1994 Ford Explorer Fuel system Problems

TL* THE CONTACT OWNS A 1994 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, AN ODOR OF GASOLINE FUMES EMITTED INSIDE OF THE VEHICLE AND THE ENGINE WARNING LIGHT ILLUMINATED. IN ADDITION, THERE WAS SMOKE COMING FROM UNDER THE HOOD. THE CONTACT EXPERIENCED BRONCHIAL HEALTH ISSUES THAT REQUIRED MEDICAL ATTENTION AS A RESULT FROM INHALING THE FUMES. THE VEHICLE WAS TAKEN TO A DEALER, WHO DIAGNOSED THAT THE FUEL LINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 190,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10614481

Incident

May 13, 2013

Mileage

190,000 mi

INVESTIGATION OF A MOTOR VEHICLE TRAFFIC COLLISION REVEALED THAT THE ACCELERATOR PEDAL ON 1994 FORD EXPLORER (UNKNOWN MILES) MAY BECOME STUCK IN THE "FULL OPEN THROTTLE" POSITION. CONDITION OCCURS WHEN THE ACCELERATOR PEDAL ARM WEARS A SLIT IN THE RUBBER SOUND/HEAT INSLUATION ON THE FLOOR BOARD. AFTER THAT OCCURS, WHEN THE ACCELERATOR IS FULLY DEPRESSED, THE ARM CAN BECOME STUCK IN THE RUBBER. CONDITION WAS DISCOVERED DURING INVESTIGATION OF A FATAL CRASH. AFTER THE CONDITION WAS DISCOVERED, IT COULD BE EASILY AND REPEATEDLY REPLICATED. NOTE: FATALITY OCCURRED WHEN THE DRIVER, FOR UNKNOWN REASONS, EXITED THE VEHICLE WHILE IT WAS STILL IN MOTION AT UNKNOWN SPEED. DRIVER DIED UPON IMPACT WITH ROAD. VEHICLE CONTINUED OFF ROAD AND CAME TO REST, MOSTLY UNDAMAGED, IN A FIELD WELL OFF ROAD SURFACE. *TT

NHTSA ID

10427754

Incident

Sep 26, 2011

WHILE DRIVING, THE CONSUMER HEARD FUEL SPLASHING AROUND IN THE TANK, WHICH CAUSED FUMES TO COME THROUGH THE VENTS. THE CONSUMER TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC, WHO STATED THE GAS TANK WAS GETTING SOAKED FROM THE FUEL LEAKAGE. THE FUEL TANK WOULD NEED TO BE REPLACED. *JB

NHTSA ID

10064925

1994 FORD EXPLORER XLT 4 WD THE PLASTIC FUEL TANK HAS DEVELOPED A SEVERE FUEL LEAK,,,NOT SAFE TO DRIVE, WAS A RECALL DONE ON THESE ? *JB

NHTSA ID

10056288

Incident

Feb 1, 2004

GASOLINE GUAGE WORKS INTERMITTENTLY OR NOT AT ALL, 4 WHEEL DRIVE DOES NOT WORK, PASSENGER WINDOW IN FRONT SIDE DOES NOT WORK. *AK

NHTSA ID

10032776

Incident

Aug 4, 2003

Mileage

75,000 mi

GAS GAUGE NOT FUCNTIONING FOR MOST 1994 FORD EXPLORERS. *PH

NHTSA ID

10030536

Incident

Jun 3, 2002

Mileage

80,000 mi

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

ACCELERATOR STUCK ON 1994 FORD EXPLORER. VEHICLE WAS STOPPED SAFELY. DATE OF INCIDENT IS 1/8/2003, NOT 2002

NHTSA ID

10000806

Incident

Jan 8, 2002

Mileage

130,000 mi

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

NHTSA ID

764922

Incident

Oct 29, 2001

CONSUMER STATES 4 TIRES AND 1 SPARE WHICH ARE FIRESTONE WILDERNESS AT 15 INCH TIRE(S) (DOT # UNKNOWN) ORIGINAL EQUIPMENT ARE HIGHLY DEFECTIVE. CONSUMER REPLACED THEM DUE TO SAFETY CONCERNS, HOWEVER MANUFACTURER WILL NOT REIMBURSE OR REPLACE TIRES STATING THE CAMPAIGN WAS OVER. *TT THE FUEL PUMP WAS REPLACED 2 TIMES AND THE AIR CONDITION WAS REPLACED. UPDATED.*JB

NHTSA ID

566395

Incident

Jan 1, 1901

I WAS TOLD BY A CERTIFIED FORD DEALER THAT THE FUEL TANK WAS BAD AND THEREFORE THE PUMP AND FUEL LINE WERE ALSO DESTROYED BY RUST AND CORROSION. FORD HAS RECENTLY SEVERED IT'S RELATIONSHIP WITH THE MANUFACTURER BUT WILL NOT COMMENT WHY. FORD REFUSES TO ADDRESS OUR CONCERN, THOUGH ONE C/S REP DID STATE THAT THE FUEL TANK WENT BAD DUE TO THE MILEAGE OF THE VEHICLE. IF THIS IS THE CASE, FORD NEEDS TO TELL CONSUMERS THAT THE PURCHASE OF USED VEHICLES MAY BE PUTTING THE CONSUMER AT RISK FOR SERIOUS PERSONAL INJURY AFTER 135,000 MILES.

NHTSA ID

761406

Incident

Apr 16, 2002

LATE NOVEMBER, 2001, I NOTICED A GASOLINE SMELL. I TOOK THE CAR TO THE DEALER AND WAS INFORMED THAT THE FUEL SENDER HAD CORRODED AWAY. MY RESEARCH SHOWS OTHER RECALLS OF FORD TRUCKS (AEROSTAR) FOR FUEL SENDERS MANUFACTURED IN THE SAME PERIOD (MY CAR MANUFACTURED APPROX. SEPT. 1993). I HAVE CONTACTED MANUFACTURER AND HAVE RECEIVED NO RESPONSE OTHER THAN CUSTOMER SERVICE SAYING THAT IT WASN'T A DEFECTIVE PART.*AK

NHTSA ID

756507

Incident

Nov 25, 2001

GAS SMELL WAS NOTICED INSIDE AND OUTSIDE THE VEHICLE. THE DEALER HAS BEEN NOTIFIED AND INDICATED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE MANUFACTURER HAD BEEN CONTACTED. *AK *NLM

NHTSA ID

898011

CONSUMER NOTICED A FUEL LEAK. ALSO, SMELLED FUEL INSIDE VEHICLE. HE TOOK VEHICLE TO AN INDEPENDENT MECHANIC WHO DETERMINED THAT SENDING UNIT NEEDED TO BE REPLACED DUE TO FUEL PIPE RUSTING THROUGH. *AK

NHTSA ID

897178

Incident

Sep 16, 2001

ENGINE LIGHTS HAS COME ON SEVERAL TIMES, ENGINE RUNS ROUGH IN GEAR AT IDLE, DEALER COULD NOT DUPLICATE THE PROBLEM, ALSO SERPENTINE BELT WAS REPLACED, AS WELL AS THE EGR PRESSURE SENSOR WHICH WAS STICKING, ALSO THERMOSTAT WAS REPLACED.*JB

NHTSA ID

562545

Incident

Dec 11, 2000

FLOATING DEVICE LOCATED IN FUEL TANK THAT MEASURES FUEL LEVELS DEVELOPED A LEAK IN IT AND WOULD NOT WORK PROPERLY. CONSUMER PAID FOR FIRST REPAIR, FORD PAID FOR SECOND REPAI, CONSUMER WILL PAY FOR THIRD REPAIR SINCE ONE YEAR WARRANTY HAS EXPIRED, CONSUMER HAS NOT HAD THE PROBLEM REPAIRED. PLEASE PROVIDE ANY ADDITIONAL INFORMATION/ATTACHMENTS.*AK SHORTED BLOWER RESISTOR CAUSED SMOKE TO COME FROM AC VENTS. NLM

NHTSA ID

893621

Incident

Dec 29, 1998

MAJOR PROBLEM REGARDING IGNITION SYSTEM: FIRST PROBLEM BEGAN ABOUT 6 MONTHS AGO. ON AN INTERMITTENT BASIS, UNABLE TO RESTART THE ENGINE AFTER LETTING IT SIT FOR APPROXIMATELY 5 OR 10 MINUTES. REPEATED ATTEMPTS IN SUCCESSION FAIL TO START THE ENGINE BUT HAVE FOUND THAT IF I GIVE IT A COUPLE OF MINUTES BEFORE TRYING TO CRANK IT UP AGAIN IT WILL USUALLY START. SEEMS TO HAPPEN ONLY AFTER SHORT TRIPS, LESS THAN 10-15 MILES. REPLACED THE FUEL CIRCUIT RELAY 2 MONTHS AGO, HAD ONLY ONE REOCCURRENCE A WEEK LATER. NOW FOR THE PAST 2 MONTHS THERE IS A MUCH WORSE AND POTENTIALLY DANGEROUS PROBLEM. THE ENGINE SHUTS OFF RANDOMLY USUALLY WHILE DRIVING BETWEEN 55-70 MPH. NO SPUTTERS, NO BACKFIRES, NO INDICATIONS THAT THE ENGINE HAS SHUT OFF OTHER THAN THE INSTRUMENT PANEL DIMS AND THE GAUGES STOP READING. THE ENGINE WON'T RESTART UNTIL AFTER A FEW MINUTES HAVE PASSED BEFORE TRYING TO CRANK IT AGAIN. THIS IS VERY DANGEROUS AS IT USUALLY HAPPENS WHILE TRAVELING 70 MPH. DEALERSHIP IS UNABLE TO DUPLICATE THE PROBLEM, NO ERROR CODES ARE REPORTING. FUEL PUMP: FUEL GAUGE NOT WORKING FOR SEVERAL YEARS, HOLE IN FLOAT PER DEALERSHIP, SO ENTIRE FUEL PUMP REPLACED AT MY COST. FUEL GAUGE APPEARED TO BE WORKING CORRECTLY; HOWEVER, ON AN INTERMITTENT BASIS ONCE THE TANK GOT DOWN TO 1/4 FULL THE GAUGE WOULD START OFF AT 1/4 BUT THEN AFTER DRIVING FOR 5 OR 10 MINS. THE GAUGE WOULD GO ALL THE WAY TO FULL. AFTER A FEW MONTHS OF WORKING SPORADICALLY, IT IS NOW CONSISTENTLY GOING TO FULL EVERYTIME THE TANK GETS DOWN TO 1/4. DEALERSHIP DIAGNOSED THE FUEL SENDING UNIT AS DEFECTIVE BUT WILL NOT COVER UNDER THE WARRANTY BECAUSE EVEN THOUGH IT HAS ONLY BEEN 6 MOS. , IT IS APPROX. 2000 MILES OVER THE WARRANTY LIMIT OF 12,000 MILES/12 MONTHS. I WOULD HAVE TO PAY THE SAME $340.00 PARTS & LABOR AS 6 MONTHS AGO. I FEEL THIS IS UNFAIR SO DECLINED THE WORK, NOW BEING CHARGED $67.00 DIAGNOSTIC FEE! CRUISE CONTROL: THE CRUISE CONTROL WON'T ENGAGE ON AN INTERMITTENT BASIS, DEALERSHIP UNABLE TO DUPLICATE.

NHTSA ID

736033

Incident

Apr 15, 2000

VEHICLE WOULD INTERMITTENTLY FAIL TO START. PROBLEM APPEARED AGGRAVATED BY WARM WEATHER AND THE COMPLETION OF A SHORT RUN. SUBSEQUENT DIAGNOSIS BY LISTED DEALER BLAMED FUEL PUMP, ALTHOUGH A SECOND OPINION DISAGREED. AFTER FUEL PUMP REPLACEMENT PROBLEM CON

NHTSA ID

734649

Incident

May 1, 2000

DUE TO DEFECTIVE FUEL SENDER UNIT FUEL LEAKED FROM VEHICLE WHICH MAY HAVE CAUSED A FIRE. *AK SINCE THE FUEL IS CONCEALED, BEING EITHER ATTACHED OR INSIDE THE GAS TANK, THE LEAK COULD NOT BE REPAIRED. AS THE RESULT, IT WAS REPLACED. *YH

NHTSA ID

870002

Incident

Sep 1, 2000

FUEL TUBE THAT PUMPS FUEL FROM TANK HAS CORRODED, CAUSING A FUEL LEAK UNDER PRESSURE. FORD AHS BEEN CONTACTED.*AK

NHTSA ID

868380

Incident

Jul 31, 2000

NO SUMMARY

NHTSA ID

728140

Incident

Aug 16, 2000

AS TANK ON THE TOP AND IN THE MIDDLE IS RUSTED, AND IS LEAKING GAS. *AK

NHTSA ID

859608

Incident

Mar 1, 2000

THE STRAP THE HOLDS THE FUEL TANK IS BROKEN AND NEEDS TO BE REPLACED. THE DEALERSHIP IS AWARE OF THE SITUATION. OWNER HAS BEEN WAITING FOR A REPLACEMENT STRAP FOR OVER 6 MONTHS. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK

NHTSA ID

857869

FUEL FILLER NECK HOSE CRACKED, CAUSING FUEL LEAKAGE. DEALER AND MANUFACTURER HAVE BEEN NOTIFIED. *AK

NHTSA ID

847446

Incident

Aug 30, 1999

EXPLORER ENGINE LIGHT COMES ON AFTER COMBINATION OF 1) DRIVING ON HIGHWAY FOR APPROX. 1 HR AND 2) HAVE TO CLIMB A LARGE HILL...APPROX. 5 MILES AT 60 MPH. TRUCK STUTTERS AND BUCKS WHILE CRUISING AT 55-66MPH WHEN THIS HAPPENS. TRUCK WAS DIAGNOSED APPROX. 10 TIMES. I HAVE ALL DOCUMENTATION FOR TRYING TO RESOLVE PROBLEM. TRUCK HAS SHUT DOWN COMPLETELY DURING ONE OF THESE EPISODES LOSING POWER TO STEERING AND BRAKING. AS A PARENT OF TWO SMALL CHILDREN I'M EVEN MORE CONCERNED. DEALERSHIP TRIED REPLACING FUEL PUMP(2X), TP SENSOR, POTENTIOMETER WITH NO FIX. DEALERSHIP SAID IT COULD BE OXYGEN SENSOR, MASS/MAP SENSOR, THROTTLE CONTROL AT ONE POINT BUT LATER CHANGED MIND. I KNOW OF ONE OTHER EXPLORER WITH SIMILAR PROBLEM. I HOPE THIS ADDS TO YOUR LIST. PLEASE LET ME KNOW IF YOU HAVE ANY INFORMATION.

NHTSA ID

700981