltage battery, its mounting and cables, the electric motor, the electric powertrain cooling loop, the powertrain control strategy and the voltage converter and inverter that steps the pack down to the 12 volt system. Service disconnect, isolation checks and the diagnostic thresholds the modules use are all written out.

Three gearboxes are treated as three gearboxes. The 10R60 behind the four cylinder, the 10R80 behind the V6 and the 10R80 MHT with its motor in the bellhousing each get overhaul, external controls and cooling sections of their own, down to the clutch pack clearances and the exploded views with part numbers on the callouts.

Body and collision work is unusually complete for a download. Front end, roof, side panel and rear end sheet metal repairs are all here, with the tolerance checks used to measure a damaged shell, the subframe and uni-body mounting section, and the paint general information. If you are a bodyshop rather than a home mechanic, that half alone is worth the price.

Ford's Police Equipment section is in the set as well, which is not something you often see. Flasher lighting, the siren and speaker system, LED lamps in the grille, mirrors and headliner, the flasher switch pad and group flash pattern programming are all documented, and the police fitment carries through into the interior trim and transmission sections.

Manual language and format

Everything is in English.

The download is a single PDF of 15,467 pages, about 714 MB, and there is nothing to extract. That matters more than it sounds. Because it is one file, a search for a connector number, a DTC or a torque figure runs across the whole vehicle at once and lands you on the page, wherever in the 152 numbered sections it happens to live. Bookmarks follow Ford's own section tree.

The file has been prepared carefully on our side. It opens without a password, printing and copying are enabled, the text layer is clean so search actually finds what you type, and the page furniture that comes with files of this kind has been taken out so you are looking at Ford's pages and nothing else.

The one thing to be square about is wiring. There are no circuit schematics in this release. Connector numbers, pin-out tables, module descriptions and the full diagnostic tree are all present and are what most jobs actually need, but if you were expecting drawings of the harness you will not find them here.

No software, no serial number, no activation. It opens in whatever PDF reader you already have, on a laptop in the workshop, a Mac, an iPad or a phone.

Questions about this manual

Will it fit my 2023 or 2024 Explorer?
Those cars are mechanically the same generation and much of this will read across, but the data set here is written to the 2020 to 2022 build and we will not claim more than that. Later running changes are not reflected.

Are wiring diagrams included?
No. Read that twice before you buy, because it is the one gap. What you do get is the diagnostic half in full: 6,157 pinpoint test references, 1,289 trouble codes and 44,167 connector references with pin-out tables. Circuit drawings are not part of this release.

Does it cover the hybrid?
Yes, and properly. The 3.3L hybrid has its own engine, cooling, ignition, starting, emissions, intake and controls sections, and on top of those the electric motor, high voltage battery and cables, electric powertrain cooling, electric powertrain control, the voltage converter and inverter, and the 10R80 MHT transmission.

Does it cover the Police Interceptor Utility?
It does. Section 100-05 Police Equipment covers the flasher lighting, siren and speaker system and the LED lamp fitments, and the police version is called out separately in the interior trim and transmission fluid specifications.

How much fluid does the ten speed take?
It depends which one you have. A dry fill is 12.9 quarts, 12.2 litres, for the 10R60, 13.0 quarts, 12.3 litres, for the 10R80, and 13.7 quarts, 13 litres, for the 10R80 MHT in the hybrid, rising to 14.8 quarts for the police hybrid. All three call for Motorcraft MERCON ULV to WSS-M2C949-A. A drain and refill takes less than a dry fill.

Is it one file or a folder full of them?
One PDF. Some manuals of this size arrive as an archive split into dozens of section files, which means you have to know where to look before you can search. This one is a single searchable document, so you type the part number and go.

How does it compare with a paperback repair book from a parts shop?
They are not the same kind of thing. A shelf book gives you a couple of hundred pages covering several model years at once, written by an author working from the outside. This is 15,467 pages of the information Ford issues to its own dealer network for one vehicle. Each of the four engines gets its own complete set of chapters instead of one shared summary. Torque figures sit inline with the step, against the exact fastener, in Newton metres and pound feet. Diagnosis runs on Ford's pinpoint trees with the connector, the pin and the expected reading named at every branch. And you get the material a general book will not attempt at all: the high voltage hybrid system, the ten speed automatics stripped to their internals, the Police Equipment fitment, and full collision and sheet metal repair with the tolerance checks. The trade off is the missing schematics, which is why we say so in three places on this page.

How you receive it

Payment is taken securely and the download link is issued as soon as it clears, usually within a minute. Nothing ships and there is no disc to wait for. The link does not expire, so if the laptop in the workshop dies you can pull the file down again.