Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - COOLING SYSTEM
9923811/15/19996090164A temperature gauge fluctuation and / or a knocking / thumping noise may be audible inthe passenger compartment on some vehicles. *tt03/09/2000
9709029718909/02/199754075Experiencing a thumping noise or tempeature gauge fluctation with some vehicles. *yc03/30/1998
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
BC348597230101/23/1997514824.0l equipped vehicles may experience temperature gauge fluctuation that may be accompanied with a thumping noise or feel in the coolant hose with the engine at normal operating temperature. *jd06/27/1997
BC101999723001/23/1997515594.0l equipped vehicles may experience temperature gauge fluctuation that may be accompnied with a thumping noise or feel in the coolant hoses with the engine at normal operating temperature. *jd06/27/1997
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
BC103559702002/01/199751830Radiators may exhibit a coolant leak at the end tank seals in cold temperatures. *jd07/17/1997
ENGINE AND ENGINE COOLING - ENGINE
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
87019710/22/200210000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt03/25/2003
98309201/01/1998607731Rear crankshaft seal oil leak. *ak02/15/2001
1404804/01/2000613703Some vehicles may experience an oil leak at the rear crankshaft area after service. **mr07/27/2000
849304/01/2000613654Some vehicles may experience an oil leak at the rear crankshaft area after service. **mr07/26/2000
1318009/01/19996090538Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs03/21/2000
699709/01/19996090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt03/14/2000
BC103319702002/01/199751789Vehicles with rear crankshaft seal oil leaks. *jd07/17/1997
BC032497020101/02/199751128Cold engine knock/tick noise. *jd06/27/1997
BC309297022502/25/199751695Rear crankshaft seal oil leaks. *tw06/27/1997
96252412/02/199650980Engine - 4.0l - new torque-to-yield connecting rod fasteners. *tw06/17/1997
96261912/16/199651003Engine - 4.0l - torque-to-yield (tty) crankshaft damper bolt. *tw06/17/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0214207/22/2002635982Some vehicles equipped with an automatic transmission and a 4.0l ohv engine may exhibit a noise / vibration, no drive, unusual noise during cranking or a no crank condition. *tt11/04/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
0119710/01/2001627752Some vehicles equipped with the 4.0l ohv engine may exhibit an engine noise which may be perceived by the customer as a piston / onnecting rod bearing knock. *tt02/22/2002
98032401/01/1998607729Cold engine upper knock/tick. *ak02/15/2001
527212/01/1998615393Brief information regarding engine stall condition. *tt01/16/2001
462308/01/1998615160Brief information for vehicles exhibiting engine stall. *tt01/02/2001
1311808/01/19996091931Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt11/16/2000
689608/01/1999608921Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt11/09/2000
98506411/01/1998613200Repeat message regarding engine stalling *tt06/19/2000
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
98032404/01/1998603517Concerns of cold engine upper knock / tick. *yc02/23/1999
BC309297050105/01/199752847Engineering is investigating rear crankshaft oil leaks. *tw09/18/1997
BC032496110111/01/199650732Cold engine knock/tick noise. *tw06/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
98R0305/01/1999606327Subject regarding positive crankcase ventilation (pcv) tube modification. *tt08/16/1999
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
986403/30/1998601312Information on a buzzing or rattle noise from the exhaust system. *tt07/21/1998
96E5703/01/199752329Emissions recall 96e57 - certain 1996 explorers equipped with the 4.0l engines and built at the louisville assembly plant on 11/18/95 and certain 1997 explorers equipped with the 4.0l engines and built at the louisville assembly plant from07/24/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98151208/03/1998609551A direct replacement part for the evaporative emission canister and bracket assembly. ak04/03/2000
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
98R0306/01/1999606329Safety recall letter informing owners of modification to the positive crankcase ventilation (pcv) system. *tt08/16/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
BC101959723001/23/199751554Exhaust noise heard in the passenger compartment most present a tip-in a nd cruise after ssm 5238 has been performed. *jd06/27/1997
BC348197230101/23/199751476Exhaust noise heard in the passenger compartment most present at tip-in a nd cruise after ssm 5238 has been performed. *jd06/27/1997
BC523896110111/01/199650848Vehicle may exhibit an exhaust manifold impingement noise. *tw06/17/1997
BC048196111311/13/199650760Vehicles may exhibit an exhaust manifold impingement noise. *tw06/17/1997

Consumer Complaints

Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
10/27/20101
 1996 ford explorer vehicle caught on fire while traveling. (ohio traffic crash report # 10-0629-91)8jb updated 12/10/10 *bf
10/27/20101
 1996 ford explorer vehicle caught on fire while traveling. (ohio traffic crash report # 10-0629-91)8jb
10/01/200360000103/10/2001
 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
07/27/2003007/15/1999
 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.
3
 Was driving and engine check light came on & stayed. been to dealer. had sensors replaced, but problem came back. temperature gauge had failed to register. fuel guage was not working, and stablizer bar had broken and was replaced. also, power locks failed to release. *ak the sensors were being replaced over and over again. *yh
12/06/1999106/01/1996
 Temperature gauge showed hot. drove to dealer 5 miles away. dignosis: blown head gasket. *ak
06/26/1996902/26/1996
 Gas gauge does not move when filled with gas or while driving. cause unkown. dealer cannot correct problem. *ak the temperature gauge is erratic, dealer replaced a wiring harness, however this did not work, dealer can not remedy the erratic temperature gauge or the inaccurate gas gauge. *slc
ENGINE AND ENGINE COOLING - COOLING SYSTEM
02/16/2004112/15/1995
 Sudden and total release of all air conditioning refrigerant (r134a) and compressor oil.*ak
11/18/20027800005/10/1998
 1) no heat, only blows cold air. 2) transmission does not shift smoothly from reverse to drive.
11/22/2000503/01/1996
 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
01/01/2000109/01/1998
 Truck has been in for service 3 times for this and still not fixed. no safety defect listed within summary. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
04/04/2001
 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
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
10/01/19993
 Radiator failed. *et
10/01/19993
 Thermostat failed. *et
10/01/19993
 Radiator failed. *et
10/01/19993
 Thermostat failed. *et
10/01/19993
 Thermostat locked up and caused antifreeze to leak out of resevroir. *et
02/28/1996102/17/1996
 Temperature sensor failed.
105/01/1996
 Radiator failed.
ENGINE AND ENGINE COOLING - ENGINE
07/01/20011250001
 The heads on the engine cracked. as a result the engine skipped when the vehicle was started. please provide any additional information. *nlm
09/24/20031
 While vehicle idled engine started to race. then, vehicle was trying to move with brakes applied. *ak
08/10/200353264104/06/1996
 While driving at any speed and without warning, the engine shut off, which caused the consumer to pull over. dealer had been notified. *ak the lower engine locked, the power steering leaked at the rack assembly, the belt tensioner was faulty and there was a whining noise from the power steering when turning left, right or at stand still. *scc *jb
03/27/20034
 The fly wheel in the engine was replaced 4 times.
05/15/2002105/12/1996
 Engine overheated due to leak from head gasekts. too much wear on gaskets for only 75,000 miles. *tt
1
 The crankshaft split directly in half.
04/25/2002
 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
1
 The crankshaft split directly in half.
1
 The vehicle shut off completely while the consumer were driving on highway, the dealer found out that the crankshaft had split in half, consumer wants the manufacturer to pay part of the cost of repair. *yh
02/01/1996
 On the freeway car stopped running. crank split in two. service rep couldn't believe it. *ak
08/17/20001
 Consumer states he heard a strange noise coming from front part of vehicle, he took vehicle in to be inspected and when mechanic put the key in the ignition and turned it, there was a loud banging sound and the engine seized, according to the mechanic's report, something behind the torque converter locked up and ruined the transmission, the transmission, flywheel and starter motor had to be replaced. *jb
11/13/19981
 While having vehicle repaired at the ford dealership for anti freeze leaking from the head gaskets the repair was not done properly, the dealership damaged/scatched vehicle and did not bolt down repair areas properly. *mjs
11/20/20001
 Engine check light came on, and consumer made an appointment, but head gasket blewout before appointment. *ak
08/12/200008/01/1996
 When driving my 1996 explorer at 50 mph on a highway i heard a loud click and lost all power. i managed to steer the car to the side of the road. the car cranked but would not turn over. my mechanic towed the car and upon examining the car found that the crankshaft was broken. he felt that my explorer's crankshaft has a definite manufacturing defect since the car mileage is only 28000miles. he urged me to contact tower ford where i purchased the explorer. tower ford advised me that they would not pay anything toward the repair of my vehicle since the warranty had expired. i am frustrated. i was lucky that i was able to escape injury on the highway and now i have a vehicle with only 28000miles with a broken crankshaft -with no help from ford. i believe that the crankshaft in my explorer has a definite manufacturing defect and ford needs to be investigated.*ak
05/01/20001
 Head gasket failed. nlm
05/19/20000
 Engine crankshaft cracked. there was no warning. mechanic said it broke in half.*ak
04/20/2000
 Water was leaking from engine head gasket. dealer has repaired the vehicle. *ak
12/06/1999106/01/1996
 Temperature gauge showed hot. drove to dealer 5 miles away. dignosis: blown head gasket. *ak
11/01/1996107/18/1996
 Oil baffle kit failed, causing oil/grease leak from front of vehicle.
06/10/1997
 She is involved in a manufacturer's recall dealing with the crankcase and the dealership refuses to do the recall because they say it is too dangerous for them to perform. *ak
10/18/1996103/18/1996
 Camshaft failed, causing front end to bounce, damaging tires.
05/07/1996111/01/1995
 Head gasket blew.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
 The vehicle check engine light comes and stays on all day. dealership change several sensors within the engine, but engine light still remains on. please provide more details. ts
06/27/20011005/03/1996
 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
09/01/20002007/01/1996
 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
02/01/2001
 Vehicle will stall out and lose power steering and abs system while driving on the freeway. contacted dealer, and the dealer was not willing to do any work on vehicle. *ak
10/01/19993
 Engine failed. *et
11/05/1999107/01/1996
 Transmission failed twice under normal driving conditions. lost power under certain circumstances. same problem both times. engine seized when vehicle hit a puddle of water at low speed. air intake is mounted unusally low on this explorer allowing water into the combustion chamber and causing hydrostatic lock. ford motor company has been contacted and reads a scripted response when i have tried to get any additional information about what i consider a serious design flaw. *ak
10/01/19993
 Engine failed. *et
01/02/200104/01/1999
 Vehicle was idling for approximately five minutes. *ak
10/07/2000107/01/1997
 Engine failure lost oil pressure locked engine
09/21/2000
 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
07/01/1998102/01/1997
 Engine failed. yh
05/12/20000
 After vehicle had been driven and was parked it caught on fire without prior warning. consumer believed fire had started in the engine. *ak
10/10/1999106/01/1997
 The air intake system points down at the wheel well, causing it to injest water during stream crossings. i crossed 3 streams at shallow depth (less than hub high), and just enough speed to make it through. on the third stream crossing, the engine died. at the dealer's, water was found in the air intake system, and in the engine, causing it to seize up, & need to be replaced.
08/29/1999
 While driving at 70 mph and without prior warning vehicle stalls and then shuts down. *ak
07/18/1999
 While driving engine compartent caught on fire. dealer cannot determine the cause of the fire. please provide further information. *ak
2
 When making a turn vehicle will cut off , giving the driver no indication. the dealer has repaired vehicle twice, problem still exists. *ak
12/01/1996311/01/1996
 Vehicle developed engine knocking noise which results from poor performance. *yc
07/01/1998102/01/1997
 Engine failed. yh
110/01/1995
 Oil seal failed.
1505/01/1996
 Engine stalls causing the steering to lock, power brakes to fail and loss of control.
06/10/1998
 On several occasions while driving the vehicle would shut off for unknown reason. vehicle has been in/out of dealer shop on two occasions and they cannot resolve the problem. *ak
03/01/199701/01/1996
 Engine failure.
01/08/199712/22/1996
 Engine and fuel injection malfunction. check engine light flashed, engine rpm's raise to 4000-5000 without acceleration, vehicle jerks as if receiving fuel intermittently. vehicle sometimes stalls and/or will not start.
09/01/1996107/01/1996
 Oil pan leaks.
06/06/199710/01/1996
 Vehicle fire, originating in the dash area. also, replaced transmission control module. *ak
09/17/1996107/01/1996
 Engine flooded by water thru air intake.
01/02/1997310/31/1996
 Engine stalled 3 times at high altitude.
06/03/1996211/01/1995
 Engine clamps defective, causing oil leak twice.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
05/29/1997410/06/1996
 While driving at slow speeds the serpintine belt slipped, causing loss of power steering, resulting in an accident. *ak
09/01/1996107/23/1996
 Fan belt failed.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1
 Egr valve and sensor failed.nlm
09/01/1996107/01/1996
 Emission control gauge failed.
10/01/1996111/01/1996
 The exhaust leaks.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
12/01/199848000405/23/1998
 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. *jb
104/01/1996
 While driving, vehicle makes a loud humming sound which comes from front end of vehicle. also, transmission has failed. consumer constantly has to take vehicle to dealer. *ak the check engine light illuminated. the speed sensor and the o2 sensor were replaced. jg
04/02/19991
 The check engine light, the dealer replaced both ego sensors. *slc
10/05/2000610/01/2000
 Returned vehicle to dealer many times complaining about brakes, he replaced one pad on one tire. says it was the only one worn, now car skids on braking and pulls to the side. egr valve is also bad and he refuses to acknowledge anything is wrong with vehicle. he states he replaced oxygen sensor unit but, it still appears old and rusted in.after the first day of having vehicle i complained about brakes.idler bearing imobilized car 2 days after purchase,he geryy rigged it without fixing it properly.
04/02/19991
 The check engine light, the dealer replaced both ego sensors. *slc
07/18/2000302/01/1996
 Oxygen sensor failure no.1 at 10300 miles on 12 nov 1996, covered under vehicle warranty. oxygen sensor failure no. 2 at 46200 miles on 4 may 1999. oxygen sensor failure no. 3 at 64600 miles on 18 jul 2000.
05/20/1996103/15/1996
 Smog control failed.
11/01/1996104/01/1996
 Oxygen sensor failed.
10/01/1996111/01/1996
 Oxygen sensor failed twice.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
10/05/2000610/01/2000
 Returned vehicle to dealer many times complaining about brakes, he replaced one pad on one tire. says it was the only one worn, now car skids on braking and pulls to the side. egr valve is also bad and he refuses to acknowledge anything is wrong with vehicle. he states he replaced oxygen sensor unit but, it still appears old and rusted in.after the first day of having vehicle i complained about brakes.idler bearing imobilized car 2 days after purchase,he geryy rigged it without fixing it properly.
10/23/19991
 Egr sensor/control failed causing check engine light to come on. mjs
1
 Egr valve and sensor failed.nlm
05/01/1996111/01/1995
 Egr valve failed.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
03/30/20071634001
 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
05/01/1997101/01/1997
 Knocking noise from engine manifold area. dealer could not find any noticeable problem. knocking noise would quiet down after the engine would heat up. problem got worse over time. independent mechanic found problem with the exhaust manifold gaskets leaking. *ak
02/01/1996202/21/1996
 Exhaust manifold gaskets failed.
 Engine manifold cracked, causing the vehicle to make a loud noise. dealer says exhaust header needs to be replaced. *ak
106/27/1996
 Exhaust pipe melted into the bottom panel of the bumper.
09/18/1996107/07/1996
 Went through an 18 inch puddle, the water came through the manifold and now the engine has ceased. *ak

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