1996 Ford Explorer Visibility Problems

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

APPROXIMATELY ONE DAY AFTER TRUCK WAS PURCHASED FROM DEALER, IT WAS NOTED THAT, WITH THE EXCEPTION OF THE DRIVER'S WINDOW, NONE OF THE WINDOWS IN THE TRUCK WOULD OPEN. THIS IS A SAFETY HAZARD AS IN THE EVENT OF AN ACCIDENT, PASSENGERS IN THE BACK SEAT WOULD NOT BE ABLE TO OPEN WINDOWS IF NEEDED FOR ESCAPE (DOORS IN PASSENGER SECTION OF TRUCK DID NOT WORK EITHER. SEE PREVIOUS COMPLAINT). *TR

NHTSA ID

10535187

Incident

Dec 27, 2012

Mileage

72,444 mi

96' FORD EXPLORER EDDIE BAUER EDITION CLIMATE CONTROL STOPPED WORKING. IT ONLY BLOWS COOL AIR. SHOP WANTS $900 TO REPLACE THE BLEND DOOR. I CAN'T DRIVE DURING WINTER IF THE WINDOWS FROST OR FREEZING RAIN. IMPAIRED VISIBILITY. *TR

NHTSA ID

10292116

Incident

Nov 23, 2008

MY FORD EXPLORER '96 SUV CABIN CLIMATE CONTROL STOPPED WORKING 2 YRS AGO AT 70K MILES. IT ONLY BLOWS BURNING HOT AIR OR FREEZING COLD AIR. DEALER WANTS $900 TO REPLACE THE BLEND DOOR. FORD WILL NOT FIX THIS. THE VEHICLE WAS EXPENSIVE & THIS IS A MANUFACTURING DEFECT THAT RUINS THE UTILITY OF THE VEHICLE. IN WINTER, WINDOWS FROST IMPAIRING VISIBILITY. THIS IS THE TOP-OF-THE-LINE EDDIE BAUER EDITION...FORD NEEDS TO TAKE RESPONSIBILITY FOR ITS MANUFACTURING DEFECTS. *JB

NHTSA ID

10205799

Incident

Sep 14, 2005

Mileage

69,000 mi

FRONT WINDSHIELD WIPERS FAIL TO OPERATE DURING WET/RAINING WEATHER. THE CONDITION IS INTERMITTENT, IE MOST WET CONDITIONS CAUSE THIS 'LOCK-UP' CONDITION. TURNING IGNITION OFF-AND-ON AGAIN IN ATTEMPT TO RESET FUNCTION DOES NOT WORK. IN ADDITION THE INTERIOR LIGHTS, REAR WIPER, ALL POWER WINDOWS, AND 4-WHEEL DRIVE FUNCTIONS FAIL. THE DEALERSHIP ENDED UP REPLACING THE, YOU GUESSED IT, GEM MODULE - THE SAME ONE CITED IN THE RECALL FOR OTHER YEAR VEHICLES. THERE IS A RECALL (NUMBER 00V072000) FOR A SIMILAR PROBLEM ON THE SAME VEHICLE MAKE AND MODEL BUT FOR YEARS 1999 AND 2000. THIS IS A 1996 FORD EXPLORER 4X4 AND HAS EXHIBITED THIS PROBLEM FOR SEVERAL YEARS NOW, ONLY RECENTLY WAS THE DEALERSHIP ABLE TO DETERMINE THAT THE GEM MODULE WAS THE APPARENT CULPRIT. *NM

NHTSA ID

10180887

Incident

Jan 16, 2007

Mileage

147,789 mi

THE AIR CONDITIONING BLEND DOOR ON MY CAR IS STUCK AND WILL NOT DEFROST THE WINDSHIELD EVEN ON COLD WINTER AND ICE DAYS, INCLUDING DURING ICE STORMS. THIS IS A HUGE SAFETY ISSUE BECAUSE WE CANNOT GET THE ICE OFF THE WINDSHIELD. WE HAVE BEEN TRYING TO GET THIS PROBLEM RESOLVED AND FIXED BY FORD MOTOR COMPANY FOR A LONG TIME NOW WITH NO RESULTS. NOW THAT ITS SUMMER, THE BLEND DOOR IS STUCK ON HOT AND ITS ONLY BLOWING COMPLETELY HOT AIR - THIS IS DUE TO A KNOWN DESIGN AND MATERIAL DEFECT WITH THE BLEND DOOR AND HAS BEEN REPORTED BY THOUSANDS OF OWNERS FOR ALL 1995 - 1999 FORD EXPLORERS AND STILL FORD REFUSES TO FIX IT AND TO PROVIDE COVERAGE TO ITS CONSUMERS TO FIX IT. IN THE WINTERS THIS IS A VERY SERIOUS SAFETY ISSUE BECAUSE OF THE CAR'S INABILITY TO DEFROST/DEFOG THE WINDSHIELD. *JB

NHTSA ID

10159948

Incident

Feb 2, 2005

Mileage

78,000 mi

FORD EXPLORER REAR WINDOW: ON 4/19/2006, TEMP. NEVER REACHED OVER 80 DEGREES AND THE REAR WINDOW EXPLODED. SUMMER OF 2005, I HAVE 5 CO-WORKERS STATED THEIR REAR WINDOW EXPLODED AS WELL. THE COMPANY WHO REPLACED THE REAR WINDOW, STATED THEY (FORD EXP.) ARE NOTORIOUS FOR THIS. WHY IS THERE NO RECALL FOR THIS OR FORD BE MADE TO PUT A HIGHER QUALITY WINDOW IN? *JB

NHTSA ID

10158209

Incident

Apr 19, 2006

SUDDEN TREAD SEPARATION ON LEFT REAR TIRE OF FORD EXPLORER CAUSED LOSS OF CONTROL AND ON-ROAD ROLLOVER. TIRE WAS A COOPER ELDORADO RADIAL ZR1, SIZE P23575R15, DOT# 3DHLEKN2900.

NHTSA ID

10124607

Incident

Aug 8, 2004

WIPERS FAIL REGULARLY. 5/01 MOTOR REPLACED. 10/02 STEM REPLACED. 1/03 RELAY REPLACED. 9/03 MOTOR REPLACED AGAIN.

NHTSA ID

10038897

Incident

Sep 15, 2003

THE BLEND DOOR FROZE -THIS DISABLES THE CARS HEATING AIR CONDITION AND DEFROSTING SYSTEMS I CONTACTED THE DEALER- AND WAS TOLD IT WOULD COST $100.00 TO DETERMINE IF THAT WAS THE PROBLEM AND THAT FORD WOULD NOT HELP(THE DEALER CHECKED) ---I THEN CONTACTED FORD MYSELF--I WAS TOLD TOO BAD--NO HELP . *JB

NHTSA ID

10013765

Incident

Jan 4, 2003

EXPERIENCED FAILURE OF HEATER/DEFROSTER IN COLD WEATHER. FORD DEALER IN ATHENS AL WANTED $1000 TO CORRECT FAILURE.*AK

NHTSA ID

757618

Incident

Jan 10, 2002

THE PLASTIC BLEND DOOR BREAKS AND YOU HAVE NO CONTROL OF HOT/COLD TEMP ON TRUCK. *AK

NHTSA ID

757123

Incident

Dec 21, 2001

PART THAT SWITCHES HEAT TO AIR CONDITIONER IS WARPED ,CAUSE UNKNOWN. PLEASE GIVE FURTHER DETAILS.*AK

NHTSA ID

884543

WHEN DRIVING THIS FALL I FOUND THAT WHEN USING THE VENT I GOT NOTHING BUT HOT AIR, THEN THE AUTOMATIC SETTING ON THE HEAT/AIR TEMPERATURE CONTROL WOULD NOT REGULATE PROPERLY. IT WOULD GO TO EXTREMES TO 85+ DEGREES, THEN DROP OFF AND BLOW UNTIL IT WAS DOWN TO 60 AND THEN BACK UP TO 85 CONTINUOUSLY. I WENT ACCORDING TO THE OWNER'S MANUAL, WHICH STATED I NEEDED TO HAVE IT PUT ON THE COMPUTER AND CHECKED AT THE DEALER. AFTER THEY KEPT MY CAR 2 X AS LONG AS PROMISED AND CHARGING ME $100 TO CALL THE ENGINEERS AT FORD ITSELF, THEY TOLD ME IT WAS THE BLEND DOOR IN THE HEATER PLENUM. THIS DOOR IS APPARENTLY MADE OF PLASTIC AND BREAKS. IN MY CASE IT WORKED FOR A LITTLE WHILE, BUT VERY SLOWLY, AND WAS IN THE PROCESS OF BREAKING. IT CURRENTLY DOES NOT WORK AND IS STUCK IN THE AIR CONDITIONING SIDE. I GET NO HEAT AND CAN'T DEFROST MY WINDOWS. I LIVE IN WISCONSIN AND WE ARE EXPECTING FREEZING RAIN TODAY, NOT TO MENTION SNOW LATER THIS WEEK. THE DEALER HAS TOLD ME THAT THE ENGINEER THEY TALKED TO SAID THIS HAS HAPPENED BEFORE. IF IT IS A BAD DESIGN, BUT BECAUSE IT IS NOT OFFICIALLY A DEFECTIVE PART ON THEIR LIST, THEY COULD NOT FIX IT WITHOUT CHARGING ME ANOTHER $700 ON TOP OF THE $100 ALREADY SPENT TO DIAGNOSE THE PROBLEM. I HAVE FOUND ON THE INTERNET THAT I AM NOT THE ONLY ONE THIS HAPPENED TO (SEE MIGHTYAUTOPARTS.COM, ON THE LINE WITH LARRY HAMMER - EXPLORING THE LIMITS OF PATIENCE). THE NEWLY DESIGNED DOOR IS MADE OF NYLON THAT IS STRONGER AND LESS SUSCEPTIBLE TO BREAKING. WHEN CONTACTING FORD CUSTOMER 1ST TO LET THEM KNOW ABOUT MY VISIT, THEY SAID AN ADVISOR WOULD BE ASSIGNED TO ME AND WOULD CONTACT ME THE NEXT DAY, THAT WAS 2 WEEKS AGO. I FEEL I AM BEING GIVEN THE RUN-AROUND. I AM DRIVING IN AN UNSAFE VEHICLE. FORD WILL NOT TAKE ANY RESPONSIBILITY FOR THE BAD DESIGN. I FULLY APPRECIATE AND ACCEPT THAT THINGS WEAR OUT ON VEHICLES AND NEED TO BE REPLACED, BUT DEFECTIVE DESIGN SHOULDN'T BE AT MY EXPENSE, IN DOLLARS OR SAFETY.

NHTSA ID

740083

Incident

Oct 15, 2000

LEFT FRONT SEAT ROCKS IN FULL ELEVATED POSITION, DEALER SAID IT WAS NORMAL PLAY IN THE POWER SEAT TRACK. NLM

NHTSA ID

558876

Incident

Dec 11, 2000

DUE TO DEFECTIVE REAR DEFROSTER, CAR BURNED AND WAS COMPLETE LOSS. FORD WAS CONTACTED BUT CLAIMED THAT THEY WERE NOT LIABLE BECAUSE NO OPEN RECALLS EXISTED. THE REPRESENTATIVE IN THE CONSUMER AFFAIRS REFUSED TO GIVE ME THEIR NAME AND REFUSED MY REPEATED (3X) REQUESTS TO SPEAK WITH THEIR SUPERVISOR. *AK

NHTSA ID

738910

Incident

Dec 28, 2000

DESIGN OF CONSOLE CAUSES REARVIEW MIRROR PLACEMENT TO BE TOO LOW. THIS CREATES A BLIND SPOT FOR DRIVER WHEN TRYING TO MERGE RIGHT. VEHICLE WAS TAKEN TO DEALERSHIP. DEALERSHIP SEEMS TO RECOGNIZE THAT THIS IS A DESIGN FLAW. FORD HAS AGREED TO LOOK INTO THIS MATTER. PLEASE PROVIDE ANY FURHTER INFORMATION.*AK

NHTSA ID

874552

GLASS IS SOFT - PITTING AND CHIPPING OCCUR EASILY

NHTSA ID

734841

FORDS SERVICE BULLETIN 99-8-8 ADMITS TO DEFECTIVE AIR PLENUM. CONSUMER COST TO REPLACE IS $700-$1000. HAS BECOME A DEALER STOCK ITEM. WHEN THE AIR DOOR BRAKES THERE IS NO AIR FLOW HOT/COLD/DEF CONTROL. CAN'T SEE WHERE YOU ARE GOING WITH FOGGED WINDOWS. FORD REVISED THE PLENUM OUT OF NYLON (#F87Z-18471-DA) CLAIMING IT WOULD NOT BREAK LIKE THE PLASTIC WHICH WAS ORIGINALLY INSTALLED. CONSUMERS SHOULD NOT HAVE TO PAY $1000 FOR A FACTORY DEFECT. CRASHES WILL OCCUR WITHOUT DEFROSTERS. THEY ADMIT IT IN THE MENTIONED SERVICE BULLETIN BUT REFUSE TO MAKE THE REPAIRS.

NHTSA ID

733824

DUE TO FAULTY DESIGN OF AIR PLENUM DOOR WHICH WAS MADE OUT OF PLASTIC, IT CAUSED A LOSS OF ABILITY TO CONTROL DEFROSTER/ HEATER AND AIR CONDITIONING. FORD HAS SENT A TSB (99-8-8) FOR DEFECT. A NEW REDESIGNED PLENUM WAS MADE OUT OF NYLON (F87Z18401DA). *AK

NHTSA ID

872229

I WAS DRIVING ALONG AND HEARD A BIG THUMP, LIKE SOMEONE THREW SOMETHING AND HIT THE SIDE OF THE TRUCK. I TOOK IT INTO FORD AND THEY COULDN'T FIND ANYTHING WRONG. IN THE MEANTIME MY ENGINE CHECK LIGHT CAME ON (SECOND TIME WITHIN 16000 MILES) AND MY WINDOW WASHER WAS BROKE SO THEY HAD TO ORDER THE PART. I WENT IN A WEEK LATER AND THEY PUT IT UP ON THE RACK AND THAT'S WHEN THE BOLT FELL OUT HOLDING MY FRONT END TOGETHER. I WAS TOLD I WAS LUCKY TO BE THERE FOR THEM TO FIX IT. IF IT WENT OUT ON ME WHEN I WAS DRIVING I WOULD HAVE BE KILLED. I WAS ALSO TOLD THAT SEEING HOW THEY COULDN'T FIND THE PROBLEM THE FIRST TIME I WOULD HAVE TO WAIT UNTIL IT DID IT CONSTANTLY . IF I WOULD HAVE WAITED , I WOULDN' T HAVE BEEN AROUND FOR THEM TO FIND THE PROBLEM. NO ONE COULD EXPLAIN TO ME WHY THIS HAPPENED. I WAS TOLD BY FORD MOTOR COMPANY THAT THIS ISN'T A RECALL ITEM. $500 PLUS LATER I WAS ALSO TOLD THAT THEY COULDN'T PAY FOR IT BECAUSE IT WAS OUT OF WARRANTY. HOW WOULD THEY LIKE MY FAMILY OWNING FORD MOTOR COMPANY FOR THEIR SHODDY WORKMANSHIP??? THAT COULD HAVE BEEN A NICE LAW SUIT. I HAVE OWNED THIS VEHICLE FOR 2 YEARS AND I'M CONSTANTLY PUTTING MONEY INTO IT (BESIDES MY MONTHLY CAR PAYMENTS) TO KEEP IT ON THE ROAD. I AM VERY DISSATISFIED WITH THIS VEHICLE AND WILL NEVER BUY A FORD PRODUCT AGAIN. I JUST WANT THE BUYERS TO BEWARE!!! *AK

NHTSA ID

721341

Incident

Feb 2, 2000

INTERMITTENTLY THE WINDSHIELD WIPERS BECOME INOPERABLE, CAUSING POOR VISIBILITY. DEALER HAS BEEN NOTIFIED. *AK

NHTSA ID

848881

THE REAR WINDOW SHATTERED WHILE VEHICLE WAS PARKED, NO REASON WHY IT SHATTERED. *YC

NHTSA ID

547197

Incident

Jun 13, 1999

FRONT DIFFERENTIAL VENT TUBE SPRAYS OUT LUBRICANT BEACAUSE THE VENT MECHAMISM IS DEFFECTIVE. YH

NHTSA ID

782036

THE DESIGN OF THE WIPERS ALLOWS ICE TO BUILD UP ON WIPERS AND WINDSHIELD RESULTING IN POOR VISIBILITY.

NHTSA ID

544208