1996 Ford Explorer Body & Structure Problems

SUDDEN UNINTENTIONAL ACCELERATION: ON THREE DIFFERENT OCCASIONS, FROM YEARS 1998-2015. THE FIRST INCIDENT OCCURRED IN TOWN, 1998. I HAD TO APPLY THE EMERGENCY BRAKE TO DISENGAGE THE SURGING ACCELERATOR. I HAD THE VEHICLE TOWED TO THE DEALER, WHO COULD FIND NOTHING WRONG. PERHAPS A FLOOR MAT PROBLEM, THEY SAID. I REPLACED THE MATS WITH AN AFTER MARKET PAIR- SUV COMPATIBLE AND MUD RESISTANT WITH MANY, GRIPPERS ON THE UNDERSIDE. WITHIN A YEAR, I QUIT DRIVING THE VEHICLE AND MY HUSBAND TOOK THE EXPLORER AS HIS DAILY DRIVER. HE NEVER EXPERIENCED THE PROBLEM, I HAD HAD. I SOLD MY CAR AFTER RETIREMENT AND ON OCCASION NOW DRIVE THE 1996 FORD EXPLORER AGAIN. I HAVE HAD TWO MORE INCIDENTS OF SUA WITHIN 2014-2015 - BOTH ON THE INTERSTATE, BOTH WITH THE REPLACEMENT MATS. AT THE BEGINNING OF BOTH TRIPS, I ENSURED THAT THE MAT LOOKED A SAFE DISTANCE FROM THE PEDALS. BUT-BOTH TIMES, THAT THE UNINTENTIONAL ACCELERATION HAPPENED, I REACHED DOWN AND GRABBED THE MAT BEHIND MY FEET AND PULLED IT AWAY FROM THE ACCELERATOR PEDAL. THIS DISENGAGED THE RUNAWAY SPEED. I BELIEVE THE PROBLEM IS NOT ONLY THE MANUFACTURING STRUCTURE OF THE MATS, BUT THE SIZE/SHAPE OF THE FORD PEDAL. THE PEDAL SIZE IS A PROBLEM FOR SHORT STATURE DRIVERS. I AM 5'1" AND I MUST PULL THE SEAT FAR ENOUGH FORWARD TO REACH THE PEDAL, BUT TRY TO STAY A SAFE DISTANCE AWAY FROM THE STEERING WHEEL AIRBAG. THIS LEAVES ME STRETCHING MY FOOT/TOES TO REACH THE PEDAL AND APPLYING PRESSURE IN AN AREA THAT CAUSES THE FLOOR MAT TO GET STUCK UNDER THE ACCEL. PEDAL. I DID REMOVE THE MAT, COMPLETELY!, NOW! ALL THREE INCIDENTS WERE UNEXPECTED AND PANIC ATTACKS TO MY CORE. I AM IMMENSELY FORTUNATE TO NOT HAVE KILLED SOMEONE OR MYSELF. IT REALLY CONCERNS ME THAT SOMEONE ELSE WOULD OWN MY FORD EXPLORER, AND NOT KNOW OF THIS HIDDEN DANGER. MY VEHICLE HAS ONLY ABOUT 84,000 MILES ON IT.

NOTICED THAT THE RECLINER HANDLE WAS BENT ON THE DRIVERS SIDE. THE NEXT TIME I WENT TO RECLINE THE SEAT THE HANDLE BROKE OFF AT THE RIVET POINT. COMMON PROBLEM ACCORDING TO THE DEALER. THE PART CAN ONLY BE BOUGHT FROM FORD AND THE COST IS $100. THERE WAS A SERVICE BULLETIN FOR THIS PROBLEM FOR A LATER YEAR EXPLORER. DEALER SAID THE NEW PART IS MORE HEAVY DUTY AND MADE TO REPLACE THE STOCK VERSION THAT WAS LIGHT DUTY. NO RECALL WAS ISSUED AND THEY HAVE STOPPED MAKING THE PART. *TR

TL*THE CONTACT OWNS A 1996 FORD EXPLORER. THE CONTACT STATED THAT THE LIFTGATE ASSIST GAS CYLINDER BRACKET SNAPPED AT THE WELDING POINT, WHICH CAUSED THE LIFTGATE TO CLOSE WITHOUT WARNING. AS OF OCTOBER 16, 2007, THE DEALER HAD NOT INSPECTED THE VEHICLE. THE DEALER AND MANUFACTURER STATED THAT HIS VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 97V137000 (STRUCTURE: BODY: HATCHBACK/LIFTGATE: SUPPORT DEVICE). THE FAILURE MILEAGE WAS 132,000 AND CURRENT MILEAGE WAS 134,000.

GAS PEDAL CAME OFF FROM ITS MOUNTING TO FLOOR BOARD DRIVING WHILE VEHICLE. MOUNTING PLATE SEEMS TO HAVE ONLY ONE BOLT SECURING IT TO THE FLOORBOARD. THEIR ARE THREE MOUNTING HOLES FOR THE PEDDLE BACKING PLATE AND THREE HOLES THROUGH FLOOR BOARD. TOP HOLE HAD STRESSED METAL INDICATIVE OF WHAT EVER WAS USED TO HOLD GAS PEDDLE BACKING PLATE. LUCKY US FOR JUST GETTING OFF THE EXPRESS WAY. SOMETHING BAD COULD HAPPEN TO ME AND MY WIFE. *TR

TL*THE CONTACT OWNS A 1996 FORD EXPLORER. THE CONTACT STATED THAT THE HATCHBACK SUPPORT GATE WOULD NOT PROPERLY SUPPORT THE GLASS. ALSO, THE CHILD SAFETY LOCKS DO NOT WORK PROPERLY. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALER FOR INSPECTION. SHE NOTIFIED THE MANUFACTURER AND THEY STATED THAT HER VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 97V137000 (STRUCTURE:BODY:HATCHBACK/LIFT GATE:SUPPORT DEVICE) OR NHTSA CAMPAIGN ID NUMBER 96V070000 (LATCHES/LOCKS/LINKAGES:DOORS:LATCH). THE FAILURE MILEAGE WAS 120,000 AND CURRENT MILEAGE WAS 129,000.

I HAD OPENED MY HOOD TO CHECK THE FLUID LEVELS AND THE TWO GAS SUPPORTS THAT HOLD IT UP FAILED AND THE HOOD ALMOST HIT ME IN THE HEAD. HAD I NOT BEEN PAYING ATTENTION IT WOULD HAVE CAME DOWN ON MY HEAD AND CAUSED SERIOUS INJURY. *JB

VEHICLE IS AN SUV WITH A REAR LIFTGATE / HATCH THAT RAISES UPWARDS WHEN OPEN. ON THIS DAY I WAS LOADING SOME ITEM IS THE REAR OF THE VEHICLE WHEN THE LIFTGATE SUDDENLY FELL AND STUCK ME ON THE HEAD. THE LIFTGATE IS NORMALLY SUPPORTED BY A GAS TYPE STRUT ON EACH SIDE. THERE ARE BALL TYPE PINS ATTACHED TO THE LIFTGATE AND THE BODY FOR THESE GAS STRUTS TO ATTACH TO. THE UPPER PIN ON THE RIGHT SIDE OF THE LIFT GATE SNAPPED OFF AND ALLOWED THE LIFTGATE TO FALL. IT APPEARS IT WAS RUSTING THROUGH, HOWEVER THERE IS NO OTHER RUST ON ANY PORTION OF THE LIFTGATE. ONLY ONE GAS TYPE STRUT WILL NOT SUPPORT THE WEIGHT OF THE TAILGATE. IN ONLY TWO DAYS I HAVE FOUND FOUR OTHER PEOPLE WHO HAVE EXPERIENCED THIS SAME PROBLEM WITH 1995 & 1996 EXPLORERS. *NM

LIFTED THE HOOD OF THE TRUCK AND THE SUPPORTS FAILED. THE HOOD ALMOST CAME DOWN ON MY HEAD. *JB

GAS PEDAL MOUNTING BRACKET SEPARATED FROM FIREWALL. *TR

AFTER THE DISCOVERY OF SOME SMALL RUST ON MY PASSENGER DOORS I TOOK IT TO FORD TO BE FIXED. THEY ENDED UP DISCOVERING MY FRAME IS RUSTED ALONG THE BOTTOM OF MY DOORS. I AM NOW VERY CONCERNED ABOUT SAFETY WITH THIS VEHICLE. IT HAS ONLY 97,000 WHICH FOR A SUV IS NOT MUCH.*AK

NHTSA CAMPAIGN 97V074000, 97V137000, 97V070000. FORD ISSUED A THROTTLE, LIFTGATE, AND DOOR ASSEMBLY RECALLS. THIS VEHICLE WAS NOT INCLUDED IN THE RECALLS, BUT THE CONSUMER WAS EXPERIENCING THE SAME PROBLEMS AS THOSE VEHICLES THAT WERE RECALLED. THE VEHICLE IDENTIFICATION NUMBER WAS OUTSIDE THE REMEDY SCOPE. *JB

ON OR AROUND THE DATE INDICATED, A GENTLEMAN FROM STAPLES OFFICE SUPPLY WAS LOADING A CHAIR AND DESK INTO THE BACK OF MY FORD EXPLORER WHEN THE HATCH COLLAPSED. LUCKILY, I WAS STANDING THERE AND CAUGHT THE HATCH BEFORE IT FELL ON HIS HEAD AND BACK AND POSSIBLY REALLY INJURED HIM. APPARENTLY, THE LEFT HYDRAULIC ARM OF THE HATCH SHEARED COMPLETELY OFF THE BRACKET WELDED TO THE VEHICLE. UPON INSPECTION, BOTH SIDES ARE COMPLETELY RUSTED AND THE OTHER ARM COULD SHEAR OFF AT ANY TIME. NOWHERE ON THIS VEHICLE IS THERE RUST AND THESE WELDED BRACKETS ARE IN THE INTERIOR SEAL OF THE REAR HATCH AND ARE IN NO WAY EXPOSED TO WATER. WE WERE ABLE TO UNHOOK THE ARM TOTALLY WITH THE LITTLE PINS HOLDING IT IN PLACE. THEN THE HATCH WOULDN'T CLOSE PROPERLY ONCE THE ARM WAS REMOVED. (I WAS TOLD THIS WAS PROBABLY DUE TO THE CHANGE IN WEIGHT DISTRIBUTION.) I CALLED FORD (NATIONAL 800 NUMBER NOT THE LOCAL DEALER) AND ASKED THEM ABOUT IT. THE CUSTOMER SERVICE WOMAN IMMEDIATELY TOLD ME THAT THEY HAD NO COMPLAINTS ON THAT AND THAT THERE WAS NO RECALL SO I WOULD HAVE TO PAY FOR IT. I TOOK THE VEHICLE TO A BODY SHOP WHICH GAVE ME A QUOTE OF $468 TO WELD NEW BRACKETS ON (BOTH SIDES WILL NEED TO BE REPLACED TO PREVENT FUTURE INJURIES). THE HYDRAULIC ARMS THEMSELVES WORK FINE. UPON VIEWING YOUR SITE, I SEE THERE WAS A RECALL THE YEAR AFTER THE CAR WAS MADE DEALING WITH THE RIGHT SIDE HYDRAULIC ARM AND IMPROPER WELDING. (RECALL # 97V137000) I BASICALLY JUST WANT IT FIXED AND WANT THEM TO FIX ANYBODY ELSE'S SO NOBODY ELSE WILL GET HURT. WHAT IF A MOM IS UNLOADING GROCERIES WITH HER KID AND THE DOOR COMES CRASHING DOWN ON THEM??? HOW MANY INJURIES OR DEATHS WILL IT TAKE FOR THEM TO FIX SOMETHING LIKE THIS??!! *JB

CONSUMER STATES THAT THE DOOR BEHIND THE DRIVERS SEAT HAS A LOT OF PLAY IN THE HANDLE. CONSUMER CAN'T OPEN DOOR. PLEASE PROVIDE ANY FURTHER INFORMATION. MR

SUPPORT FRAME THAT HOLDS CAR TOGETHER ON FRONT OF VEHICLE WAS SEVERELY CRACKED. CONSUMER TOOK VEHICLE TO DEALER, AND THEY WERE NOT GOING TO DO ANYTHING. CONSUMER FELT THAT THE ENTIRE FRONT END OF VEHICLE COULD FALL OFF. THEN, CAR WOULD FLIP OVER, AND PASSENGER COULD BE INJURED OR KILLED. VEHICLE WAS ROLLING DEATH TRAP. FRAME SHOULD NEVER BREAK, IT COULD BE BENT, BUT NOT BROKEN. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK

WHEN SHUTTING OFF ENGINE AUTOMATIC DOOR LOCKS ENGAGED. DRIVER'S REAR DOOR LOCK WAS REPLACED IN SEPTEMBER 2001, PASSENGER REAR DOOR LOCK WAS REPLACED DECEMBER 19, 2001.

POWER DOOR LOCKS ARE NOT WORKING, THEREFORE THE DOORS DO NOT OPEN FROM THE INSIDE. THIS COULD BE EXTREMELY DANGEROUS IF TRAPPED INSIDE. SHOULDN'T THEY ALWAYS OPEN MANUALLY? ISN'T THERE A LAW PROVIDING SAFETY FOR DOOR LOCKS?

CONSUMER STARTED EXPERIENCING DIFFICULTY CONTROLLING THE VEHICLE, THE ABS LIGHT CAME ON AND THE VEHICLE CAUGHT FIRE, ONE PERSON WAS INJURED WHILE PUTTING OUT THE FIRE, THE AXLE HAD BROKEN AND MELTED, BUT NO ONE KNOWS EXACTLY WHAT CAUSED THE FIRE. *SLC

CONSUMER WAS TRAVELING ABOUT 65MPH ON HIGHWAY AND HEARD A LOUD NOISE TREAD SEPARATED FROM LEFT REAR TIRE, AND DAMAGED THE LEFT REAR QUARTER PANEL, KNOCKING OFF THE CHROME COVER OFF, AND BOLTS BROKEN AND BENT THE REAR QUARTER PANEL. *AK

THE DRIVER LOST CONTROL OF THE VEHICLE AND PROCEEDED TO SKID INTO THE SOUTHSIDE OF THE ROADWAY INTO A DITCH AND COLLIDED WITH A UTILITY POLE, THERE WERE 2 FATALITIES(TEXAS OFFICERS ACCIDENT REPORT, BRIDGESTONE/FIRESTONE, P235/75R15, RADIAL ATX M/S, VDHL1PM435, LEFT REAR). NLM

LEFT REAR DOOR HANDLE BROKE. DEALER AND MANUFACTURER HAVE BEEN NOTIFIED. *AK