1996 Ford Explorer Fuel system 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

TL* THE CONTACT OWNS A 1996 FORD RANGER. THE CONTACT STATED THE STRAPS TO THE GAS TANK RUSTED AND BROKE CAUSING THE GAS TANK TO DROP TANK DROPPED ONTO DRIVESHAFT CAUSING FUEL LEAKAGE. THE VEHICLE HAD NOT BEEN INSPECTED. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 194,000. UPDATED 09/29/2011 *LN *TR

NHTSA ID

10419805

Incident

Aug 10, 2011

Mileage

194,000 mi

WHILE WE WERE DRIVING ON I-84 NEAR MIDDLETON, ID, OUR GAS PEDAL (THROTTLE PEDAL) UN-WELDED (FELL OFF) COMPLETELY. WE GOT TO THE SIDE OF THE ROAD (IT SLOWED DOWN--WASN'T "STUCK" AT ANY SPEED) AND DIDN'T HAVE AN ACCIDENT. WE WERE TOWED TO CALDWELL, ID, WHERE A MECHANIC REPAIRED IT. I THINK HE PUT IN 3 NUTS/BOLTS TO KEEP THE PEDAL AFFIXED. I HAVE CALLED FORD MOTOR CO. (DID ON 8/16/10), BUT OBVIOUSLY THIS COULD'VE BEEN VERY DANGEROUS. WE GOT LUCKY. I WONDER IF OTHER FORDS HAVE HAD WELDED PARTS FALL OFF/UN-WELD WHILE DRIVING. *TR

NHTSA ID

10352174

Incident

Aug 15, 2010

Mileage

205,000 mi

TL*THE CONTACT OWNS A 1996 FORD EXPLORER. THE CONTACT STATED THAT DASHBOARD LIGHTS WERE TOO DIM. THE GAS CAP WAS NOT SECURE ON THE TANK AND DID SHE WAS UNABLE TO REPLACE THE GAS CAP ON TIGHT. THE DEALER ADVISED HER THAT THE CATALYTIC CONVERTER NEEDED TO BE REPLACED BECAUSE IT ADDED TO THE POLLUTION. SHE RECEIVED RECALL NOTICE 09V399000,VEHICLE SPEED CONTROL AND THE DEALER REPLACED THE CATALYTIC CONVERTER INSTEAD OF THE SPEED CONTROL DEACTIVATION SWITCH. SHE CALLED THE DEALER AND THE MANUFACTURER BUT RECEIVED NO ASSISTANCE. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 157,000.

NHTSA ID

10316850

Incident

Aug 17, 2009

Mileage

157,000 mi

STRONG ODOR OF FUEL INSIDE VEHICLE.*AK

NHTSA ID

10086478

Incident

Aug 8, 2004

I HAD THIS SAME PROBLEM WITH MYH 1994 EXPLORER. WHEN THE TEMPERATURE IS OVER 85 DEGREES OUTSIDE AND THE AIR CONDITIONER IS ON, WE GET AN EXTREMELY STRONG ODOR OF RAW GASOLINE INSIDE THE CAR. IT MAKES US NAUCEOUS. THIS HAPPENS ESPECIALLY WITH IN-TOWN STOP AND GO DRIVING. *AK

NHTSA ID

751129

FUEL PUMP WAS BEING REPLACED. TOWNSEND FORD PERFORMED THE JOB. TECH BROKE CHEAP PLASTIC CLIP REQUIRING FUEL FILLER NECK TO BE REPLACED. IT'S DEFECTIVE. WILL NOT SEAL. GAS VAPOR LEAK. CHECK ENGINE STAYS ON. FORD HAS PROBLEM WITH SUPPLIER. NONE IN COUNTRY TOLD TO ME ABOUT A COUPLE MONTHS AGO. STILL NONE NOW. GAS VAPOR LEAK IS HEALTH HAZARD AND UNSAFE IN MY OPINION. THEY KEEP BLOWING ME OFF ON RESOLUTION. CAN YOU HELP? -THANKS-*AK

NHTSA ID

749938

Incident

Apr 2, 2001

THE DEALER IS BEEN INFORMING THAT THEY ARE WORKING ON FUEL GUAGE PROBLEM FOR ALMOST 1 YEAR AND REPLACED THE ASSEMBLY IN THE FUEL TANK AND CONTACTED FORD SEVERAL TIMES. I ALSO CONTACTED THEM AND SPOKE TO SHAWN @ 1-800-392-3673 EXTN: 3066. HE TOLD ME FORD WILL CONTACT ME, BUT, FAILED TO CONTACT. ABS PROBLEM CAME RECENTLY. DEALER REAPLACED A PART, BUT, DID NOT RESOLVE THE PROBLEM. AS PER THE DEALER THE FORD MOTORS ARE AWARE OF THE FUEL GUAGE PROBLEM FROM THE BEGINING BUT, FAILED TO COME UP WITH A RECOMMENDATION.

NHTSA ID

748925

Incident

May 1, 2001

A STRONG SMELL OF FUEL INSIDE OF VEHICLE. DRIVER HAS TO ROLL DOWN WINDOWSBECAUSE FUMES MAKE CONSUMER SICK. *AK

NHTSA ID

883294

Incident

Mar 16, 2001

DURING A ROUTINE TRANSMISSION FLUID AND FILTER CHANGE I DISCOVERED A POTENTIAL PROBLEM.DURING THE REFILL AND CHECK OF PROPER FLUID LEVEL THE DIPSTICK GIVES A FALSE INDICATION THAT THE FLUID IS AT THE CORRECT LEVEL. IT INDICATED TO ME THAT THE LEVEL WAS OVER FULL. THIS WAS EVEN VERIFIED BY A CERTIFIED ASE TECHNICIAN AT A LOCAL WALMART. HE NOTED THE LEVEL WAS LOW. I DISCOVERED THAT YOU HAVE TO LOOK AT THE OPPOSITE SIDE OF THE DIPSTICK TO ACQUIRE THE CORRECT READING. BY DOING THIS I DISCOVERED THE FLUID WAS NEARLY 2 QUARTS LOW. THE READING ON THE FRONT SIDE NEVER CHANGED WHERE THE CROSS HATCHED INDICATORS ARE. THIS COULD BE FIXED BY A SIMPLE CHANGE IN THE DIPSTICK. THIS PRESENTS A PROBLEM OF TRANSMISSION FAILURE DUE TO IMPROPER FLUID LEVELS. I BELIEVE OWNERS SHOULD BE NOTIFIED. *AK

NHTSA ID

740452

FUEL PUMP BROKE. THERE WAS A RECALL FOR THIS PROBLEM, BUT THIS VEHICLE WAS NOT AFFECTED BY RECALL ALTHOUGH IT HAS SAME PROBLEM. *AK WITH CRUISE CONTROL ENGAGED, VEHICLE WON'T STOP UNLESS CONSUMER STOMPED ON GAS PEDAL SEVERAL TIMES, CONSUMER STATES THE GAS PEDAL SEEMED STUCK AND ACCELERATION WOULDN'T STOP. *SLC

NHTSA ID

879483

Incident

Dec 1, 1997

TRANSMISSION FAILED TWICE UNDER NORMAL DRIVING CONDITIONS. LOST POWER UNDER CERTAIN CIRCUMSTANCES. SAME PROBLEM BOTH TIMES. ENGINE SEIZED WHEN VEHICLE HIT A PUDDLE OF WATER AT LOW SPEED. AIR INTAKE IS MOUNTED UNUSALLY LOW ON THIS EXPLORER ALLOWING WATER INTO THE COMBUSTION CHAMBER AND CAUSING HYDROSTATIC LOCK. FORD MOTOR COMPANY HAS BEEN CONTACTED AND READS A SCRIPTED RESPONSE WHEN I HAVE TRIED TO GET ANY ADDITIONAL INFORMATION ABOUT WHAT I CONSIDER A SERIOUS DESIGN FLAW. *AK

NHTSA ID

740037

Incident

Nov 5, 1999

FUEL SHUT OFF SWITCH ACTIVATED BY FRONT PASSENGER'S LEG TWICE WHILE VEHICLE IN OPERATION*AK

NHTSA ID

735745

Incident

Oct 25, 2000

GAS GAUGE DOES NOT MOVE WHEN FILLED WITH GAS OR WHILE DRIVING. CAUSE UNKOWN. DEALER CANNOT CORRECT PROBLEM. *AK THE TEMPERATURE GAUGE IS ERRATIC, DEALER REPLACED A WIRING HARNESS, HOWEVER THIS DID NOT WORK, DEALER CAN NOT REMEDY THE ERRATIC TEMPERATURE GAUGE OR THE INACCURATE GAS GAUGE. *SLC

NHTSA ID

824240

Incident

Jun 26, 1996

ENGINE AND FUEL INJECTION MALFUNCTION. CHECK ENGINE LIGHT FLASHED, ENGINE RPM'S RAISE TO 4000-5000 WITHOUT ACCELERATION, VEHICLE JERKS AS IF RECEIVING FUEL INTERMITTENTLY. VEHICLE SOMETIMES STALLS AND/OR WILL NOT START.

NHTSA ID

529567

Incident

Jan 8, 1997

HEATER SWITCH FAILED.

NHTSA ID

603599

Incident

Jul 1, 1996

FUEL GAUGE FAILED.

NHTSA ID

606096

EXTREME FUEL FUMES INSIDE VEHICLE.

NHTSA ID

604871

Incident

May 1, 1996

VEHICLE WAS DRIVEN AND PARKED ON THE CARPORT, UNDER THE HOOD COMPARTMENT FIRE, CAUSING THE VEHICLE/CARPORT TO COMPLETELY BURN. ALSO, SMOKE DAMAGES, FIR EWAS CAUDED BY FAULTY FUEL INJECTORS. *AK

NHTSA ID

811733

Incident

Apr 22, 1997

FUEL GAUGE INOPERATIVE.

NHTSA ID

602775

Incident

Jun 1, 1996

WATER SPLASHED UP INTO THE AIR INTAKE PORT, CAUSING ENGINE TO SEIZE.

NHTSA ID

510332

Incident

Sep 17, 1996

FUEL VENT TUBE FAILED, FUEL SPRAYED OUT OF THE FUEL TANK WHEN FILLING THE TANK. *AK

NHTSA ID

980704

Incident

Feb 14, 1996

A SPLINTERED TWO BY FOUR PIERCED THE GAS TANK. TT

NHTSA ID

976716

Incident

Dec 14, 1995