The Ford Explorer continues the tradition of reliable performance across varying weather conditions, with particular attention paid to its sophisticated engine cooling system. As temperatures rise during summer, this system becomes crucial for maintaining optimal engine function and preventing heat-related damage. The latest Explorer model features several advancements in cooling technology that represent significant improvements over previous generations.

Core Components of the Cooling System

At the heart of the Explorer cooling system is a high-efficiency radiator constructed from aluminum alloys. This lightweight yet durable material enables rapid heat dissipation—a critical factor when operating in temperatures exceeding 30°C. The radiator’s design incorporates multiple thin-finned channels that maximize surface area, allowing for greater thermal transfer between the coolant and ambient air.

The cooling system utilizes a dual-circuit architecture that independently manages engine and transmission temperatures. This separation allows the vehicle’s computer to prioritize cooling resources based on real-time thermal demands, directing additional cooling capacity to whichever system requires most during extreme conditions.

Advanced Pump and Flow Management

The Explorer features an electronically controlled variable-speed water pump—a significant upgrade from the mechanical pumps found in earlier models. This intelligent component adjusts its operation based on actual cooling needs rather than simply engine speed. During high-temperature conditions, the system can increase the coolant flow rate to up to 160 litres per minute, compared to approximately 100 litres in previous generations.

This pump delivers precision control to reduce parasitic power loss when full cooling isn’t needed, boosting fuel efficiency while preserving reserve cooling for tough conditions. During highway driving in 35°C weather, the system recovers up to 2.5 kilowatts of power that would otherwise be lost to unnecessary cooling.

Intelligent Thermal Management System

Perhaps the most innovative aspect of the Explorer cooling technology is its predictive thermal management system. The vehicle can anticipate cooling needs before they become critical using data from ambient temperature sensors, GPS elevation information, and learned driving patterns.

For example, when the navigation system detects an approaching steep grade in hot weather, the cooling system will proactively increase coolant flow and fan speed before engine temperature rises. This predictive approach helps maintain optimal operating temperatures even under challenging conditions like towing in mountainous terrain during summer.

Enhanced Radiator Fan Technology

The Explorer cooling fan system uses dual high-output electric fans that move up to 3,000 cubic metres of air per hour. Brushless DC motors drive the fans, allowing them to operate independently of engine speed. This setup provides precise cooling control, even at idle or during low-speed driving conditions common in summer traffic when cooling demands peak.

The fan control module employs pulse-width modulation technology to vary fan speed in small increments rather than simple on/off operation. This granular control allows the system to maintain target temperatures within a narrow 2°C range, preventing the temperature fluctuations that can cause thermal stress on engine components.

Auxiliary Cooling Systems

Beyond the primary engine cooling circuit, the Explorer incorporates several auxiliary cooling systems for specific components. The transmission receives dedicated cooling through a plate-type heat exchanger capable of dissipating up to 8 kilowatts of heat. For models equipped with turbocharged engines, an air-to-water intercooler reduces intake air temperatures by as much as 60°C before it enters the combustion chamber, maintaining power output even in extreme heat.

The hybrid variant adds further complexity with a dedicated cooling loop for the high-voltage battery pack. This system maintains battery temperatures between 20-35°C—the optimal range for lithium-ion chemistry—regardless of ambient conditions, ensuring consistent electric performance and battery longevity even during extended operation in hot weather.

Heat-Rejection Materials and Design

Engineers have incorporated specialized heat-rejection materials throughout the engine compartment. The underside of the hood features a composite heat shield capable of reflecting up to 95% of radiant engine heat. Similarly, exhaust manifolds employ multi-layer heat barriers that keep surface temperatures below 280°C, significantly cooler than conventional designs.

Strategic airflow management plays an equally important role. The front fascia incorporates active grille shutters that automatically adjust based on cooling needs. When maximum cooling is required, these shutters fully open to allow up to 85% greater airflow through the radiator than closed positions used for aerodynamic efficiency in cooler conditions.

Emergency Cooling Protocols

The Explorer implements a series of protective measures for situations where cooling demands exceed normal parameters. The engine control module will initiate a multi-stage protection protocol if engine temperatures approach critical levels despite maximum cooling effort. This begins with subtle interventions like adjusting ignition timing and gradually progresses to more noticeable actions, including reducing available power and eventually illuminating warning indicators if conditions persist.

This graduated response helps protect engine components while still allowing the vehicle to reach a service location safely, avoiding the sudden shutdowns that characterized older thermal protection systems.

Facts about the 2025 Ford Explorer Cooling System:

• The coolant used in the Explorer can withstand temperatures from -37°C to 132°C without changing physical properties, making it suitable for extreme conditions.

• During development testing, prototype Explorer cooling systems operated continuously for 500 hours at 43°C ambient temperature without performance degradation.

• The engine’s electronic control unit makes approximately 400 cooling-related calculations per second to optimize thermal management.

• The radiator in the Explorer contains enough internal passages that, if laid end-to-end, would stretch over 300 metres.

• The cooling system uses specialized ceramic-coated thermostat components that respond to temperature changes 40% faster than conventional metal thermostats.

Questions and Answers About the 2025 Ford Explorer 

What material is used in the Explorer radiator construction?

• The radiator is constructed from aluminum alloys, which provide lightweight yet durable properties for rapid heat dissipation.

How does the cooling system behave differently in hot weather than in moderate conditions?

• In hot weather, the system increases coolant flow rate up to 160 litres per minute, activates dual cooling fans at higher speeds, opens active grille shutters for maximum airflow, and may engage auxiliary cooling systems for the transmission and intercooler.

What is the purpose of the dual-circuit cooling architecture?

• The dual-circuit architecture independently manages engine and transmission temperatures, allowing the vehicle’s computer to prioritize cooling resources based on real-time thermal demands.

How much air can the cooling fans move at maximum capacity?

• The dual high-output electric fans can move up to 3,000 cubic metres of air per hour at maximum capacity.

What happens if the engine approaches overheating despite maximum cooling effort?

• The engine control module initiates a multi-stage protection protocol that begins with adjusting ignition timing and gradually progresses to reducing available power and illuminating warning indicators if conditions persist.

How does the predictive thermal management system work?

• It uses data from ambient temperature sensors, GPS elevation information, and learned driving patterns to anticipate cooling needs before they become critical, proactively adjusting coolant flow and fan speed.

What temperature range does the hybrid model maintain for its high-voltage battery?

• The hybrid variant maintains battery temperatures between 20-35°C regardless of ambient conditions, which is the optimal range for lithium-ion chemistry.

How do the active grille shutters affect cooling performance?

• When maximum cooling is required, these shutters fully open to allow up to 85% greater airflow through the radiator than in closed positions.

What improvements does the variable-speed water pump offer over mechanical pumps?

• The electronically controlled variable-speed water pump adjusts based on actual cooling needs rather than engine speed, reducing parasitic power loss and improving fuel efficiency while maintaining reserve cooling capacity.

How precise is the temperature control in the Explorer cooling system?

• The system can maintain target temperatures within a narrow 2°C range, preventing temperature fluctuations that can cause thermal stress on engine components.