1996 Ford Explorer fuel system 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 Aug 17, 2011 · Fuel system · 194,000 miles · IL

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

Filed Aug 26, 2010 · Fuel system · 205,000 miles · OR

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.

Filed Mar 4, 2010 · Acceleration, Electrical · 157,000 miles · IA

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.

Filed Aug 9, 2004 · Fuel system · CA

Strong odor of fuel inside vehicle.

Filed Aug 26, 2001 · Fuel system · CO

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.

Filed Aug 6, 2001 · Fuel system · MA

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-

Filed Jul 22, 2001 · Brakes, Fuel system · MT

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.

Filed Mar 16, 2001 · Fuel system · CA

A strong smell of fuel inside of vehicle. Driver has to roll down windowsbecause fumes make consumer sick.

Filed Feb 5, 2001 · Fuel system, Steering · NM

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.