1996 Ford Explorer Engine 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

1996 FORD EXPLORER VEHICLE CAUGHT ON FIRE WHILE TRAVELING. (OHIO TRAFFIC CRASH REPORT # 10-0629-91)8JB UPDATED 04/22/11 *BF

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. *TR

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. *AK

SUDDEN AND TOTAL RELEASE OF ALL AIR CONDITIONING REFRIGERANT (R134A) AND COMPRESSOR OIL.*AK

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.*AK

REPAIR SHOP STATED THAT THE EXPLORER BY FORD HAS A WEAK SPOT THAT HE HAS HAD TO REPAIR ON NUMEROUS OCCASIONS. IT IS THE L CYLINDER #4 THAT CRACKED.

THE FLY WHEEL IN THE ENGINE WAS REPLACED 4 TIMES.

1) NO HEAT, ONLY BLOWS COLD AIR. 2) TRANSMISSION DOES NOT SHIFT SMOOTHLY FROM REVERSE TO DRIVE.

ENGINE OVERHEATED DUE TO LEAK FROM HEAD GASEKTS. TOO MUCH WEAR ON GASKETS FOR ONLY 75,000 MILES. *TT

AT 65MPH THE VEHICLE LOST ALL POWER BECAUSE FLYWHEEL'S CENTER HUB BROKE. VEHICLE IS CURRENTLY BEING INSPECTED BY A INDEPENDENT MECHANIC. MANUFACTURER AND DEALER HAVE NOT BEEN NOTIFIED. PLEASE ADD MORE INFORMATION.*AK

THE HEADS ON THE ENGINE CRACKED. AS A RESULT THE ENGINE SKIPPED WHEN THE VEHICLE WAS STARTED. PLEASE PROVIDE ANY ADDITIONAL INFORMATION. *NLM

VEHICLE STALLS AT AT A STOP. CONSUMER HAS TO REV ENGINE HARD TO KEEP IDLING. DEALER HAS BEEN INFORMED, BUT HAS FOUND NO PROBLEM. *AK

3-4 HOURS AFTER DRIVING VEHICLE CAUGHT FIRE IN ENGINE BLOCK, FIRE MARSHALL THOUGHT FIRE STARTED IN ENGINE COOLING FAN. VEHICLE STILL AT DEALER AT THIS TIME. *AK

VEHICLE WAS IDLING FOR APPROXIMATELY FIVE MINUTES. *AK

WE HAVE OWNED THIS EXPLORER SINCE 1996 AND EVERY YEAR THE THERMOSTAT OR THE SENSOR HAS TO BE REPLACED. IS THEIR A FIX TO THIS PROBLEM FROM FORD. *AK

ENGINE CHECK LIGHT CAME ON, AND CONSUMER MADE AN APPOINTMENT, BUT HEAD GASKET BLEWOUT BEFORE APPOINTMENT. *AK

ENGINE FAILURE LOST OIL PRESSURE LOCKED ENGINE

VEHICLE WILL SUDDENLY STALL, USUALLY WHEN WEATHER IS REALLY HOT OUTSIDE UNEXPECTEDLY WHICH PUT CONSUMER AND FAMILY IN DANGEROUS SITUATION. CONSUMER TOOK VEHICLE TO FORD, BUT DEALER COULD NOT DETERMINE CAUSE.*AK

WHILE TRAVELING AT VARIOUS SPEEDS (5 MPH - 75 MPH), THE ENGINE STALLS WITHOUT WARNING FOR APPROXIMATELY 5-10 SECONDS AND THEN EITHER RESUMES OPERATION ON ITS OWN, OR MUST BE RESTARTED WHILE COASTING IN NEUTRAL. SOMETIMES THE ENGINE WILL RESTART EASILY, BUT SOMETIMES IT TURNS OVER SEVERAL TIMES BEFORE RESTARTING. OBVIOUSLY THIS HAS CREATED SOME EXTREMELY DANGEROUS SITUATIONS FOR MYSELF AND MY FAMILY. LOSING POWER ASSISTED FUNCTIONS (STEERING, BRAKING) AT HIGH SPEEDS HAS LEFT ME WITH LITTLE CONTROL OF THE VEHICLE ON SEVERAL OCCASIONS. I HAVE HAD THIS PROBLEM INVESTIGATED TWICE AT A FORD DEALERSHIP BUT THEY HAVE BEEN UNABLE TO FIND A PROBLEM. THEY ALSO INSTALLED A FLIGHT RECORDER ON THE VEHICLE TO MONITOR THE ERROR CODES WHEN THE PROBLEM HAPPENED BUT WERE UNABLE TO FND ANYTHING CONCLUSIVE. AFTER READING THE MANY REPORTS OF STALLING ON THIS WEBSITE I FIND IT HARD TO UNDERSTAND HOW THIS ISSUE COULD NOT BE CONSIDERED A DEFECT AND A SERIOUS SAFETY ISSUE. I WOULD TRULY LIKE TO RECEIVE ANY ASSISTANCE OR GUIDANCE ON HOW TO RESOLVE THIS MATTER. IT IS UNFAIR THAT FORD SELLS THE EXPLORER WITH OBVIOUS SAFTELY ISSUES BUT IS UNABLE TO FIX THEM.*AK