1994 Ford Explorer Electrical Problems

1994 FORD EXPLORER HAD SMOKE COMING OUT OF THE AIR-CONDITIONER VENTS INTO THE PASSENGER COMPARTMENT, SLIGHT AT FIRST, THEN SO HEAVY THAT FORWARD VISIBILITY WAS OBSCURED. AFTER STOPPING THE VEHICLE, A SMALL FIRE WAS SEEN BURNING THE PLASTIC EVAPORATOR COVER WHERE THE BLOWER MOTOR RESISTOR ASSEMBLY IS MOUNTED IN THE EVAPORATOR COVER. SOME SNOW THROWN ON THE FIRE PUT IT OUT. THE BLOWER MOTOR APPEARS TO BE SHORTED OR MAYBE JAMMED FROM ROTATING, CAUSING THE RESISTOR TO GET HOTTER THAN NORMAL, IGNITING THE PLASTIC COVER. MAYBE LEAVES OR OTHER FLAMMABLE DEBRIS CONTACTED THE RESISTOR, BUT I CAN'T TELL AS THE FLAMES BURNED UP ANYTHING IN THE AREA AROUND THE RESISTOR ASSEMBLY. FORTUNATELY, I WAS ABLE TO BRING THE VEHICLE TO A SAFE STOP, IN SPITE OF VERY LIMITED VISIBILITY IN THE HEAVY SMOKE. I WAS ON A SLOW SPEED, LOW TRAFFIC CITY STREET. THE RESULTS WOULD HAVE BEEN MUCH WORSE IF THE FIRE OCCURRED AT HIGHWAY SPEEDS. THE BLOWER MOTOR WILL BE AVAILABLE FOR INSPECTION WHEN I REMOVE AND REPLACE IT TO TRY AND GET THE AIR SYSTEM WORKING FOR HEAT AT LEAST. *TR

NHTSA ID

10374872

Incident

Jan 5, 2011

Mileage

185,876 mi

WHILE DRIVING, THE SUV CAUGHT FIRE FROM UNDER THE HOOD. THE VEHICLE WAS CONSUMED BY FLAMES IN LESS THAN 5 MINUTES. ALTHOUGH MANY MAKES AND MODELS OF FORDS HAVE BEEN RECALLED ( FAULTY CRUISE CONTROL - POTENTIAL FIRE HAZARD), THE 1994 FORD EXPLORER HAS NOT BEEN RECALLED. *TR

NHTSA ID

10308714

Incident

Jan 7, 2010

Mileage

150,000 mi

TL*THE CONTACT OWNS A 1994 FORD EXPLORER. WHILE DRIVING BETWEEN 25-30 MPH, WHITE SMOKE APPEARED FROM THE AIR CONDITIONING VENTS. THE CONTACT PULLED OVER AND EXITED THE VEHICLE. THE VEHICLE CONTINUED TO SMOKE AND THEN CAUGHT FIRE ON THE FRONT PASSENGER SIDE UNDERNEATH THE VEHICLE. THE VEHICLE WAS DESTROYED. A FIRE REPORT WAS FILED. THE CURRENT AND FAILURE MILEAGES WERE 150,000.

NHTSA ID

10230920

Incident

Apr 24, 2008

Mileage

150,000 mi

TL*THE CONTACT OWNS A 1994 FORD EXPLORER. WHILE DRIVING 2 MPH THE CONTACT ACTIVATED THE HEATER AND NOTICED SMOKE COMING FROM THE VENTS. SHE TURNED OFF THE ENGINE. SHE THEN RESTARTED THE VEHICLE AND ACTIVATED THE AIR CONDITIONER. THE CONTACT NOTICED FIRE ASCENDING FROM THE HOOD NEAR THE PASSENGER SIDE OF THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE MANUFACTURER STATED THAT THEY WOULD CONDUCT AN INVESTIGATION TO DETERMINE THE CAUSE OF THE FIRE. THE VEHICLE HAS NOT BEEN INSPECTED YET, AND THE INSURANCE COMPANY WAS UNABLE TO DETERMINE THE CAUSE OF THE FIRE. THE CURRENT AND FAILURE MILEAGES WERE 145,000.*AK

NHTSA ID

10188814

Incident

Apr 6, 2007

Mileage

145,000 mi

(1) PURCHASE OF A NEW 2002 FORD EXPLORER; (2) DEFECTIVE VEHICLE FROM THE ONSET. ONGOING PROBLEMS WITH SERIOUS "SAFETY" ISSUES. (3) HAVE REPEATED TAKEN THE VEHICLE INTO THE DEALERSHIP, BUT THE PROBLEMS HAVE NOT BEEN RECTIFIED. *NM

NHTSA ID

10150527

Incident

Nov 2, 2002

Mileage

7,300 mi

I BOUGHT THIS 1994 FORD EXPLORER EDDIE BAUER SUV FROM A DEALER. THE CAR HAD A PROBLEM WITH ALARM SO THE DEALER REMOVED IT. THE ABS LIGHT COMES ON AND OFF. A WEEK AFTER THE PURCHASE, WHILE DRIVING, THE ENGINE STOPS, CAR COMES TO A HALT IN THE MIDDLE OF THE ROAD, AND THE STEERING LOCKS. I ALMOST GOT HIT BY A TRUCK. IT STARTS BACK ON AFTER FEW MINUTES. IT DOES NOT START IF HAZARDS, HEADLIGHTS OR ANY ELECTRICAL COMPONENTS ARE ON. AFTER THAT THE SAME THING HAPPENED 5 TIMES IN 2 WEEKS ONCE AT NIGHT 12''O CLOCK. IT IS HIGHLY UNSAFE TO DRIVE THE CAR NOW. I'M NOT DRIVING IT ANYMORE. THE DEALER DOES NOT KNOW WHAT THE PROBLEM IS AND DOES NOT WANT TO TAKE THE CAR BACK. *JB

NHTSA ID

10136448

Incident

Aug 29, 2005

Mileage

129,980 mi

DT: 1994, FORD, EXPLORER LIMITED, CONSUMER WAS DRIVING ON HIGHWAY WHEN THE VEHCILE STARTED SMOKING. CONSUMER STARTED HAVING BREATHING PROBLEMS. THE SMOKE STARTED THICK, AND CONSUMER COULDN'T SEE, AND HE PULLED OVER. WHEN THE CONSUMER GOT OUT OF THE CAR HE EEN SPARKS, THEN THE CAR BLEW UP. OWNER HAD NO PHYSICAL INJURIES. THE FIRE WAS SO HOT THAT TIRES MELTED AND EVEN THE KEYS MELTED. *AK

NHTSA ID

10123740

Incident

May 31, 2005

Mileage

124,000 mi

VEHICLE WAS ON THE ROAD WHEN ALL OF A SUDDEN ENGINE CAUGHT ON FIRE TOOK VEHICLE TO DEALER FOR CHECKUP, BUT THE CAUSE WAS UNDETERMINED AT THIS TIME.*AK

NHTSA ID

10119216

Incident

Apr 19, 2005

Mileage

120,000 mi

ON JULY 31, 2004, AT 5:00AM, I WAS AWAKEN BY POUNDING ON MY DOORS AND WINDOWS. AS I WAS COMING DOWN THE STAIRS I LOOKED OUT THE WINDOW CAUSE I SAW ALOT OF LIGHT. I OPENED THE DOOR TO FIND THE FIRE DEPARTMENT TELLING ME AND MY KIDS TO GET OUT OF THE HOUSE. HE STATED THAT MY CAR WAS ON FIRE. THIS HAD HAPPEN AFTER MY CAR HAD BEEN PARKED IN THE SAME SPOT SINCE 7:00PM THE PRIOR DAY. MY VEHICLE WAS A 1994 FORD EXPLORER XL, 4 DOOR. THANK GOD THAT SOMEONE HAD SAW IT BECAUSE WHERE MY VEHICLE WAS PARKED WAS RIGHT NEXT TO MY GAS METER ON THE HOUSE. THIS COULD OF KILLED ME AND MY CHILDREN. THE FIRE DEPARTMENT HAD TO PRY OPEN MY HOOD TO PUT THE FIRE OUT. THEY EVEN TRYED BREAKING OUT MY WINDOW TO GET TO IT. BY THEN THE WHOLE ENGINE COMPARTMENT WAS DESTROYED THE DASH BOARD, GLOVE BOX AND EVERYTHING IN THE FRONT END WAS DESTROYED. I ONLY HAD NO-FAULT INSURANCE SO THEY TOLD ME THERE WAS NOTHING TO BE DONE. I DIDN'T RECEIVE ANYTHING TO HELP ME FIX OR REPLACE IT. I HAD TO CALL A TOW TRUCK TO TAKE IT AWAY. I DIDN'T RECEIVE ANYTHING FROM THEM EITHER. I DID TAKE PICTURES OF THE VEHICLE AFTER THIS HAPPENED.

NHTSA ID

10112308

Incident

Jul 31, 2004

Mileage

90,000 mi

1) SMELLED BURNING ELECTRICAL INSULATION WHILE DRIVING IN A RESIDENTIAL AREA OF IDAHO FALLS, ID. PREVIOUSLY THAT DAY, THE VEHICLE HAS BEEN DIFFICULT TO START ON ONE OCCASION. MULTIPLE VEHICLE STARTS AFTERWARDS HAD BEEN WITHOUT INCIDENT.*AK 2) PULLED OVER TO THE SIDE OF THE ROAD TO INVESTIGATE. FOUND THE ALTERNATOR OUTPUT WIRE GLOWING RED AND THE INSULATION BURNING. IMMEDIATELY STOPPED THE ENGINE, AND REMOVED THE BATTERY CABLES. ALTERNATOR WAS TOO HOT TO TOUCH (THEREFORE > 140F). 3) REPLACED THE ALTERNATOR. REMOVED SIX INCHES OF BURNED UP ALTERNATOR OUTPUT WIRE (#6 AWG) AND THE CONNECTION LUG (#6 AWG W/ 1/4" POST). RELUGGED THE OUTPUT WIRE AND INSULATED THE LUG WITH ELECTRICAL TAPE AND HEAT SHRINK TUBING. NOTED THAT THE CONNECTION LUG HAD SHORTED TO THE ALTERNATOR FRAME BY THE EVIDENCE OF MELTED ALUMINUM FROM THE ALTERNATOR ON THE LUG. THE FACTORY INSTALLED LUG WAS NOT INSULATED BETWEEN THE LUG SHAFT AND THE ALTERNATOR CASE. IT WAS PROTECTED ON ITS EXTERNAL SIDE BY A BOOT SLIDE ON BOOT. OLD PARTS AND PICTURES ARE AVAILABLE.

NHTSA ID

10098866

Incident

Nov 11, 2004

Mileage

129,000 mi

1994 EXPLORER 4.0 V6 AUTOMATIC TRANSMISSION REBIULT 3 TIMES IN PAST YEAR .COUNTLESS TIMES VEHICLE HAS STALLED ACTING AS IF THE FUEL PUMP QUIT, FUEL PUMP REPLACED, COIL PACKS REPLACED, RELAYS REPLACED. ONCE ON THE HIGHWAY AT 70 MPH, ANOTHER TIME WHILE PULLING INTO TRAFFIC. USUALLY UPON START UP. AIR CONDITIONER SWITCH SHORTED OUT, SAW BURNED WIRES ON SWITCH UPON REPLACEMENT. ANTIFREEZE SPEWED OUT FROM SIDE OF MOTOR, ASSUMED TO BE AROUND HEADS BUT HAS NOT BEEN TO SHOP YET.*AK

NHTSA ID

10096436

Incident

Oct 20, 2004

Mileage

114,000 mi

ON 14 APRIL 2003 I PAID FOR SERVICE ON AN "INTERMITTENT START" PROBLEM; CHECKED THE BATTERY CHARGING SYSTEM, THE ALTERNATOR, AND TESTED THE BATTERY.PAID FOR LABOR $76.50 AND $79.95 FOR BATTERY ASSY. HERE IT IS 2004 AND THE PROBLEM WAS NOT FIXED BUT HAS GOTTEN WORSE. PURCHASED TWO NEW ALARM/ENTRY DEVICES (FOBS) ON 29 JUN 04 BECAUSE WE WERE TOLD BY ONE OF THE MECHANICS THAT THE NEW DEVICES SHOULD SOLVE THE PROBLEM. THIS BILL CAME TO $211.10. ALREADY PAID $70.65 ON OR ABOUT APRIL 28, 2004 FOR A DIAGNOSTIC TO FIND OUT WHAT THE PROBLEM WAS AND TOLD THE REPAIR PART NEEDED COST $210. I WAS UPSET AND ONLY PAID FOR THE DIAGNOSTIC. I'M GLAD WE DIDNT PAY FOR THAT PART, BECAUSE EACH SUCCESSIVE TIME, THE SOLUTION TO THE "PROBLEM" HAS BEEN DIFFERENT AND COST ADDITIONAL MONEY. NOTHING THE MECHANICS HAVE DONE HAS RESOLVED THE PROBLEM; ONLY MADE THINGS WORSE AND THE COST HAVE TOTALED $814.67 FOR THIS PROBLEM SO FAR. THE MECHANIC SAID THE VEHICLE NOT STARTING BACK UP AFTER IT HAS BEEN TURNED OFF IS TIED IN TO THE ALARM SYSTEM. THEY HAVE REPLACED THE ANTI THEFT CONTROL MODULE ON 26 JULY 2004, $368.82. NOW THE WIRING IS NOT PERFORMING, AS IT SHOULD!!! VEHICLE IS NOT STARTING AGAIN, THE INTERIOR LIGHTS WON'T GO OUT WHEN THE VEHICLE IS TURNED OFF AFTER IT WAS "FIXED", BRAKE LIGHTS COME ON, AND CHECK ENGINE LIGHT ALSO COMES ON; SEEMS TO HAVE A WIRING/ELECTRICAL PROBLEM NOW. MR. LEE HIGGS, RED TEAM SERVICE MANAGER, HAD THE FUSE TO THE INTERIOR LIGHTS TAKEN OUT SO THE LIGHTS WONT DRAIN THE BATTERY, AT LEAST UNTIL THEY CAN GET IT BACK IN TO BE FIXED "AGAIN". THE VEHICLE HAS BEEN IN AND OUT OF THE SERVICE DEPARTMENT AND THE PROBLEMS ARE INCREASING INSTEAD OF DECREASING. WE ARE STILL WAITING FOR AN OPENING IN THE SERVICE DEPARTMENT TO PUT THE VEHICLE BACK IN THE SHOP TO GET THIS RESOLVED AGAIN! *AK

NHTSA ID

10086963

Incident

Apr 14, 2003

I BOUGHT MY 1994 FORD EXPLORER (4WD) IN MAY OF 1999 AND HAVE HAD NUMEROUS PROBLEMS SINCE. THE VEHICLE HAD APPROXIMATELY 50900 MILES WHEN I BOUGHT IT. IT NOW HAS 89000 MILES. I HAVE REPLACED THE BRAKE ROTORS TWICE AND REPLACED THE BRAKE PADS THREE TIMES. THE LAST TIME I COMPLETED BRAKE WORK WAS BECAUSE THE LEFT FRONT CALIPER OVERHEATED AND FAILED. I THEN REPLACED BOTH FRONT CALIPERS. THERE IS A BAD VIBRATION PROBLEM AT SPEEDS OF 55-67 MPH. I RECENTLY PURCHASED FOUR NEW TIRES, HAD THEM BALANCED, HAD THE FRONT END ALIGNED, AND REPLACED THE SHOCKS TO FIX THIS PROBLEM. IT STILL VIBRATES AT THE ABOVE MENTIONED SPEEDS. ALSO, THE VEHICLE HAD NUMEROUS PROBLEMS WITH THE PCM (CHECK ENGINE LIGHT). I REPLACED THE PCM AS A LAST RESORT BECAUSE I HAD ALREADY REPLACED ALL THE SENSORS THAT COULD HAVE BEEN CAUSING THE PROBLEM. REPLACING THE PCM CORRECTED THE PROBLEM FOR ABOUT A YEAR, BUT NOW THE CHECK ENGINE LIGHT COMES ON AGAIN DURING INITIAL STARTING AND THEN GOES OUT AFTER DRIVING ABOUT 2-3 MILES. I ALSO HAVE A SOUND COMING FROM MY AIR VENTS WHEN THE A/C IS TURNED ON. NOW FOR MY MOST RECENT PROBLEM. THE TEMPERATURE GAUGE WAS READING HOTTER THAN NORMAL SO I OVERHAULED THE COOLING SYSTEM INCLUDING: NEW THERMOSTAT, NEW COOLING FAN (OLD ONE WAS CRACKED ALL AROUND THE HUB), NEW FAN CLUTCH, NEW RADIATOR, NEW ENGINE COOLANT TEMPERATURE SENSOR, AND NEW FLUID FLUSH AND REFILL. THE TEMPERATURE GAUGE STILL READS THE SAME. I HAVE NO IDEA WHAT TO DO NOW. ANY RECALL INFORMATION YOU COULD PROVIDE WOULD HELP. I HAVE ALL RECEIPTS FOR PARTS PURCHASED AND WORK PERFORMED.*AK

NHTSA ID

10086453

Incident

Aug 6, 2004

Mileage

88,500 mi

1994 FORD EXPLORER CAUGHT ON FIRE, JUST AFTER WIFE AND BABY GOT OUT OF VEHICLE. IT BURNED THE DRIVER SIDE DOOR, AND PART OF THE DASH. NHTSA CAMPAIGN #97V083000, I THINK IS RELEVANT, AND RESPONSIBLE FOR THIS ACCIDENT. I NOTIFED FORD OVER 3 WEEKS AGO, AND THEY KEEP TELLING ME CONSUMER AFFAIRS WILL CALL, BUT THEY NEVER HAVE YET. *LA

NHTSA ID

10043075

Incident

Sep 24, 2003

CONSUMER STATES THAT ELECTRICAL CURRENT THAT RUNS THROUGH THE AUTOMATIC PASSENGER'S SIDE DOOR IS SO STRONG THAT IT CAUSES PASSENGER'S ARM TO BE BURNED. *AK

NHTSA ID

10032108

ON FOUR SEPARATE OCCASIONS, MY EXPLORER HAS STALLED AFTER DRIVING IT FOR AWHILE, IT WOULD RESTART AFTER ABOUT AN HOUR. THE ENGINE WOULD TURN OVER BUT NOT FIRE.S THERE A RECALL? THE CASE IS HOWARD VS. FORD 763785-2. *AK

NHTSA ID

10028632

Incident

Jul 17, 2003

ABS LIGHT ON. BRAKES FAILED DURING SUDDEN STOP. USING EXCESSIVE COOLANT. PROBLEMS STARTING. *NLM

NHTSA ID

10023356

Incident

Mar 1, 2003

Mileage

86,000 mi

TRUCK HAS BEEN DYING FOR THE LAST SEVERAL YEARS. EITHER WHEN IT GET TO HOT OUT SIDE OR IT JUST NEEDS TO TAKE A LITTLE BREAK. THEN WANT START UNTIL IT FEELS LIKE IT SHOULD. WHETHER ITS RUNNING OR WHEN I START IT UP. CHECKED THE FUEL PUMP, CHANGED THE SPARK PLUGS,WIRES, BATTERY CABLES, EVERYTHING BUT, IGNITION MODULE. WHICH I'M DOING TOMORROW. *NLM

NHTSA ID

10023178

Incident

Jun 16, 2003

WHILE VEHICLE WAS PARKED THE MIRROR SWITCH CAUGHT FIRE. *TT

NHTSA ID

10021753

Incident

May 27, 2003

Mileage

156,000 mi

THE CONSUMER NOTICED THE DRIVER SIDE DOOR WAS ON FIRE. *TS *JB

NHTSA ID

10011804

Incident

Jun 27, 2002

Mileage

93,375 mi

ELECTRICAL SYSTEM UNDER FROM HOOD. WIREING HARNESS THAT FEEDS INTO THE DISTRIBUTION BOX. THEIR ARE NUMEROUS PROBLEMS WITH EGR SYSTEM, IDLEING, VEHICLE BLINKERS LAG, RADIO, HEAT, AC, WILL WORK THEN SOMETIMES THEY WONT. WILL NOT CONSISTANTLY START AFTER BEING PARKED. EXPLORER CUTS OUT WHILE DRIVING. HAVE TRACED THE PROBLEMS TO THE DISTRIBUTION BOX. THE PROBLEMS CAN SOMETIMES BE TEMPERALILY REMADIED BY PUSHING DOWN OR JIGGLING OF THE BREAKERS. HAVE HAD THE BREAKERS EXAMINED AND THEY HAVE WHAT APPEARS TO BE HEAT DAMAGE FROM ELECTRICAL SHORTS IN THE WIRING HARNESS.

NHTSA ID

10005822

Incident

Oct 1, 1998

Mileage

75,000 mi

REAR LAP AND SHOULDER BELTS DO NOT TIGHTEN TO KEEP THE ADULT OR CHILD FROM MOVING FORWARD IN AN ACCIDENT OR DURING AN EMERGENCY SLAMMING ON OF BREAKS. ADDIDIONALLY THE REAR SEATBELT LOCKS DO NOT RELEASE AFTER BEING BUCKLED WITHOUT A LOT OF TUGGING AND JIGGLING.

NHTSA ID

10005820

Incident

Jan 1, 1998

THE VEHICLE THAT WAS PARKED AND UNOCCUPIED BEGAN SMOKING FROM THE DRIVER SIDE DOOR. THE VEHICLE HAD CAUGHT FIRE WITH POSSIBLE ELECTRICAL SHORT AND WAS A TOTAL LOSS. *YH

NHTSA ID

8019527

Incident

Jun 27, 2002

IGNITION SWITCH IS INOPERATIVE, IT WILL LOCK UP WHILE DRIVING OR DRIVER WILL NOT BE ABLE TO START VEHICLE.*AK

NHTSA ID

8017769

TEXAS "SALVAGE TRUCK" HOW DID IT GET "RESOLD" IN ARIZONA!. NO SAFETY DEFECT LISTED. *AK

NHTSA ID

764922

Incident

Oct 29, 2001