1996 Ford Explorer engine problems

Filed Nov 16, 2017 · Engine, Fuel system · 5,000 miles · CA

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.

Filed Feb 9, 2014 · Acceleration, Electrical · 149,000 miles · TX · fire

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.

Filed Jan 21, 2014 · Engine, Visibility · 178,000 miles · OH · fire

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.

Filed Dec 6, 2010 · Engine · OH · fire

1996 ford explorer vehicle caught on fire while traveling. (ohio traffic crash report # 10-0629-91)8jb updated 04/22/11

Filed May 3, 2010 · Engine, Transmission · 178,450 miles · NE

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.

Filed Jun 16, 2007 · Engine · 163,400 miles · PA

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.

Filed Dec 28, 2004 · Engine · 48,000 miles · SC

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.

Filed Feb 28, 2004 · Engine · 1 miles · IL

Sudden and total release of all air conditioning refrigerant (r134a) and compressor oil.

Filed Feb 11, 2004 · Engine · 60,000 miles · MA

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.

Filed Nov 25, 2003 · Engine · 125,000 miles · MA

The heads on the engine cracked. As a result the engine skipped when the vehicle was started. Please provide any additional information.