1996 Ford Explorer Engine Problems

I PURCHASED THIS EXPLORER THE FIRST YEAR THAT THE V-8 WAS AVAILABLE. THE EXHAUST MANIFOLD FRACTURED 4 TIMES DURING THE 12 YEARS THAT I HAD THE VEHICLE. THE PART COST OVER $300 AND WAS ON "NATIONAL BACKORDER" FOR OVER A YEAR, SO I HAD MY NEPHEW (CERTIFIED WELDER) WELD THE PIECE TOGETHER AND REINSTALLED BY AN AUTO MECHANIC. MY NEPHEW STATED THAT WHEN YOU HAVE "POT-METAL" WELDED TO STEEL, IT WILL ALWAYS FRACTURE, SO THIS PART WAS NEVER MANUFACTURED CORRECTLY. FORD DENIED MY REQUEST FOR REIMBURSEMENT, EVEN AFTER THE 3RD TIME IT FRACTURED (PERSISTENT PROBLEM?) IT RELEASED FUMES INTO THE CAR THROUGH THE VENTS AND FLOORBOARDS. NOW I SEE THERE IS A PROBLEM WITH THE NEWER EXPLORERS AND I FEEL THAT THIS HAS BEEN A MANUFACTURING PROBLEM FOR MANY, MANY YEARS, BUT JUST NOW HAS CAUGHT UP WITH FORD BECAUSE IT WAS INVESTIGATED BY NEWS MEDIA, WHERE I HAD NO RECOURSE BACK IN THE DAY FOR THE CORRECTION ON MY VEHICLE.

NHTSA ID

11046568

Incident

Jan 1, 1996

Mileage

5,000 mi

15 MINUTES AFTER PARKING THE VEHICLE AND GETTING OFF THE VEHICLE CAUGHT ONFIRE UNDER THE HOOD IN THE DRIVERS SIDE. THE FIRE EXPANDED QUICKLY CAUGHT DRIVERS SIDE FRONT TIRE AND MOVED ON TO THE ENTIRE MOTOR BEFORE THE FIREFIGHTERS CAME AND STOPPED THE FIRE. *TR

NHTSA ID

10563623

Incident

Feb 8, 2014

Mileage

149,000 mi

I OWN A 1996 FORD EXPLORER SPORT 4X4, 4.0 LITER V6 WITH 5 SPEED MANUAL TRANSMISSION. THIS IS A MOTOR MADE IN GERMANY AND THE TRUCK, IN THE LOUISVILLE, KY. FORD PLANT. RODENTS TOOK UP RESIDENCE IN THE HEATING SYSTEM, AND FILLED THE HEATER BLOWER ASSEMBLY AND DUCTING WITH SCAVENGED MATERIALS, WHICH TOOK UP APPROX. 1 CUBIC FOOT OF SPACE, ONCE EXTRACTED. MUCH TO MY BENEFIT, THE MATERIAL JUST SO HAPPENED TO BE FIRE RESISTANT STUFFING FROM MY ARCHERY TARGET, STORED IN THE SAME BUILDING. I STARTED MY VEHICLE AND IMMEDIATELY UPON TURNING ON THE HEATER, I HEARD A TERRIBLE NOISE WHICH ENDED ABRUPTLY. MY HEATER STOPPED WHEN THE NOISE STOPPED. IN AN EFFORT TO DIAGNOSE THE PROBLEM I INSPECTED THE ENGINE COMPARTMENT. I THEN NOTICED A BURNT SMELL, BUT SAW NO SMOKE. UPON REPLACING MY BLOWER MOTOR I INSPECTED THE OLD ONE, WHICH HAS CHARRED REMNANTS OF THE FOREIGN MATERIAL INSIDE AND WRAPPED AROUND THE ELECTRICAL COMPONENTS. THE ONLY OPENING TO THE INNER COMPONENTS OF THE BLOWER MOTOR IS ABOUT 1" IN DIAMETER AND HAS A RUBBER TUBE PLUGGED INTO IT. IT APPEARED UNDISTURBED AND WAS CONNECTED WHEN I FIRST SERVICED IT. I ALSO DISCOVERED AN OPENING ON THE LOWER SIDE OF THE BLOWER FAN HOUSING, NEAR THE FIREWALL. THIS UNOBSTRUCTED OPENING FACILITATED THE RODENTS' ENTRY TO THE HEATING SYSTEM. IT IS OF MY OPINION THIS IS UNSAFE, AND HAD THE FOREIGN MATERIAL NOT BEEN FLAME RESISTANT, I'M CONVINCED MY VEHICLE WOULD HAVE BURNED. I ENTERED MY VIN NUMBER INTO FORD'S OFFICIAL WEB SITE, AND WAS RETURNED ZERO RESULTS FOR RECALLS OF ANY SORT. I DID NOT FIND ANY RECALLS RELATED TO HEATER BLOWERS FOR SIMILAR MODELS EITHER. I HAVE REPAIRED THE HEATING SYSTEM BUT AM AT A LOSS FOR HOW TO PREVENT THIS IN THE FUTURE, AS THIS OPENING STILL EXISTS AND I'M UNAWARE OF ANY SANCTIONED REMEDIES. *TR

NHTSA ID

10560811

Incident

Jan 1, 2014

Mileage

178,000 mi

1996 FORD EXPLORER VEHICLE CAUGHT ON FIRE WHILE TRAVELING. (OHIO TRAFFIC CRASH REPORT # 10-0629-91)8JB UPDATED 04/22/11 *BF

NHTSA ID

10370063

Incident

Oct 27, 2010

1996 EXPLORER, HAS BEEN A GREAT VEHICLE. STARTED LOOSING POWER AND SHIFTING DOWN AND STRANGE TIMES. THEN THE O/D FAIL LIGHT STARTED TO FLASH. I UNDERSTAND THIS IS A COMMON FAILURE AND FORD KNOWS ABOUT IT BUT REFUSES TO ACKNOWLEDGE THE FACT OR ACCEPT RESPONSIBILITY. THEY NEED TO RECALL THESE TRANSMISSIONS. *TR

NHTSA ID

10328640

Incident

May 3, 2010

Mileage

178,450 mi

I HAD TO REPLACE THE INTAKE MANIFOLD OF THE 1996 FORD EXPLORER AT MILE NUMBER 163400 ON MARCH 30, 2007. IT WAS LEAKING AT #1 CYLINDER. THERE WAS A 'ECRET WARRANTY' IN EFFECT. I BELEIVED FOR EXPLORER'S 10 YEARS OLD AND YOUNGER. MINE WAS JUST OVER THE 10 YEAR MARK. *AK

NHTSA ID

10193521

Incident

Mar 30, 2007

Mileage

163,400 mi

CONTINUOUS ISSUES WITH THE PCV/EGR SINCE VEHICLE PURCHASE IN 1998. SPENT OVER $1200 ATTEMPTING TO RESOLVE THE PROBLEM. BOTH INDEPENDENT AND DEALER MECHANICS HAVE BEEN INVOLVED WITH NO SUCCESS. THE CEL LIGHT HAS BEEN ON FOR OVER THREE YEARS NOW BECAUSE I NO LONGER WISHED TO SPEND MONEY DIAGNOSING THIS PROBLEM. *JB

NHTSA ID

10104621

Incident

Dec 1, 1998

Mileage

48,000 mi

SUDDEN AND TOTAL RELEASE OF ALL AIR CONDITIONING REFRIGERANT (R134A) AND COMPRESSOR OIL.*AK

NHTSA ID

10060014

Incident

Feb 16, 2004

Mileage

1 mi

I HAVE RESEARCHED AND FOUND NUMEROUS COMPLAINTS ABOUT BLOWN OR LEAKING HEAD GASKETS ON THE 1996 FORD EXPLORER, AND THAT IS MY COMPLAINT IS.I HAVE A 1996 FORD EXPLORER XLT WITH 66,000 MILES IS GARARGED YEAR ROUND AND IS MAINTAINED REGULARLY AND IS ONLY DRIVEN BY MY WIFE LOCALY BACK AND FORTH TO WORK APPROXIMATLY 10-20 MILES A DAY I FEEL THAT THERE IS NO WAY I SHOULD HAVE BOTH HEAD GASKETS LEAKING COOLANT WITH REALITIVLY LOW MILEAGE FOR THE YEAR.THERE IS DEFINATLY A PROBLEM HERE AND FEEL THAT THIS NEEDS TO BE INVESTIGATED FURTHER BY FORD, I WAS ALSO SPEAKING WITH A GENTLEMAN AT A LOCAL AUTO PARTS STORE (WHERE I WORK PART TIME ) AND HE IS HAVING THE SAME PROBLEM WITH HIS 1998 FORD EXPLORER XLT, BOTH ENGIES INVOLVED ARE THE 4.0 V6. I HOPE FORD WILL DO WHAT IS NESESARY TO RECTIFY THIS PROBLEM NOT ONLY FOR MYSELF BUT FOR OTHERS THAT WILL ULTIMATLY HIT THEM QUITE HARD IN THE POCKETBOOK FOR WORK DONE AT A SEVICE CENTER.I DO NOT WANT TO DRIVE THE VEHICLE UNTILL I FIND OUT WHAT CAN BE DONE BY FORD BUT HAVE TO IN ORDER TO GET MY WIFE BACK AND FORTH TO WORK, I DO NOT KNOW IF ANYTHING CAN BE DONE TO SEAL THE PROBLEM WITHOUT TAKING THE HEADS OFF AND REPLACING THE GASKETS.I HAVE CHECKED INTO WHAT THE COST WOULD BE AND HAVE BEEN TOLD ANYWHERE FROM $1,200-$1,500 DOLLARS,A BILL I CANNOT AFFORD.IT IS A SHAME BECAUSE WE LOVE THE VEHICLE AND HAVE HAD A NUMBER OF FORD PRODUCTS BUT ARE SERIOUSLY CONSIDERING TRADING IT IN ON ANOTHER BRAND OF VEHICLE.*AK

NHTSA ID

10057052

Incident

Oct 1, 2003

Mileage

60,000 mi

THE HEADS ON THE ENGINE CRACKED. AS A RESULT THE ENGINE SKIPPED WHEN THE VEHICLE WAS STARTED. PLEASE PROVIDE ANY ADDITIONAL INFORMATION. *NLM

NHTSA ID

10048654

Incident

Jul 1, 2001

Mileage

125,000 mi

WHILE VEHICLE IDLED ENGINE STARTED TO RACE. THEN, VEHICLE WAS TRYING TO MOVE WITH BRAKES APPLIED. *AK

NHTSA ID

10040556

Incident

Sep 24, 2003

WHILE DRIVING AT ANY SPEED AND WITHOUT WARNING, THE ENGINE SHUT OFF, WHICH CAUSED THE CONSUMER TO PULL OVER. DEALER HAD BEEN NOTIFIED. *AK THE LOWER ENGINE LOCKED, THE POWER STEERING LEAKED AT THE RACK ASSEMBLY, THE BELT TENSIONER WAS FAULTY AND THERE WAS A WHINING NOISE FROM THE POWER STEERING WHEN TURNING LEFT, RIGHT OR AT STAND STILL. *SCC *JB

NHTSA ID

10034178

Incident

Aug 10, 2003

Mileage

53,264 mi

REPAIR SHOP STATED THAT THE EXPLORER BY FORD HAS A WEAK SPOT THAT HE HAS HAD TO REPAIR ON NUMEROUS OCCASIONS. IT IS THE L CYLINDER #4 THAT CRACKED.

NHTSA ID

10030448

Incident

Jul 27, 2003

THE FLY WHEEL IN THE ENGINE WAS REPLACED 4 TIMES.

NHTSA ID

10014626

Incident

Mar 27, 2003

1) NO HEAT, ONLY BLOWS COLD AIR. 2) TRANSMISSION DOES NOT SHIFT SMOOTHLY FROM REVERSE TO DRIVE.

NHTSA ID

10002776

Incident

Nov 18, 2002

Mileage

78,000 mi

THE VEHICLE CHECK ENGINE LIGHT COMES AND STAYS ON ALL DAY. DEALERSHIP CHANGE SEVERAL SENSORS WITHIN THE ENGINE, BUT ENGINE LIGHT STILL REMAINS ON. PLEASE PROVIDE MORE DETAILS. TS

NHTSA ID

8021977

VEHICLE STALLS AT AT A STOP. CONSUMER HAS TO REV ENGINE HARD TO KEEP IDLING. DEALER HAS BEEN INFORMED, BUT HAS FOUND NO PROBLEM. *AK

NHTSA ID

8013832

Incident

Jun 27, 2001

ENGINE OVERHEATED DUE TO LEAK FROM HEAD GASEKTS. TOO MUCH WEAR ON GASKETS FOR ONLY 75,000 MILES. *TT

NHTSA ID

785997

Incident

May 15, 2002

WHILE DRIVING, VEHICLE MAKES A LOUD HUMMING SOUND WHICH COMES FROM FRONT END OF VEHICLE. ALSO, TRANSMISSION HAS FAILED. CONSUMER CONSTANTLY HAS TO TAKE VEHICLE TO DEALER. *AK THE CHECK ENGINE LIGHT ILLUMINATED. THE SPEED SENSOR AND THE O2 SENSOR WERE REPLACED. JG

NHTSA ID

8009112

AT 65MPH THE VEHICLE LOST ALL POWER BECAUSE FLYWHEEL'S CENTER HUB BROKE. VEHICLE IS CURRENTLY BEING INSPECTED BY A INDEPENDENT MECHANIC. MANUFACTURER AND DEALER HAVE NOT BEEN NOTIFIED. PLEASE ADD MORE INFORMATION.*AK

NHTSA ID

8008704

Incident

Apr 25, 2002

WHILE TRAVELING AT VARIOUS SPEEDS (5 MPH - 75 MPH), THE ENGINE STALLS WITHOUT WARNING FOR APPROXIMATELY 5-10 SECONDS AND THEN EITHER RESUMES OPERATION ON ITS OWN, OR MUST BE RESTARTED WHILE COASTING IN NEUTRAL. SOMETIMES THE ENGINE WILL RESTART EASILY, BUT SOMETIMES IT TURNS OVER SEVERAL TIMES BEFORE RESTARTING. OBVIOUSLY THIS HAS CREATED SOME EXTREMELY DANGEROUS SITUATIONS FOR MYSELF AND MY FAMILY. LOSING POWER ASSISTED FUNCTIONS (STEERING, BRAKING) AT HIGH SPEEDS HAS LEFT ME WITH LITTLE CONTROL OF THE VEHICLE ON SEVERAL OCCASIONS. I HAVE HAD THIS PROBLEM INVESTIGATED TWICE AT A FORD DEALERSHIP BUT THEY HAVE BEEN UNABLE TO FIND A PROBLEM. THEY ALSO INSTALLED A FLIGHT RECORDER ON THE VEHICLE TO MONITOR THE ERROR CODES WHEN THE PROBLEM HAPPENED BUT WERE UNABLE TO FND ANYTHING CONCLUSIVE. AFTER READING THE MANY REPORTS OF STALLING ON THIS WEBSITE I FIND IT HARD TO UNDERSTAND HOW THIS ISSUE COULD NOT BE CONSIDERED A DEFECT AND A SERIOUS SAFETY ISSUE. I WOULD TRULY LIKE TO RECEIVE ANY ASSISTANCE OR GUIDANCE ON HOW TO RESOLVE THIS MATTER. IT IS UNFAIR THAT FORD SELLS THE EXPLORER WITH OBVIOUS SAFTELY ISSUES BUT IS UNABLE TO FIX THEM.*AK

NHTSA ID

760090

Incident

Sep 1, 2000

VEHICLE WILL STALL OUT AND LOSE POWER STEERING AND ABS SYSTEM WHILE DRIVING ON THE FREEWAY. CONTACTED DEALER, AND THE DEALER WAS NOT WILLING TO DO ANY WORK ON VEHICLE. *AK

NHTSA ID

8003720

Incident

Feb 1, 2001

THE CRANKSHAFT SPLIT DIRECTLY IN HALF.

NHTSA ID

562455

THE VEHICLE SHUT OFF COMPLETELY WHILE THE CONSUMER WERE DRIVING ON HIGHWAY, THE DEALER FOUND OUT THAT THE CRANKSHAFT HAD SPLIT IN HALF, CONSUMER WANTS THE MANUFACTURER TO PAY PART OF THE COST OF REPAIR. *YH

NHTSA ID

562255

ON THE FREEWAY CAR STOPPED RUNNING. CRANK SPLIT IN TWO. SERVICE REP COULDN'T BELIEVE IT. *AK

NHTSA ID

748343