Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
95V164001FORD MOTOR COMPANYfrom 01/01/1992 to 03/01/1993V (Vehicle)36478408/30/1995ODIFORD MOTOR COMPANY08/25/199508/31/1995
Defect SummaryThe hydraulic lift cylinders are attached to brackets that are welded to the liftgate. the bracket welds can fracture.
Consequence SummaryWith a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinderball stud to disengage.
Corrective SummaryDealers will install reinforcement brackets.
NotesSystem: structure; hatchback hydraulic cylinder.vehicle description: multi-purpose passenger vehicles.note: owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time, should contact ford at 1-800-392-3673. also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
95I007000FORD MOTOR COMPANYfrom 02/01/1990 to 02/01/1995I102938010/25/1995ODIFORD MOTOR COMPANY01/31/199602/09/1996
Defect SummaryVehicle description: multi-purpose passenger vehicles. this is not a safety recall in accordance with federal regulation 573. however, it is deemed a safety improvement campaign by the agency. the campaign will reinforce the bracket attachments of the rear liftgate gas assist cylinders which could pull away from the inside of the liftgate.
Consequence SummaryIf a bracket and gas assist cylinder were to detach completely from the liftgate and no longer bear against the liftgate as intended, the remaining assist cylinder would not hold the liftgate in an open position. personal injury could occur.
Corrective SummaryFord dealers will reinforce the bracket attachments.
NotesFord has decided to conduct a safety improvement service campaign to reinforce the bracket attachments without charge. owners can contact ford at 1-800-392-3673.
99V310001FORD MOTOR COMPANYfrom 04/01/1993 to 02/17/1995V (Vehicle)47058201/03/2000ODIFORD MOTOR COMPANY11/03/199911/08/1999
Defect SummaryVehicle description: on certain sport utility vehicles, the hydraulic lift cylinder bracket welds could fracture.
Consequence SummaryWith a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinder ball stud to disengage, unexpectedly allowing the liftgate to fall from an open position.
Corrective SummaryDealers will install liftgate reinforcement brackets. depending upon the condition of the liftgate sheet metal in the area of the bracket, dealers may also install a larger reinforcement.
NotesFord recall no. 99s34.owner notification is expected to begin during january 2000.owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
STRUCTURE - BODY - ROOF AND PILLARS
97V235001FORD MOTOR COMPANYfrom 01/05/1990 to 01/15/1993V (Vehicle)18500003/02/1998ODIFORD MOTOR COMPANY12/18/199702/25/1998
Defect SummaryVehicle description: multi-purpose passenger vehicles equipped with factory installed sunroof. the sunroof glass panel assembly can separate while the vehicle is moving due to incorrect hinge engagement. this was caused by improper sunroof installation of the glass panel.
Consequence SummaryUnexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
Corrective SummaryOwners will be provided with an instruction booklet which thoroughly outlines, with illustrations, the proper procedures for the removal, storage, and reinstallation of the sunroof's glass panel. a warning label for attachment to the sunroof's latch knob will also be provided to the owners.
NotesOwner notification began march 2, 1998. owners who do not receive the instruction booklet and warning label within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
STRUCTURE
974702/17/199751689Frame- rivet replacement with bolts- service tips. *jd06/27/1997
STRUCTURE - BODY
9516108/01/199545947Sheet metal-roof panel and drip rail replacement- seam sealer application procedure.*sd04/25/1996
STRUCTURE - BODY - DOOR
9422910/01/199437751Inside door handle breaks when opening. *tw01/06/1995
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
BC000195090609/01/199545787Advance notification to dealers of recall on hydraulic lift tubes and a change in normal procedures due to media coverage. *tw04/25/1996
STRUCTURE - FRAME AND MEMBERS
9721001/20/199751393Body - rust perforation - quarter panel - service tips. *tw06/27/1997

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
STRUCTURE
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235001
 Sunroof (air roof) shattering and separation
RQ99016FORD MOTOR COMPANY07/29/1999LIFTGATE SUPPORT BRACKET FAILURE99V310001
 Summary:on august 22, 1995, ford conducted safety recall, 95v-164, on 1992 and 1993 model year explorer due to liftgate failures.the rear liftgate hydraulic cylinder bracket can become unattached allowing the liftgate to suddenly drop.the recall remedy was to install reinforcements on the brackets.ford also initiated a safety improvement campaign in october 1995, for 1991-1995 model year explorer vehicles which were not included in the recall, to install reinforcements on those bracket that were found to be loose or detached.this campaign ended in october 1996. since november 1996, odi has received 51 consumer complaints alleging liftgate failures caused by the bracket separation, of which 19 reported the liftgate struck the occupant causing 12 injuries.one complaint was on 1992 model year vehicle, three complaints were on 1993 model year vehicles, and 47 complaints were on 1994 model year vehicles. this rq is to determine the extent of the problem experience and the scope of safety recall 95v-164.
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235000
 Sunroof (air roof) shattering and separation
RQ99016FORD MOTOR COMPANY07/29/1999LIFTGATE SUPPORT BRACKET FAILURE99V310002
 Summary:on august 22, 1995, ford conducted safety recall, 95v-164, on 1992 and 1993 model year explorer due to liftgate failures.the rear liftgate hydraulic cylinder bracket can become unattached allowing the liftgate to suddenly drop.the recall remedy was to install reinforcements on the brackets.ford also initiated a safety improvement campaign in october 1995, for 1991-1995 model year explorer vehicles which were not included in the recall, to install reinforcements on those bracket that were found to be loose or detached.this campaign ended in october 1996. since november 1996, odi has received 51 consumer complaints alleging liftgate failures caused by the bracket separation, of which 19 reported the liftgate struck the occupant causing 12 injuries.one complaint was on 1992 model year vehicle, three complaints were on 1993 model year vehicles, and 47 complaints were on 1994 model year vehicles. this rq is to determine the extent of the problem experience and the scope of safety recall 95v-164.
PE96074FORD MOTOR COMPANY12/17/199605/23/1997SUNROOF (AIR ROOF) SHATTER
 The sunroof shattered or was blown off.in all but one case this occurred while driving.
EA00012FORD MOTOR COMPANY04/14/200010/20/2000SPARE TIRE WINCH CABLE
 From the beginning of the 1991 model year production until the middle of the 1994 model year production, ford used a galvanized steel cable to lift, and hold in stored position, the explorer spare tire.on may 19, 1994, based on the results of ford durability testing, ford changed to a 4.00mm stainless steel cable.there have been over 100 incidents in which the original galvanized steel cable failedallowing the spare tire to drop from its rear storage well.one of these incidents caused a following vehicle to be involved in a collision and on six other occasions the wheel made contact with following vehicles, resulting in property damage.
PE99072FORD MOTOR COMPANY11/30/199904/14/2000SPARE TIRE WINCH CABLE
 Odi received 18 complaint alleging that the winch cable, that lifts and retains the spare tire under the rear of the vehicle, fails while the vehicle is underway.this results in the spare wheel dropping onto the roadway.
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235002
 Sunroof (air roof) shattering and separation
DP98001FORD MOTOR COMPANY01/06/199802/04/1998HEAVY LATERAL VIBRATION
 The petition alleges that early model ford explores sport utility vehicles develop heavy lateral vibrations at speeds above 55 mph and when encountering bumps at low speeds.the petition further alleges that these vibrations could possibly cause loss of vehicle control.

Consumer Complaints

Fail datemilesoccurencesPurchase date
STRUCTURE
10/20/20081400001
 Sun roof flew off the explorer onto the road and shattered in a million pieces almost hitting a biker. *tr
 Vibration due to design flaw.
STRUCTURE - BODY
1
 Center console folding arm plastic support broke.
07/07/19957
 Glove box is small and its locking mechanism inhibits storage capacity.
STRUCTURE - BODY - DOOR
02/01/2000103/01/1993
 Inside left door handle comes completly off in hand when closing door. bottom hinge on left door broke. catalatic converter rattles when accelerated to 55 mph. *ak
107/01/1993
 Drivers side door is sagging door does not seal, are there any known recalls ?
04/08/20000
 When closing driver's door handle detached without prior warning. *ak
104/30/1992
 The handle for front left side door is loose. yh
02/23/2000105/01/1998
 The built in handle used to close the driver side door has broken off from the door panel. i have brought the ford explorer to a dealer for repair and have been told that i will have to purchase an entire door panel to fix the problem. it would appear that inadequate materials were used in the construction of this door panel and handle unit. the vehicle in question is a ford exploere, limited edition that has been well taken care of. *ak
11/12/1999108/01/1993
 Applicable ford recall letter #95m87 issued october 1995. no safety defect mentione din summary. *ak
07/29/19942303/01/1993
 The door handles on the vehicle have broken off over 20 times, resulting in myself and passengers falling in and out of vehicle. the door handle assembly is part of the interior door and would cost over $300 each side. ford said that this isn't a defect. the handles have been glued repeatedly over the last six years! a door handle should not break off when you open it or close it from the interior! thanks! *ak
10/01/1998201/01/1995
 On about 12/1/97 my right front inside door panel handle to my explorer gave way. this occurred while i was exiting my vehicle. i nearly fell out of the door. i went to the dealership (palmetto ford) where i bought the car in 1995. the auto body shop foreman told me this was a regular occurance with ford explorers. he said there was no known recall for the handle and the price to replace it was about $600.00 i called the ford customer service bureau and learned the same. they were not willing to help any further. i ended up purchasing another panel for $200.00 from a used parts dealer. the same incident occurred on 10/03/98 with the left front door handle. it is obvious to all persons with knowledge of this vehicle (customers, dealers, and repair specialists) that this is a known hazard and defect. in both cases the handle (which is fitted into the interior panel) breaks away from the panel without notice. this may cause an individual to fall due to the suprise of the event. also, if a major event should occur and the handle did break during this incident, the consumer would be locked inside the vehicle until he/she opened the door from the outside. i am certain once you investigate my report, you will find it very accurate and well known to the ford company, dealers, etc. unfortunately, they have chosen to allow this deficiency to continue with disregard for the safety and economic harm to it's customers.
2
 Door grab handles on drive front and passenger rear plastic broken.
1
 Driver's side door loose and misaligned, needs to be lifted to close.
10/18/1997110/01/1996
 Inside door handle fell off.
08/05/1997
 Consumer had vehicle repaired under a recall . after repairs were made owner noticed that the power mirror did not turn, and the automatic door locks did not lock and were off center. owner said that the condition of the vehicle has gotton worse due to the repairs. 97v-083000. *ak
 While attempting to use electric mirror adjuster on driver's side door , door caught on fire. *ak
09/27/1996
 Electrical door panel short circuit, causing flames to ignite from panel. please describe futher details.*ak
12/01/1995112/07/1992
 Front door panels have stress cracks in them.
09/18/1996
 With key out of ignition and parked, left side control panel on driver's door burnt. local fire dept found fuse blown. please describe details.*ak
05/27/1996
 Vehicle caught on fire while parked in garage due to driver side electrical door panels malfunctioning and catching on fire. *ak
03/22/19952
 Left rear door handle broke.
STRUCTURE - BODY - DOOR - HINGE AND ATTACHMENTS
03/09/20041
 Consumer had problems at different times getting the front and rear doors locked. the hinges broke, causing the door to become inoperative. *ak
01/01/1999209/01/1995
 Door hinges would cause doors to be uneven. driver's door fails to close properly due to the hinges. took to dealership, and mechanic indicated hinges were defective and needed to be replaced.*ak consumer added that the design of the door handles made it difficult to shut door. *tt
02/01/2000103/01/1993
 Inside left door handle comes completly off in hand when closing door. bottom hinge on left door broke. catalatic converter rattles when accelerated to 55 mph. *ak
10/12/199701/01/1993
 The driver's side door doesn't line up too close the door. have to pick up the door in order for the door to close. took to the dealer, and they said it must be a faulty design with the manufacturer. *ak
12/01/19974
 Driver's side door hinge is misaligned. when door opens, it moves a lot or has a lot of play. door not able to shut properly due to misalignment. have to push or lift door up on highes to realign it. *ak
01/01/1997
 The drivers's side door welding is coming apart from the truck and the door no longer closes right and may not be latching right. *ak
07/02/1996
 Owner states that the upper door hinge is weak and sometimes door must be slammed to close; also the lower hinge has started to weaken due to the lack of support from top hinge. *ak received from consumer who stated this is not his vehicle or problems. *slc
STRUCTURE - BODY - HATCHBACK/LIFTGATE
08/26/19936
 Rear hatch handle repaired six times.
08/26/19936
 Rear hatch window repaired four times.
08/02/1995
 Pe95-032; rear hatch bracket became detached from hatch door. please describe details. tt
 The weld on the bracket for the rear cargo door broke. tt
06/16/1995
 Back hatch broke and hit owner in the head. tt
03/27/1995
 Vehicle rear gate lift weld broke off while in use and knocked person off. tt
STRUCTURE - BODY - HATCHBACK/LIFTGATE - HINGE AND ATTACHMENTS
1
 Hinge that holds the back door open was welded incorrectly, when the door was opened the hinge broke and the door fell on the consumer's head. yh
07/02/1997302/14/1995
 Consumer was opening the liftgate when brackets broke, causing the liftgate to fall on top of consumer. owner paid for repairs after ford refused to honor the warranty. *ak
 Consumer was opening the door when a bracket came loose and hit consumer in back. tt
07/06/1995
 When open the rear hatch latch try to close it, the hinges fell off . tt
03/22/19951
 Lifted hatch, broke off hinge and fell on owner's head. tt
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
07/15/20041
 Consumer stated the nhtsa campaign recall #95v164001 failed. the hydraulic lift cylinders were attached to brackets that were welded to the liftgate. the bracket welds can fracture. the dealership stated they did all that they were going to do. *jb
10/01/20011
 Manufacturer closed the recall case and will not perform repair according to the dealer. *la the service dealer had inspected the rear lift gate and said that the repair was subject of a recall that ford issued. recall#95v164001 *sc the consumer stated the paper work stated the repair had been performed when it had not been, because the first time the consumer was at the dealership, due to time constraints the consumer was unable to leave the vehicle. *jb
05/15/20010
 There was a recall 95v164001/ hydraulic cylinders. took vehicle to dealer, and they replaced hydraulic cylinders. . went back to dealer for a water leak coming from door, dealer readjusted door, but it was still leaking. dealer will not correct problem again. *ak
309/01/1995
 The brackets attaching the hatch door stay up when opening trunk even though recall 95v164001 was complete, dealer tweeked upper back rear of vehicle when doing recall. *slc
 Nhtsa recall 99v310001 and manufacture's recall 99s34/ hydraulic cylinders broke. no parts were available. *ak
1
 Recall of the breacket on the liftgate 99v-310 cannot be completed due to lack of parts. nlm
110/01/1995
 Liftgate failed prior to recall (95v-164). yh
1
 Recall component failed prior to recall notification, however vehicle has not been repaired due to scheduling problem, consumer concerned about amount of time required for repair (99v-310). *mjs
03/08/20001
 Recall repair for lift cylinder brackets (99v310001) was not performed because there were no parts available. nlm
02/04/19991
 The liftgate cylinder failed prior to recall notice 99v310001. nlm
02/16/2000
 Recall 99v310000/ hydraulic lift cylinders. parts needed to perform recall repairs were not available. *ak
08/13/1999
 While driving on the highway heard a snapping noise like metal. the hydraulic lift cylinders, that are attached to brackets and welded to the liftgate, broke off. the bracket welds fractured.
02/14/1999
 Vehicle is used. owner had parked vehicle & went to rear to lift hatch. the cylinder attachment had broken off from the right side of the frame as it was closing. the left side had failed to hold & fell on the owner. hatch was heavy & needed 2 individuals to lift it. had contacted manufacturer who was unwilling to authorize repairs under a recall that has expired. *ak
04/11/1999105/18/1993
 The right rear bracket separated from the hydraulic lift cylinder causing failure, prior to recall notice (95v164000 & 95v164001). *yc
05/01/1999112/01/1996
 Bracket & cylinder totally broke/detached from liftgate. dealer has failed to honor recall notice to fix @ no charge. i did not receive recall letter upon purchase of used vehicle & was not aware of the defect until it occurred. requesting written notice from nhtsa to direct dealer to repair my vehicle @ nc under recall program. thank you. recall 95v16401. *ak
 Consumer had become aware of recalls 95v164 and 94v169. upon contacting the dealer and manufacturer , he was informed that the recalls had expired. consumer is the second owner of the vehicle. *ak
101/01/1995
 Liftgate bracket failed, recall component however consumer is having trouble receiving repair work, no notice received by consumer of the recall malfunction.
01/17/199905/01/1996
 Yes, when this cylinder exploded. my wife became startled and almost lost control of car. i just found out that there is a recall on these hydraulic cylinders. they needed to be reinforced.looking at the part this was a defect, it just pulled loose. *ak
06/01/1998111/01/1993
 While hatch was open the weld between the bracket and the hatch sheared causing it to fall on the shoulders of the driver.
11/01/199406/21/1993
 Battery/manifold absolute pressure (map) sensor/radius arm bushing/hydraulic lift cylinders (rear door) and driver's side mirror failed.
12/01/19971
 Hydraulic hatchback failed.
10/12/1997108/01/1993
 Rear hatch back rod broke landing on consumer's head due to weld failure.
08/09/1997402/14/1995
 Hatchback cylinder broke and fell on owner's wife . the door was hanging off on one side. owner has notified the dealerand manufacturer. *ak
 Consumer received manufacturer's notice in the fall of 96, he contacted a local dealer to have repairs done; when he was told that the recall had expired, and if he had the repairs done he would have to pay for it. *ak
 The hydraulic lift cylinder came detached. repair was made to the top cylinder, now bottom cylinder is detached. dealer refused to fix it. *ak
05/01/1997
 Recall related hydraulic lift cylinder failure, 95v164-001, never received recall notice, contacted manufacturer and dealership; expired the recall time frame, and would repair the vehicle. *ak
10/15/1996108/01/1993
 Hatchback support rod failed, causing injury.
05/29/1996112/07/1992
 Lift gate cylinder brackets failed.
09/01/19951
 Liftgate has stress cracks at the point of attachment to the gas assist cylinder. *sd
03/25/1996
 Recall related, 95i007000, received 2nd notice, contact dealership/mfr. parts are national backorder no know date of delivery
03/19/1996
 Received a recall notice, recall #95s21, dealer would not do the repairs. *ak
 Has contacted three dealerships to get recall done 95s21 structure; hatchback hydraulic cylinder. please describe. *ak
10/15/1995
 Recall related, 95v164000, structure hatchback hydraulic lift, in for repair oct.15,1995 did not replace parts on bb order. tt
208/01/1993
 Body shop manager @ tipton ford in brownville tx., failed to respond on (2) requests to correct recall 95s21. tt *slc
09/01/1995
 Hatchback hydraulic bracket welds failed, allowing the liftgate to fall. tt
07/05/1995
 Rear left door support bracket broke, resulting in gate collapsing.
 The rear hatch latch support rod broke. tt
08/01/19941
 Rear hydraulic cylinders snapped off and were replaced; hydraulic sylinders are breaking again. tt
06/16/19951
 Pe95-032 active, suupport rods holding hatch fell off, hatch opened up, resulting in an injury. *ak
01/01/1995
 Pe95-032 active, rear hatchback support failed will not support the hatchback. tt
10/24/19941
 Rear hatch fails to support itself. door fell down hitting owner in shoulders due to weld on frame breaking. tt
STRUCTURE - BODY - HOOD
09/01/200006/01/1993
 The insulation blanket under vehicle's hood deteriorated and fell down into the engine compartment. i have been pealing away the hanging down material periodically, however my concern is that material may fall apart, falling upon the engine and possibly causing a fire.*ak
STRUCTURE - BODY - TAILGATE
08/20/19991
 Rear tailgate lift clinder mounting bracket weld failed on passenger side. the weld that broke was from lift cylinder bracket to tailgate. tailgate will now no longer stay open on its own.
08/27/1999109/01/1993
 Liftgate welds broke. recalled by ford, however only for vehicles manufactured from jan 1992 to mar 1993. my vehicle was manufactured 5/26/93. ford refuses to repair. claiming vehicle does not qualify due to manufacture date.
STRUCTURE - BODY - TAILGATE - HINGE AND ATTACHMENTS
10/20/199801/01/1997
 Rear lift gate hinge (window hinge only) failed. hinge snapped in such a manner that indicates casting was likely bad at time of manufacture or that design is faulty.
08/01/19971
 The brackets on the liftgate broke off completely. dealer will not fix because the car exceeded mileage. *ak
09/06/19956
 Tailgate hinge torn loose at weld.
STRUCTURE - BODY - TRUNK LID
11/30/1999109/01/1997
 The weld failed due to manufacture defect under normal use. this failure should be repaired at the cost of the manufacture with no limitations to mileage or years on the road.
STRUCTURE - FRAME AND MEMBERS
02/01/20002
 Both rear rocker panels were rusted out. the body has a 6 year warranty against rust, but the rust was not noticed until the side skirts over the rocker panels were knocked off. when i called ford, they stated there was nothing they could do, because the vehicle was over 6 years old. the rust was bad enough , that it had to be developing well within the 6 year time frame.*ak
07/01/1999104/01/1993
 Rusting, rear quater panel, around gas cap(inside and out.)filler tube could come lose. know of 30 vechicals 1993-1994 with this problem. could become a gas filling problem. clarke ford in hudson, ohio the car is 5 years old, we dont care. called ford service 1-800-392-ford, and they said they would look into it. also ford said if i repair it, save all reciepts incase of recall. *ak

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