2006 EXPLORER DESIGN EMBRACES TRUCK HERITAGE

Since its inception, Explorer's balance of exterior size and interior package defined the mid-size sport utility vehicle (SUV) as a vehicle suited not just for hunting, fishing and camping, but also for carrying people. Its design also has defined the segment, with consistent cues throughout its 15-year history: the bold grille, body color C-pillars and black wrap around D-pillars, the integrated wheel lips and running boards, and the Eddie Bauer models with two-tone paint.

"The Explorer really is an icon: If you think of an SUV, chances are you think of the Explorer," says Chelsia Lau, Explorer chief designer. "In our latest research, customers first critiqued non-branded Explorers. When we added the Ford oval, customer responses were dramatically more positive — this is the instant perception that comes with 15 years of leadership.

We really wanted to reinforce Explorer's truck heritage, which from the beginning gave it strength and credibility. The design brief had 'bold' and 'rugged' all over it, a clear connection with the Built Ford Tough F-150. We were very particular about the preservation of its classic attributes as we injected a fresh, energetic touch, capturing the Explorer's rugged spirit to make that classic look bolder and stronger."

The Explorer is leading Ford's differentiation between crossover offerings and traditional SUVs. Customers view these vehicle segments differently, and their reasons for purchase are also different:

"We define our target customers for Explorer as 'sensation seekers," says Chris Feuell, SUV group marketing manager. "They are goal-oriented, seeking to constantly challenge themselves and they are doers, as opposed to spectators. They want an SUV that looks the part and keeps pace with their busy and active lifestyle, whether for hiking, camping, taking roadtrips to the national parks or carrying pets. So we've redesigned the new Explorer, and realigned our series offerings, to fit buyer's busy lives, while still enabling them to seek out excitement when the opportunity arises."

The 2006 Explorer is all new from the
A-pillars forward, with a bolder character to fit its increased capability and SUV heritage.
The 2006 Explorer features the same footprint, solid proportions and planted stance as the outgoing model. However, the new Explorer has a much larger presence, due to the all-new, bold front clip, the powerdome hood, the more pronounced wheel lips, the bumper overriders and the strong geometric graphics in the lamps. These changes visually communicate power, capability and durability, reinforcing Explorer's authentic SUV roots.

This emphasis on the Explorer's rugged, truck-based character is for a large part inspired by the influx of crossovers in the segment.

"The 2006 Explorer is really at the forefront of Ford's positioning differentiation between traditional, more capable SUVs and crossovers," says Feuell. "As the crossover market grows, it's important to clearly differentiate between the two. The customers view them as different products, and their reasons for buying them are different as well. So you will see much more alignment with Ford's traditional SUVs and pickups from a design standpoint, from a capability standpoint and to some extent from a communications standpoint."

Big, bold — and chrome — grilles inspired by F-Series pickups

The 2006 Explorer's most noticeable exterior statement is its all-new front end, from the base of the windshield forward. The new grilles, with three distinct styles wrapping the larger seven-inch Ford blue oval, make the strongest statement.

"Since the introduction of the new F-150 in 2003," says Lau, "we have used the F-Series' grilles to communicate the toughness of Ford trucks and to serve as a differentiator among series. Now, we're applying that same approach to the Explorer."


The 2006 Explorer accomplishes this by utilizing three grille themes:

The chrome-finished, four-bar grille bracketed by aggressive nostrils is unique to the 2006 Explorer Eddie Bauer trim level.
  • XLS uses onyx grey for both its upper and lower grille openings. The upper carries four full-width horizontal bars while the lower grille is open. The horizontal bars establish a strong geometric flavor for Explorer's new face.
  • XLT and Limited also feature four horizontal bars in the upper grille. In addition, the lower grille incorporates a single horizontal accent bar. For these two series both the upper and lower grilles are chrome.
  • Chrome also is used for the Eddie Bauer edition. In this case, the upper opening carries a bolder, three-bar grille bracketed by nostrils. This design was first seen on the Mighty
    F-350 Tonka concept truck in 2002, and now is used on production F-Series Super Duty models and certain trim levels of the F-150, such as the new 2005 F-150 King Ranch. "This grille," says Lau, "perfectly fits the most rugged member of a rugged family." The lower grille of the Eddie Bauer is also a unique single horizontal bar design.




"Our 'grille strategy' asserts the toughness and truck capability of the sales leader," said Patrick Schiavone, design director, Ford North America Truck, at the time the 2006 Explorer was being styled (Schiavone is now responsible for Ford car design). "We definitely wanted to move the excitement needle up a notch with the grille on the new Explorer. The result is a look that symbolizes Explorer's strength but with an underlying tone of sophistication that really gives this truck aspirational qualities. We call it 'tough luxury.'"

Powerdome hood, geometric lights and tailored bumper complete
"tough luxury"

Complementing the "tough luxury" look of the Explorer's new front end is a bumper that emphasizes the strength of the vehicle. To accommodate the longer dimensions of Explorer's all-new, stouter frame

"Ribbons" on the powerdome hood neatly connect edges of the central bumper overrider.

(for improved protection in frontal impacts), the bumper features a central overrider section. Not only does this convey a tailored strength that is part of Explorer's heritage, it also delivers a more aspirational appearance by lessening front overhang at the corners.

As with all Explorers since the 2002 model year, the bumper on the 2006 Explorer is set at a level compatible with many passenger cars. This safety feature is designed to help to reduce damage to cars in common slow-speed incidents and to allow lower vehicles' energy-absorbing bumpers to do their work.

Adding to the grille's prominence is a chiseled chamfer, or "ribbon," that runs along either side new aluminum hood's powerdome. The ribbon begins near the base of the windshield and runs forward, following the power bulge as it cascades to meet the grille. On its downward run, the ribbon flanks the grille opening until reaching the top of the bumper. The hood is a great indicator of the new, more-powerful, 292-horsepower V-8 engine.


The new headlights feature geometric details, such as sharp horizontal lines in the lenses and jeweled reflectors.

Also flanking the grille are new dual-beam headlights. The rounded areas for each beam's reflectors continue the geometric theme of the grille. Another geometric touch is the way the inside edge of the clear portion of the headlight lens parallels the grille's outer edge.

The new headlights also incorporate the side-marker lights and turn signals. A geometric layout is apparent here as well. This area of the lens sports numerous crisp horizontal lines that add an extra dimension and help emphasize the strong stance of the 2006 Ford Explorer.

Below the bumper face and flanking the lower grille opening on each side are rectangular areas that echo the geometric shape of the headlights. On XLT, Eddie Bauer and Limited trim levels, these areas are fitted with standard fog lamps.

Integrated running boards and available 18-inch wheels create a cleaner,
stronger profile

"Subtle but significant changes to the Eddie Bauer model's side profile reveal a new approach in cladding treatment," says Lau. "The wheel lips and running boards, enhanced by the Pueblo Gold paint, are neatly integrated, creating a clean connection from the front to the rear."

The look of the running boards (step bars for XLS) and wheel lip moldings is keyed to the appearance of the all-new roof side rails used on each trim level:


The 2006 Ford Explorer profile is defined by wrap-under doors, neatly integrated running boards and roof rails, and available 18-inch wheels.
The section height of the roof rail is larger for a stronger appearance. The center and end mounting-rail brackets are heftier than before. The end brackets also serve as caps that give the rails a stout yet tailored appearance and echo the shape of the ends of the running boards and step bars.

The running boards remain functional yet unobtrusive. As with the previous Explorer, the outer edge of the running board does not project much beyond the outermost point of the Explorer's sheet metal. Nonetheless, there is still plenty of room to step on the running boards because the door bottoms and rocker panels tuck inward toward the center of the vehicle.

This inward tuck also helps keep passengers' pant legs clean when entering or leaving an Explorer that's recently made a run down a muddy two-track.


New, chrome-finished 18-inch wheels are a perfect accent to the chrome grilles offered on Eddie Bauer (shown) and Limited models.
The profile is completed by one of six available sets of wheels. The XLS is standard with 16-inch, five-spoke steel wheels. The XLT comes standard with 16-inch, machined-aluminum six-spoke wheels, or available 17-inch, machined-aluminum five-spoke wheels. A unique, 17-inch, painted-aluminum split-five-spoke wheel is standard on Eddie Bauer models. A strong, five-spoke, chromed 17-inch wheel is included on Limited models.

However, the designers' choice is the optional 18-inch, split-six-spoke chromed wheels optional on the Eddie Bauer and Limited models. These are the first 18-inch wheels offered on Explorer.

"The 18-inch wheels really make the truck stand out," says Lau. "The larger wheels and strong spoke design completes the bolder, more rugged, more capable appearance of the 2006 Explorer. And the chrome finish sets off the monochromatic finish of the Limited models, while it complements the chromed grille of Eddie Bauer models."

New taillamps and liftgate echo the strong lines of the front end.

Like the front of the 2006 Explorer, the rear infuses the classic look with a new bold attitude.


The rear design of the 2006 Ford Explorer echoes the strong styling of the front, with geometric taillamps bracketing a larger,
9-inch Ford blue oval.

As with the previous model, the 2006 Explorer front and rear bumpers help differentiate the series: The XLS and XLT models feature molded-in color bumper clips. The Eddie Bauer models are finished in a new Pueblo Gold color. The Limited model features a monochromatic finish that helps distinguish the top-of-the-line model.

Most noticeable are the new taillights with their strong geometric theme, echoing the front end. Sharp round and horizontal linear shapes grace the red lenses. And the perimeter shape mirrors that of the headlamps.

Between these lenses, Explorer retains the two-piece liftgate, a feature that is much appreciated by consumers for its practicality and ease of use. For 2006, the rear liftgate has a simplified, more modern design execution. A chrome strip appliqué gives the rear emphasis and coordinates with the same element on the front end. Finally, the revised tailgate also has a more prominent, nine-inch Ford blue oval.

Side mirrors designed for sight and sound, part of NVH improvements

Some changes made to Explorer's outside can best be appreciated inside. For example, new roof beads, revised side mirrors and a new moonroof deflector are just three of the comprehensive changes to every aspect of the Explorer — including chassis, powertrain and interior — to quell noise, vibration and harshness. The result is the quietest interior in its class.

2006 EXPLORER IS QUIETEST,
MOST COMFORTABLE EXPLORER EVER

An all-new interior that is quieter, more comfortable and more flexible than any in its class gives the 2006 Explorer a clear advantage over other mid-size sport utility vehicles (SUVs).

The new Explorer benefits from Ford's tripled interior-design investment, a strategic move to capitalize on consumer demand for more upscale interiors. Three trends are driving this demand — significantly increasing commute times, the boom in home improvements and the migration of luxury features to mainstream products.

Quietest Explorer ever

Attention to some of the tiniest details inside and out make the 2006 version the quietest Explorer ever, and by far the quietest vehicle in its class.

"One of the universal complaints about all SUVs is noise," says Judy Curran, Explorer chief engineer. "For the 2006 Explorer program, we set out to reduce interior noise to best-in-class levels, proving that SUVs don't have to be noisy."

As such, the team focused on every aspect of the vehicle, from the exterior, interior, chassis and powertrain to quell noise, vibration and harshness.

Measured in sones — which are better at measuring the mid-level sound waves of normal conversation than decibels — at highway speeds, the 2006 Explorer's third row is quieter than the second row of most competitors. In fact, the Explorer's third row is just as quiet as some competitors' front row.

"The Explorer sets the benchmark in interior quietness,'" says Lucy Yuen, Explorer NVH supervisor. "We accomplished our goal of making sure occupants in the first row could effortlessly hold a conversation with passengers in the second and third rows at highway speeds."


Measured in the first row at highway speeds, the 2006 Ford Explorer features the quietest interior in its class.


More significantly, the 2006 Ford Explorer's interior is dramatically quieter than its closest competitor when measured in the second- and third-row seats.

New materials make up some of the weapons launched in the war on noise, including:

Tough-luxury inspired by the groundbreaking F-Series pickup truck line

"The Explorer's interior raises the bar for SUVs much like the F-150 changed the game for pickup trucks," says Peter Horbury, vice president, Design. "People are spending much more time in traffic so they want us to put more of the comfort, style and amenities from homes into vehicle interiors."

Before the introduction of the 1991 Ford Explorer, sport-utilities were truck-based station wagons, with utilitarian interior appointments. A large part of the success of the Explorer can be attributed to its more comfortable — and less truck-like — interior.


The 2006 Explorer's fine craftsmanship, flow-through center console and two-tone seats are inspired by the "tough luxury" of the F-150 pickup.

Fifteen years later we have come full circle: For 2006, the Ford Explorer interior is redesigned to be more truck-like. But, not just any truck. Explorer's new interior design is inspired by the "tough luxury" theme of the ground-breaking F-150 pickup.

"We really pushed the envelope of what a truck interior could be with the 2004 F-150," says Pat Schiavone, design director of Ford Truck North America when the F-150 and 2006 Explorer were designed (Schiavone is now responsible for Ford car design). "The F-150 interiors featured a bold confidence and tough, visual strength necessary for a pickup. But, they also added a level of sophistication and craftsmanship that was unheard of in a pickup."

According to Chelsia Lau, Explorer chief designer of the 2006 Explorer, the result makes the Explorer feel both more rugged and more refined:

"The interior really defines the 'tough luxury' theme of the 2006 Explorer. The overall design has a clean and modern feel. Instrumentation has an intuitive layout and functional features are accentuated by strong geometric shapes. A prominent center stack makes a bold statement that echoes the exterior power bulge. Deeper more expressive grains enhance the visual and tactile quality. A high level of craftsmanship and upscale materials such as Preferred SuedeTM inserts and wood-grained trims add warmth and richness to the interior."

The influence of the F-150 design can be seen on specific items, such as the bright-ringed gauges on the instrument panel and the circular air vents. It's also very evident in the Explorer's new flow-through center console, with the prominent center-stack, clean symmetrical control and floor-mounted shift lever — a first for Explorer.


Bright-ringed gauges and premium leather wrapping the steering wheel are just two of the luxurious details of the new Explorer.
Yet, the F-150 influence is even more evident in the feeling of craftsmanship and sophistication throughout the Explorer interior. Also, Explorer adopts the F-150's modular design elements, which allowed the design team to tailor the look and feel of the interiors to the different series. Thus, the Explorer now offers four trim levels, and 12 distinct color and trim packages: All-new, more comfortable seating, class-exclusive features

As traffic congestion gets worse, Explorer owners seek more comfort as they typically have longer commutes and drive further on weekend excursions.

"One of the most consistent things all Explorer owners have in common is they spend a lot of time on the road," says Chris Feuell, SUV group marketing manager. "Explorer owners on average commute 70 miles roundtrip every day. In addition, they routinely take longer road trips, spending an average of 300-500 miles on the road at a stint. As such, seating comfort, quietness and other amenities are vitally important to make the ride more pleasant for all passengers."

Thus, the engineering team completely overhauled the seating accommodations for improved comfort, reduced NVH, ease of use and flexibility.

Five million customers, one can of frozen orange juice
"We are fortunate to have an asset that isn't available to our competition," says Curran. "We have more than five million customers, which serve as the largest SUV customer clinic in the industry."



The 2006 Ford Explorer's available third-row seat has been redesigned to fold completely horizontal (as has the second-row row bench seat, not shown), inspired by customer comments about golf balls and orange juice cans rolling out of the cargo area.

According to Curran, feedback from owners — including many on the Explorer engineering team — inspired many of the refinements and improvements of the Explorer interior.

"Today's Explorer has fold-flat seats, yet some customers complained about the incline of the load floor, almost 10 degrees from vertical: One customer opened the liftgate and had a can of frozen orange juice ruined as it fell onto the pavement. Another had golf balls rolling out, bouncing down the parking lot.

For 2006, the second- and third-row seats were redesigned to fold flat. Not merely creating a smooth load floor, but to fold with virtually zero included angle of incline. We created the flattest load floor in the industry (among seven-passenger SUVs), to pass our newest measure, what we call the Orange Juice Test."



The front bucket seats are redesigned for enhanced comfort for drivers and passengers. A new foam offers a better balance between initial cushion and firmness — a critical factor for long-term comfort behind the wheel. Lumbar adjustment is standard, while six-way and 10-way power adjustments are available to fine tune the front-seat positions.

The seat frames are also new, with a full inch of additional seat travel, a half inch forward and half inch rearward. Combined with the available power-adjustable pedals and telescoping steering wheel, the Explorer now easily accommodates drivers from the two-and-a-half percentile female (4' 11" tall) to the 95 percentile male (6' 2" tall).

Three new second-row seat choices

The new front seat frames also benefit second-row passengers. The seat frames are set wider, and with a higher clearance, offering a more comfortable footwell for backseat passengers.

The second-row seats are also new, offered in three styles: Class-exclusive power-fold, 50/50-split-bench third-row seat

Finally, the third-row seat also is redesigned, inspired by customer feedback.

"The current Explorer's third-row seat was designed to accommodate a 95th percentile male (6' 2") in the third row," says Rick Bolt, manager, SUV Package and Ergonomics. "Yet, customer feedback proved that not many six-foot-tall people were sitting back there. In fact, the majority of occupants were under 5' 7." They still appreciated the best-in-class legroom. Yet, for these occupants better forward visibility was much more important than maximum headroom."

So, the engineering team raised the hip-point by 1.75 inches, creating theater seating for the third row. As a result, shorter-stature occupants have a better view of the road ahead.

"The Explorer still offers the best third row seats in the market with the most legroom in the class, and competitive headroom," says Bolt. "It really speaks to the package leadership of the Explorer. To match our interior accommodations, competitors either introduced a long-wheelbase variant or dramatically increased their exterior envelope."

Third row statistics
  legroom (in.) headroom (in.)
2006 Ford Explorer 34.9 37.4
2005 Nissan Pathfinder 28.1 36.7
2005 Toyota 4 Runner 24.1 32.9
2005 Honda Pilot 30.2 38.9
2005 Chevrolet TrailBlazer 31.2 38.1

Third row-accommodations now also include storage trays on either side, with cupholders and compartments to hold juice boxes or more grown-up digital devices.

The third-row seats also feature a new 50/50-split-bench design. This, too, was inspired by customer requests. Many wanted to carry longer items like skis in the interior, not on the roof rack. In addition, the seats are now easier to fold and raise, thanks to an additional pull handle at the bottom of the seatback. For the ultimate in convenience, the 2006 Explorer will be available with an optional power-fold third row, the first in its class.

The 2006 Ford Explorer's available third-row seat now features a 50/50 split for increased flexibility carrying people and cargo.
"Ford Motor Company pioneered power-fold third-row seats in the Lincoln Navigator," says Curran. "Now, the 2006 Explorer is the first to bring this feature to the mid-size SUV segment. This is one of those features that once owners experience its ease of use, they will wonder how they ever lived without it."

Small changes deliver large improvements in ergonomics

Other ergonomic changes collectively add to the Explorer's ease of use and overall comfort.

"The refinements in package are just as impressive as the new design," says Raj Nair, SUV and Body-on-Frame Vehicles executive director. "These are changes repeat customers will really appreciate. Some of them are things customers might not even have noticed — maybe didn't even think of. Yet, now we wonder why we didn't do this in the first place."

Not only is the interior visually appealing, it is also ergonomically improved. The center stack includes more visible and more accessible controls for the climate and audio controls.

"The refinements in packaging will really be appreciated by repeat customers," says Nair. "Some are instantly noticeable, like the shifter is right where you would want it on the center console. Others are more subtle, like the heated-seat switch is moved to the center console for better visibility and the reach for the 4x4 controls has been decreased."

Other ergonomics improvements include:
Interior package incorporates new adaptive-safety and side-impact protection

Not all of the package improvements are visible, however. The 2006 Ford Explorer features a class-leading suite of safety features, many of which had to be incorporated into the interior:

"One of the toughest challenges for the 2006 Ford Explorer was accommodating the significant safety advances without sacrificing interior room or packaging comfort," says Bolt. "We added a lot of safety features, from adaptive load-limiting safety belt retractors to additional padding between the exterior and interior door panels. Yet, our overall package envelope didn't expand. Through careful design and engineering, we were able to integrate these changes while retaining Explorer's best-in-class interior efficiency and comfort."

Available, DVD-based navigation system just one of the amenities

Finally, the Explorer benefits from new features to make those weekend road trips all the more enjoyable.

For example, the 2006 model is the first Explorer to be available with a navigation system. This DVD-based system is one of the first in the industry to offer spoken upcoming street names.


The 2006 Explorer's available DVD-based navigation system is the first for Explorer.
An auxiliary climate control system is available, providing heating and cooling control for the rear-seat passengers. In addition, rear-seat passengers benefit from the available rear entertainment system, with a DVD player. This system allows up to three different sources of sound at a time: For example, the front seats can listen to talk shows through the radio; the second-row seats can listen to the video system through headphones; while the third-row passengers can listen to the CD-player through yet another set of headphones.