1996 Ford Explorer technical service bulletins
238 technical service bulletins and manufacturer communications cover the 1996 Ford Explorer.
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Front axle leaks fluid from vent tube - vehicles equipped with 4X4 or AWD
- Low line pressure reading at wide open throttle (WOT), slipping shifts and / or delayed engagements with...
- Remote keyless entry (RKE) - service tips
- New transmission cooler flusher - service tips
- Various noise issues from the rear leaf springs while driving
- Fluid may leak out of the front axle vent tube
- New service part - number 5 needle bearing and race kit - 4R70W transmission - service tip
- Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (CMP) installation...
- Air ride control lamp on after shock absorber replacement / contact request
- Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies causing surge,...
- Lamp-brake-invadvertent disabling of brake shift interlock
- Some vehicles equipped with an automatic transmission and a 4.0L ohv engine may exhibit a noise /...
- Experiencing a clicking / popping noise from the upper steering column area when turning the steering wheel
- Some vehicles may exhibit a no 1-2 upshift, no 2-3 upshift, a no engine braking condition in manual 1 or...
- Some vehicles built prior to 9/15/2001 may exhibit low line pressure readings while in drive, no 2ND gear,...
- Certain vehicles with 4X4 or all-wheel drive may have a fluid leak from the front axle vent tube
- Some vehicles may exhibit a squeak, snap, rattle, or clunk in the front end when turning or going over bumps
- Engine oil system priming procedures, service tips for reports of premature engine failure
- Some vehicles equipped with the 4.0L ohv engine may exhibit an engine noise which may be perceived by the...
- Owner notification program supplement 7 revised information - regarding replacement of wilderness at tires
- Brake shift interlock
- Concerns with high brake pedal force to stop after rotor machining
- Some vehicles may exhibit heater core leaks
- Information regarding transmission fluid usage charts
- On some vehicles, including sport and sport trac, the front axle leaks fluid from the vent tube
- Some 4X4 vehicles may exhibit a fluid leak from the front axle vent tube
- Concerns with vehicles exhbit fluid leakage from the front axle vent tube
- Information on replacing a gem module on 4X4 vehicles equipped with 4.0L sohc, ohv and the neutral tow kit
- Some vehicles may exhibit a malfunction indicator lamp (MIL) illumination along with a P0420 diagnostic...
- This recall action involves replacement of the front stabilizer bar links in certain 1995 through 1997...
- Letter Pursuant to Part 573 of Title 49 of the Code fof Federal Regulations, Defect and Noncompliance...
- On some vehicles, the accelerator pedal bracket may become loose or separated from the dash panel
- Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the...
- Subject regarding climate control - eatc - blower motor control service tips
- Subject regarding additional coverage program for sway bar links
- Subject pertaining to supplemental tire inflation label
- Information regarding front sway bar link
- Some vehicles equipped with a 5.0L engine may exhibit a rubbing noise during right hand turns from the...
- Information regarding pump alignment tools
- Some vehicles may experience an oil leak at the rear crankshaft area after service
- Subject regarding neutral tow inoperative after gem replacement
- Information on 5R55E - 4R55E - 4R44E pump alignment tools
- Information regarding the new transmission cooler flusher- service tip
- Some all wheel drive vehicles may experience a low speed whining noise from the transfer case
- Some vehicles may experience a condition of no 4 x 4 low range engagement or a stuck in 4 x 4 low range
- Information on diagnosing a vehicle with malfunction indicator lamp illuminated and diagnostic trouble...
- A temperature gauge fluctuation and / or a knocking / thumping noise may be audible inthe passenger...
- Information on replacing and / or repairing malfunctioning (door, ignition and decklid) locks
- Some vehicles may exhibit a condition of no 4X4 low range engagement or a stuck in 4X4 low range, with no...
- Some vehicles may exhibit a squeak noise from the rear while driving, especially when going bumps
- Some vehicles equipped with manual transmission may exhibit neutral gear rollover noise (a light metallic...
- Some vehicles equipped with four wheel anti-lock brakes (4WABS) may exhibit wheel speed parameter...
- All vehicles with electronic shift on the fly transfer cases will display contact plate pids opposite of...
- Experiencing very light steering vibration / shimmy / nibble at engine idle or low speeds (parking lot...
- All 4X4 vehicles with electronic shift onthe fly transfer cases will display contact plate pids opposite...
- Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses
- Information on replacing the front bumper bracket
- Concerns with burning odor or smoke, and / or rustling noise while blower motor is on
- Vehicles equipped the neutral tow feature, be aware that when the neutral tow feature is enabled and the...
- Some vehicles may exhibit a condition of no 4X4 low range engagement or a stuck in 4X4 low range, with no...
- Exhibiting a squeak type noise from the rear stabilizer bar while driving, especially when going over bumps
- Some vehicles equipped with four wheel anti lock brakes may exhibit wheel speed parameter identifications...
- Exhibiting very light steering vibration / shimmy / nibble at engine idle or low speeds
- Information for servicing and diagnosing brake vibration, brake inspection, and brake friction material...
- Information on identifying non-approved / alternate refrigerants which could cause safety, and performance...
- Some vehicles may exhibit the check engine light on with diagnostic trouble code PO420
- Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with...
- Information regarding neutral tow kit availability
- Information regarding camshaft position (CMP) sensor alignment tool chart
- Information regarding neutral tow kit available
- Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting...
- Information on the new flush and fill tool available through rotunda
- Some vehicles may exhibit a burning odor or smoke, and / or rustling noise occuring when the blower motor...
- Some vehicles may exhibit an occasional hoot / moan from the idle air control (IAC) valve
- Some vehicles may exhibit an audible pinging or creaking noise that may be heard from the driveline when...
- Conditions with the brake lamps inadvertently disabling the brake shift interlock
- Information designed to aid in the diagnosis, testing and repair of noise, vibration and harshness (NVH)...
- Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on...
- Ford motor company has released a private labeled material to be used for iron particle / acid rain...
- Safety recall letter informing owners of modification to the positive crankcase ventilation (PCV) system
- The malfunction indicator lamp (MIL) may illuminate and diagnostic trouble codes (DTCS) P0171, P0174,...
- Information on refilling tissues for the center console facial tissue compartment
- Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making...
- Use kleenex brand juniors or li'l travelers to refill tissues for certain vehicles with the high series...
- Experiencing a delayed or no 2-3 upshift, primarily when the transmission is cold on vehicles with ford...
- Concerns or erratic or insufficient temperature control
- Subject regarding door trim panel replacement - service tip
- Ford motor company now recommends sae 5W-30 viscosity grade for servicing any ford gasoline-powered...
- Subject regarding positive crankcase ventilation (PCV) tube modification
- Information on maintaining tire pressure
- Information regarding reprogramming powertrain control modules (PCMS)
- Experiencing a whinning noise from the transfer case
- Ford motor company has released a new electrical grease ( F8AZ - 19G208-AA ) to reduce the possibility of...
- Some vehicles may exhibit a hard start / long crank, cold start stall, cold rough idle concern
- Information on vehicles exhibiting steering wheel shimmy, vibration or grunt on slow speed turns
- Brief information regarding engine stall condition
- Some vehicles may exhibit a fluid leak concern from the front axle vent tube
- For all vehicles with generic electronic module (GEM) concerns that require a module replacement, the...
- All vehicles with antilock brake module concerns that require a module replacement, the technician must...
- Mass air flow (maf)- sensor contamination- service tip
- Information regarding replacement and / or repairs on any lock component
- Revised message regarding steering wheel shimmy, vibration or grunt on slow speed turns action on sohc...
- Information regarding the tire inflation pressure for all models during predelivery process and during...
- Some vehicles equipped with pats (securilock) except certain models now have availability of fleet keys...
- Repeat message regarding engine stalling tt
- Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern
- Information on setting the tire inflation pressure for 1991 through 1999 model year vehicles in the...
- Experiencing a " buzzing " or " rattling " noise from the exhaust system
- Concerns with the power seat control button ( knob ) may detach from the switch actuator
- Steering wheel shimmies, vibration or grunt on slow speed turns..
- Locks failed
- A direct replacement part for the evaporative emission canister and bracket assembly
- Some vehicles may exhibit malfunction indicator light on with evaporative diagnostic trouble codes P0442,...
- Brief information for vehicles exhibiting engine stall
- Steering wheel shimmy, vibration or grunt on slow speed turns
- Some trucks built with 16 inch chrome styled steel wheels and trucks built with 16 inch steel wheels may...
- Some vehicles built with 16 inch chrome styled steel wheels and with 16 inch steel wheels may exhibit...
- Some vehicles may exhibit a drift/pull, show signs of tire wear, or exhibit poor ride quality
- Some customers notice a grinding, whining, pulsing, or fluttering at the brake pedal at speeds below 19...
- Information on tire company telephone numbers for customer assistance
- Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio
- Conditions with axle wind-up on tight turns with control trac transfer case
- Concerns with false ABS activation while light braking at low speeds
- Symptoms with the gear dtc's and extended / delayed / no shift / flashing fault indicator lamp
- Concerns of cold engine upper knock / tick
- Concerns with built-in rear child safety seat may not easily accommodate some children
- Information on a buzzing or rattle noise from the exhaust system
- Some vehicles may experience a stall and/or stumble during a cold engine decel
- Hub-mount brake rotor machining equipment from rotunda is now approved for warranty and service use
- Service tip information regarding elimination of sanding rotors and drums
- Recommended guidelines for towing behind recreational vehicles
- The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable
- Availability of hub-mount brake rotor machining equipment
- Concerns with axle wind-up and / or clunking, popping, ratcheting type noises when making cornering maneuvers
- Subject regarding the availability of hub-mount brake rotor machining equipment
- Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust...
- Some vehicle may exhibit malfunction indicator lamp (MIL) illuminated with diagnostic trouble codes (DTCS)...
- Subject regarding an overheating condition occurring to the lamp outage module (LOM-2) with the...
- Subject regarding lamp outage module housing and surrounding plastic components melted - eddie bauer and...
- MIL light on with evaporative DTC P0442, P0455
- Gear dtc's and extended/delayed/ no shift
- Cold engine upper knock/tick
- Rear crankshaft seal oil leak
- Concerns with "pinging" or "creaking" being heard from the driveline when shifting from park to drive or...
- Experiencing difficulty diagnosing vehicles with evaporative fuel system diagnostic trouble codes
- Experiencing difficulties with the malfunction indicator lamp (MIL)
- Experiencing a "thumping" noise or tempeature gauge fluctation with some vehicles
- New clutch slave cylinder with a redesigned lip seal
- DTC P0402 in memory under investigation by engineering
- May 1997 gem software has errors - june software is correct
- Service fix for vehicles which exhibit shudder/bind in turns while in 4X4 mode.
- Engineering is investigating rear crankshaft oil leaks
- Vehicles may exhibit shudder/bind in turns while in 4X4 auto mode
- Vehicles with DTC P0402 in memory are under investigation by engineering department
- When performing TSB 97-4-9, do not use a baffle to correct hte issue, use the revised axle cover plate
- Fuel economy- customer expectations versus vehicle usage
- Interior- leather seat cleaning procedure- service tip
- Fluid- transmission fluid usage charts
- Cd player- "skips"- high series console- normal driving conditions
- Emissions recall 96E57 - certain 1996 explorers equipped with the 4.0L engines and built at the louisville...
- Rear crankshaft seal oil leaks
- Frame- rivet replacement with bolts- service tips
- Axle- front axle leaks fluid from vent tube- vehicles built through 8/96 equipped with 4X4 and AWD
- Replacement headlamp bulbs - several aftermarket companies are offering replacement bulbs with a higher...
- Gem concern - check for more than one gem controlled component that is inoperative or for a string of...
- Door latch switch is causing the door ajar light/chime not to work properly
- Air conditioning- R-134A tracer dye installed in a/c system and three o-ring spring lock couplers- service tip
- Remote keyless entry- rke inoperative- vehicles built through 10/30/96
- Transfer case- binding or shudder- diagnostics- vehicles with 4.0L engine- service tip
- Vehicles with rear crankshaft seal oil leaks
- Radiators may exhibit a coolant leak at the end tank seals in cold temperatures
- Customers report inoperable remote entry or keyless entry feature
- When servicing the lamp outage module (LOM) on a vehicle please verify if the vehicle has 1) an...
- The ngs displays incorrect date for the ing gem pid on the vehicles
- Exhaust noise heard in the passenger compartment most present at tip-in a nd cruise after ssm 5238 has...
- When performing TSB 96-24-16, the existing transfer case vibration damper should not be adapted and...
- 4.0L equipped vehicles may experience temperature gauge fluctuation that may be accompanied with a...
- Vehicles may exhibit reverse operating characteristics when switching the air suspension switch from...
- Exhaust noise heard in the passenger compartment most present a tip-in a nd cruise after ssm 5238 has been...
- Performing TSB 96-24-16, the existing transfer case vibration damper should not be adapted and reinstalled...
- 4.0L equipped vehicles may experience temperature gauge fluctuation that may be accompnied with a thumping...
- The ngs displays incorrect data for the ign gem pid on the vehicles
- Customers report inoperable remote entry or keyless entry feature
- When servicing the lamp outage module (LOM) on the above vehicles please verify if the vehicle has 1) an...
- Revised vent tube for 1995-97 explorers & mountaineers with water ingestion into transfer case
- Procedure to purge potential water contamination from transfer case
- Transfer case bind or shudder
- Power locks cycle by themselves remove each power lock switch and measure the open resistance
- Cold engine knock/tick noise
- 4.0L ohv/sohc 4X4 explorers with transfer case bind or shudder
- Revised vent tube for vehicles with water ingestion into transfer case
- Update to TSB 96-21-9 additional calibration added- any calibration revision level for a vehicle with a...
- Lamp outage module (LOM) on the vehicles- please verify if the vehicle has: 1) an aftermarket kit for...
- Inoperable remote entry or keyless entry feature
- Malfunction indicator lamp (MIL) - diagnostic trouble codes (DTCS) P0300, P0301, P0302, P0303, P0304,...
- Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning...
- Engine - 4.0L - torque-to-yield (TTY) crankshaft damper bolt
- Locks - replace and/or repair any lock component - service tip
- Malfunction indicator lamp (MIL) - diagnostic trouble codes (DTCS) P0300, P0301, P0302, P0303, P0304,...
- Powertrain control module -reprogram powertrain control module (PCM) - service procedures - service tip
- Engine - 4.0L - new torque-to-yield connecting rod fasteners
- When a rear hego (CMS) concern is noted, please check the rear cms hego for wire chafing/damage and loose...
- Wiring - electrical diode identification and service replacements
- Torque converter - leak test procedure - service tip
- Vibration
- Noise - pinging or creaking from driveline when vehicle is put into gear
- Vehicles may exhibit an exhaust manifold impingement noise
- Instructions for diagnosing faulty ABS sensors
- Driveshaft design may cause floorpan vibration while at highway speeds or with throttle wide open
- Check engine light, code P030X, with no driveability complaint
- Vibration/shudder at 4000 - 5000 RPM wide open throttle
- Cold engine knock/tick noise
- Vehicle lean
- Vehicle may exhibit an exhaust manifold impingement noise
- Windshield and interior glass - fog/film
- Brakes - elimination of sanding rotors and drums - service tip
- Long crank - sticking idle air control (IAC) valve - vehicles built from 11/1/94 through 3/30/96 -stall -...
- Mass air flow sensor - replacement as an assembly - service tip
- Air conditioning - compressor failure - insufficient amount of refrigerant oil
- Vehicles experience chaffing on the 14401 wire harness causing the accessory fuses to become open...
- For stalling concerns, reflash the PCM w/ 96 calibration (R11 level)
- Vehicle may exhibit a 'popping' noise when the power windows is lowered or raised
- Thump/clunk noise in turns or over bumps may be caused by the kevlar patch wearing through on the torsion...
- Firestone P235 tires may exhibit a high frequency vibration at 65-75 mph
- Vehicles may experience a vibration during wide open throttle acceleration or while cruising at highway speeds
- Information for when diagnosing concerns w/ factory installed cellular phones
- A condition may exist where the malfunction indicator lamp (MIL) may illuminate and code 0446 may be...
- Some 4R70W transmissions were built with a unique case and require a spacer to be installed between the...
- Subject regarding a new single key locksets installed on certain trial vehicles
- When replacing an internal wiring harness on 4R44E/4R55E transmissions built before 11/30/95 with a new...
- The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because...
- On transmissions built before 6/20/95 (fig 1) an extended shift and a higher engine RPM than expected...
- Sheet metal-roof panel and drip rail replacement- seam sealer application procedure
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