Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
1215011/01/1998613170Information concerning the replacement of the engines on vehicles equipped with a 4.0l sohc that require service. *mjs06/19/2000
BC019097020101/02/199751057Vehicles built prior to 10/1/96 may have been built with wrong temp gauge system parts. *jd06/27/1997
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
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
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
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1461701/01/2001617995Subject pertaining to broken thermostat. *jb04/03/2001
1458301/01/2001617968Concerns with broken thermostats on engines. *jb04/02/2001
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
01M0104/01/2001619285Owner notification program regarding additional coverage program for front cam chain guide assembly which may wear or break and cause excessive cam chain noise that does not go away after five minutes of engine operation. *tt05/22/2001
01M0101/05/2001618042Subject regarding advance notice on upcoming owner notification program which will provide additional coverage on the front cam chain guide assembly on certain vehicles. *tt04/03/2001
1456001/01/2001617944Vehicles may experience start up timing chain noise. *jb04/02/2001
00M1211/01/2000616507Ford motor company is providing additional coverage for the 4.0l sohc camshaft chain tensioner and lower intake manifold gasket. *tt03/01/2001
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
98514411/01/1998613280All vehicles equipped with 4.0l sohc that require engine service please note that the xl2z-6m289-aa (drive assembly-camshaft-lh) must be used on 4.0l sohc engines if replacement is required. *tt06/20/2000
713810/01/19996090757Service tip information when servicing the 4.0l sohc short block assembly. *tt03/29/2000
1326009/01/19996090690Service tips information provided to assist when servicing vehicles with short block assembly. *tt03/23/2000
1317009/01/19996090518Information regarding 4.0 l sohc camshaft bolt torque. *mjs03/21/2000
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
698609/01/19996090291Information regarding 4.0l sohc camshaft bolt torque. *tt03/13/2000
9811801/19/1998605588Experiencing an audible noise in engine.07/13/1999
9751303/03/199751948Idle- booming noise heard at idle- 4.0l engine- vehicles built from 7/29/96 through 11/11/96. *jd07/17/1997
977603/31/199751913Idle- booming noise heard at idle- 4.0l sohc engine- vehicles built from 7/29/96 through 11/11/96. *jd07/17/1997
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
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
BC101899723001/23/199751548Block heaters may experience coolant leaks due to interference with the block. *jd06/27/1997
BC349197230101/23/199751484Some 4.0l engines with block heaters may experience coolant leaks due to interference with the block. *jd06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1504001/01/2002630022Some vehicles including 1997 through 1999 explorer sport trac equipped with a 4.0l sohc engine may exhibit a start-up noise from the left front of the engine. *tt04/11/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
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
07010107/01/2001623810Subject regarding owner notification program 01m01 supplement #2: revised technical instructions and new labor operation. nlm10/30/2001
1500606/01/2001622817Some vehicles with 4.0l sohc engines may make a start-up noise from the left front of the engine. *tt10/23/2001
1504007/01/2001621039Some explorer / sport / sport trac equipped with a 4.0l sohc engine may exhibit a start-up noise condition from the left front of the engine. *tt09/06/2001
01M0104/26/2001620173Subject regarding owner notification program 01m01 regarding additional coverage for front cam chain guide assembly. *tt07/19/2001
01M0103/02/2001619443Subject regarding additional coverage on the front cam chain guide assembly for rental vehicles with 4.0l single overhead cam (sohc) engines. *tt05/31/2001
1486804/01/2001619337Some vehicles equipped with the 4.0 sohc engine may exhibit a primary chain rattle noise (sometimes described as a spark knock-type noise). *tt05/23/2001
00M1212/01/2000616816Subject regarding owner notification suppllemental program for vehicles equipped with 4.0l sohc engines - camshaft chain tensioner and lower intake manifold gasket additional coverage. *tt03/13/2001
98032401/01/1998607729Cold engine upper knock/tick. *ak02/15/2001
527212/01/1998615393Brief information regarding engine stall condition. *tt01/16/2001
525612/01/1998615373Information on vehicles exhibiting upper engine noise. *tt01/13/2001
462308/01/1998615160Brief information for vehicles exhibiting engine stall. *tt01/02/2001
1330010/01/19996092122Some vehicles with 4.0l sohc engines may exhibit a vibration / moan / boom at idle. *tt11/27/2000
1315408/01/19996091965Subject regarding engine hotline phone numbers. *tt11/17/2000
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
1326109/01/19996091661Service tips when servicing a 4.0l sohc short block assembly. *tt11/09/2000
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
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
98506411/01/1998613200Repeat message regarding engine stalling *tt06/19/2000
504911/01/1998613181Brief information regarding upper engine noise. *tt06/19/2000
1352711/01/1999610913Some vehicles equipped with 4.0l sohc engines may exhibit an overheat condition that may be attributed to the thermostat. engineering is currently investigating this issue and is looking for thermostats and coolants samples from these05/18/2000
1348411/01/1999610897Vehicles equipped with 4.0l ohv engines may exhibit excessive oil consumption as reported by the customer. *tt05/18/2000
747111/01/1999610836Some vehicles equipped with 4.0l ohv engines may exhibit excessive oil consumption as reported by the customer. *tt05/15/2000
98151408/03/1998609554A vehicle vibrates during a hot or cold idle condition.04/04/2000
727010/01/19996090871Some vehicles equipped with 4.0l sohc engines may exhibit a vibration / moan / boom at idle. *tt03/31/2000
1317709/01/19996090532Information regarding 4.0l sohc engine repair procedure update. *mjs03/21/2000
1317209/01/19996090522Information regarding sohc engine noise (cam chain noise). *mjs03/21/2000
1317109/01/19996090520Information regarding 4.0l sohc engine noise (cam chain noise). *mjs03/21/2000
699309/01/19996090303Subject regarding 4.0l sohc engine repair procedure update. *tt03/14/2000
698709/01/19996090293Some vehicles may exhibit engine noise(cam chain noise). *tt03/13/2000
9922310/18/19996089683A no start condition when vehicle is parked on an incline with the vehicle in a nose down position and less than 1/4 tank of fuel may occur. *tt02/11/2000
98310902/25/1998607403Information regarding engines added to the fqr (ford quality renewal) assembly program. *tt09/22/1999
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
1262403/01/1999605343Some vehicles may exhibit a hesitation / lack of power on re-acceleration after decelerating from 45 - 65 mph to a slow roll condition. *tt06/08/1999
9821110/26/1998603665Experiencing a noise and vibration during idle.03/01/1999
98251112/21/1998603649Service tips on composite fuel rail. *yc03/01/1999
98032404/01/1998603517Concerns of cold engine upper knock / tick. *yc02/23/1999
BC309297050105/01/199752847Engineering is investigating rear crankshaft oil leaks. *tw09/18/1997
BC315697021902/19/199751755Explorers equipped with the 4.0l sohc engine may exhibit a hiss/whistle at tip in. *tw07/17/1997
BC315597021902/19/1997517524.0l shoc engine quits while driving and will not restart. *tw07/17/1997
BC032496110111/01/199650732Cold engine knock/tick noise. *tw06/17/1997
BC088296100410/04/199650439Information for all base engine concerns of 4.0l sohc engines. *tt04/24/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
BC075596101710/17/199650394Tensioner rattle . install a 1 inch shorter motorcraft belt (p/n f19z-8620-c). *tt04/24/1997
BC518896100110/01/199650466Concern of a tensioner rattle w/ 4.0l sohc, install a 1 inch shorter motorcraft belt (p/n f19z-8620-c). *tt04/24/1997
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
98031304/01/1998603507Experiencing idle vibration / exhaust boom. *yc02/23/1999
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
BC223797050105/01/199752778Recall 97s67 - modification of the pcv valve requires a special tool whicl will sent to listed parts managers. *tw09/12/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
BC101929723001/23/199751551Vehicles may experience a high pitched whistle during heavy acceleration at 3800-5000 rpm when engine is warm. *jd06/27/1997
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
BC349497230101/23/199751487Various vehicles may experience a high pitched whistle during heavy acceleration at 3800-5000 rpm when engine is warm- to fix, remove existing muffler and replace with same part. *jd06/27/1997
BC048196111311/13/199650760Vehicles may exhibit an exhaust manifold impingement noise. *tw06/17/1997
BC523896110111/01/199650848Vehicle may exhibit an exhaust manifold impingement noise. *tw06/17/1997

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi

Consumer Complaints

Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
02/09/2011150000
 Tl-the contact owns a 1997 ford explorer. the contact stated that while driving approximately 20 to 30 mph the vehicle would misfire and seem as if it's going to stall. the vehicle was inspected by a dealer who informed the contact that she needed to replace the engine. the manufacturer was then contacted and advised her that her vehicle was included in any recalls. the vehicle has not been repaired. the failure mileage was approximately 150,000. tb
01/16/2011234000
 Tl-the contact owns a 1997 ford explorer. the contact stated that driving approximately 45 mph when another driver informed him that there was a fire starting from underneath the vehicle. once he exited the vehicle it burst into flames. the police were called and there was a report available. the vehicle was towed but, he doesn't know to where. the manufacturer was contacted and advised him to take pictures and that the vehicle was under a recall due a defect and that it would possibly cause a fire. the failure mileage was approximately 234,000. the vin was unavailable. tb
10/06/200768105/10/2001
 My 1997 ford explorer died while i was driving. i had the vehicle towed to a ford dealership and was informed that the cam shaft chain was broken or let go. i was advised by ford they knew about this problem, but didn't notify everyone who owned them because they didn't have enough parts to repair or replace and they only told the ford dealerships about this problem and not the public. and they also purged all the old records as they call them and cannot tell if they notified the ford dealership where i purchased my vehicle. i was told by hackettstown ford when i purchased my vehicle that it was one of the sales managers wifes car and it is in mint condition and well maintained. when i found out about the problem with my vehicle., i was told by ford that there are over 5 million ford exploreres and mercury suv still on the road. there is no way a consumer can tell if this is going to happen youor vehicle just dies, and i cannot imagine how many people have been in accidents or even killed because of this problem or are still driving these vehicles and wont know until it happens. it cost me $14,999 when i purchased this vehicle and it cost me over $6,000. for a new engine. who is watching out for us? if i was told to have my vehicle checked i would have it only cost about $100.00 to pull they engine down to the cam shaft chain and check for the problem. i had my vehicle looked at by four mechanics who knew right away what the problem was. please help me and the public with this problem, i am disabled and had to borrow the money for the engine and will have to pay the money back for the next 4 years. i couldn't buy a new vehicle because my vehicle fits me perifect because of having 35 surgeries from a auto accident in 1974.if i see another explorer i stay far away from it. . the funny thing is when you call ford in detroit they ask you how many fords you have purchased in your lifetime and would you ever buy another one. *tr
08/04/200715200107/15/2003
 Tl*the contact owns a 1997 ford explorer. while driving 5 mph, the vehicle began to shake. the contact placed the vehicle in park and shut off the engine. he exited the vehicle, raised the hood, and noticed that the engine was on fire. the contact was able to extinguish the fire. the vehicle was towed to his residence and has not been to a mechanic. the cause of the fire and the dealer information were unknown. the current and failure mileages were 15,200.
11/22/20061
 On a 1997 ford explorer had problems with transfer case. first noticed when driving on interstate with cruise control on vehicle made grinding noise and would not decelerate had to put into neutral to stop. when decelerating while driving vehicle it would also make grinding noise almost sounding like it was not down shifting. few weeks later when vehicle was put into reverse it would make a grinding noise and would not go into gear. did not feel safe to drive. ending up having to have a mechanic rebuild transfer case, cost almost $1000.00. now five months later having problems with check engine light continuously coming on. replaced sensors and spark plug on #4 cylinder twice. this will be replacement number 3 for spark plug in four month period. mechanics cannot seem to figure out why. *jb
02/09/200798000210/01/2006
 Tl*- the contact stated that he had not been able to start up the 1997 ford explorer since 02/09/07. the contact had replaced the starter, the spark plugs, and continues to experience the same failure. they pulled the front end of the motor and noticed something snapped and was sitting in the pan. the contact had been on the internet and had noticed that other explorers were having the same problem. the current and failure mileage were both 98000 miles.*ak
11/01/20061150001
 When i stopped using my ac and turned on the heat in my 97 ford explorer all i get is cold air. this happens at all heat settings including defrost. i talked to a ford dealership and the service man there said it is probably the blend door and that it would cost $800-1000 to repair. nothing has been done yet as i don't have that much spare cash for this repair. the vehicle does have 116,000 miles on it but i have been checking this out on the internet and it seems to be a major safety issue with 95-99 explorers. is there any recourse from ford on this? *jb
02/15/200324000
 The vehicle in question is a 1997 ford explorer with 38643km. the a/c heater unit was blowing out only cool air. does not help when you get -30c weather and you try to defrost your windshield with cold air. yes it is out of the 3 year warranty period but certainly not the 60000km. i do not understand how a vehicle with less than 40000km can have such a problem ? ford's answer is as follows: cause: diagnosed-temp blend door is broke. correction: replaced interior heater case. ford refuses to pay any portion because it is out of warranty. other websites with same problem listed: http://www.mightyautoparts.com/data/otl1200.pdf http://www.carsurvey.org/viewcomments_review_16717.html http://www.epinions.com/content_66590314116
01/05/2004900001
 While driving at 35 mph consumer heard a noise, then vehicle stalled. the spark plugs blew out. an independent technician indicated that engine cylinder need to be replaced. *ak
05/01/1999
 Ford is aware of a recurring problem, the particular problem being a worn or broken cam chain guide which creates a noisy symptom which my vehicle has, then ford should be willing, if not liable, to fix it.
03/22/20010
 While driving engine will overheat without a prior warning. had been taken to dealer, but no repair had been made. *ak
07/22/1999207/19/1999
 Vehicle experienced several engine problems, consumer stated that the engine sounded like no oil was in it when started, dealer has replaced gaskets, upper intake cam tensioner three times, and there was a coolant leak. left front door hinge replaced, it was making noise. power steering pump was replaced, it was noisy when turning the wheel. vanity mirror on driver's side would not close all the way and popped when opened, dealer replaced it. the right front of the vehicle was lower than the left front. brakes were squeaky, dealer replaced front brake pads and turned rotors. a tap noise was heard while playing cd's. vehicle experienced several transmission problems, while going over bumps and railroad tracks, transmission jumped out of gear, dealer intalled overhaul kit because the clutch had burned. 4 wheel drive was inoperable and made a rubbing/groan noise, when reversing and putting intor drive, consumer heard popping noise, dealer replaced rear transfer case flange and removed driveshaft. vehicle would not start, it would turn over, dealer found the pcm was not wiring, dealer replaced pcm. *slc
03/04/1997102/12/1997
 Temperature gauge failed.
ENGINE AND ENGINE COOLING - COOLING SYSTEM
05/21/2010193000
 Engine revvs and vehicle is thrusted forward at top speed from dead start or when slowing down. this is the second on this problem. both times lead to property damage, and accident.
05/20/2005108000005/19/2005
 Air blend door failure. i only have hot air.
10/10/2004104/05/2004
 I bought the explorer last april and the a/c worked fine, but when winter got here the heater would not blow warm air. i took it to a mechanic who replaced the thermostate and looked at other things, but could not fix it. i then took it to a second mechanic who looked at it and told me that he had just fixed the same problem on another 97 ford explorer--and it was the blend door. that the door was a factor defect and would cost about $650.00 to replace it. i did not have the money to have it replaced, and it is a safety hazard when it is stuck on a/c air and you can not defrost your windshild while you are driving. it has not been fixed and restricts vision out of the windshield when fogged or iced which could cause me to have a bad wreck.
12/03/2003118000103/08/2001
 My heater splitter door failed to release heat about 4 mo. ago and is still briken. i haven't had the 700.oo to fix it. *ak
02/01/200285000105/15/1998
 Rear doors won't open from inside and it is not the child deterrent lever on door, heating system overrides a/c heater sometimes dosen't work. recline lever broke off. *ak
06/01/2000
 Vehicle overheated while driving. when checking the cooling system fluids were turning into slush. contacted dealer, and the dealer was not willing to help.*ak
03/22/20010
 While driving engine will overheat without a prior warning. had been taken to dealer, but no repair had been made. *ak
11/01/1998108/01/1997
 Water pump leak. *yc
03/08/1999
 While driving at 60 mph heard some noise and the consumer pulled over and noticed water and anti-freeze coming from the vehicle. consumer turned vehicle off.when trying to start the vehicle back up, the vehicle won't start. *ak
701/08/1997
 Vehicle experienced misalignment. in addition, replaced fuel gauge sendin gunit/air bypass valve/ water pump/seat release/passenger's door and computer. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
02/01/2001
 Well, the first thing that stopped working was the thermostat, then the window regulator and seat bealt, i went to the dealer and just to see the problem i was charged 160usd . i think it's unfair but they said i had to pay and nothing was done to the car. the tires were replaced at sears because i was scared and simply replaced them 4 months after i bought the car. i called the dealer and firestone recall but they are now asking for a dot code in which sears did not give me. now i am only asking to please try to refund something. i will never buy a ford vehicle because they give too many problems and the dealer gets away with problems in which they need to fix because they are factory problems. *ak (tiresize: 15inches)
06/01/2000
 Vehicle overheated, when checking vehicle fluid was turning into slush. contacted dealer, and dealer was not willing to help.*ak
10/20/1999204/01/1997
 Dealer said overheat was due to faulty thermostat (2nd time). suggested flushing the system every 30,000 miles to clean the system. when it overheated the first time there was and still is less then 30,000 miles on the vechile. the warranty runs out on may 24, 2000. today is may 9, 2000. i would like the problem resloved and guatanteed for a while. *ak
07/08/1997102/12/1997
 Radiator cap failed resulting in leaking.
11/18/1998211/01/1997
 Experiencing continued engine overheating and stalling, unable to rectify after replacement of faulty fuel pump and thermostat.
ENGINE AND ENGINE COOLING - ENGINE
01/01/19011
 1997 ford explorer faulty timing chain tensioner started making a noise. consumer believes ford should fix the problem at no cost. *kb
11/16/20081270001
 1997 ford explorer 4.0 sohc, my engine is making a terrible rattle sound while running, i have been told by many that its the timing chain tensioners, and that ford knows about the problem but is not doing anything to help owners to get this repaired. *tr
06/25/20081530001
 Ford 4.0l sohc timing chain issue. currently my timing chains are still in one piece. the plastic tensioners break, leading to chain slack, and eventually, breakage. there has been nothing done to correct it as of yet, the only way to repair them is to buy $500-$600 worth of parts and tools, remove the engine from the car and repair and replace the timing chains and guides. *tr
09/26/2007130000110/20/1997
 Tl*the contact owns a 1997 ford explorer. while driving 30 mph, the contact smelled smoke and then noticed smoke rising from the engine compartment. he pulled over approximately two minutes later and discovered flames coming from the engine compartment. there was a small explosion on the driver side of the vehicle. the vehicle was destroyed and a police report was filed. as of november 1, 2007, the dealer and manufacturer had not inspected the vehicle. his vin was not included in nhtsa campaign id number 07v336000 (vehicle speed control). the contact felt that a leak in the engine compartment caused the fire. the current and failure mileages were 130,000.
05/24/200655000108/01/1997
 Dt*: the contact stated the engine idled roughly. while sitting at a stop sign the vehicle idled erratically. while traveling around curves or down hills, at any speed, the engine felt as if it was going to stall. however, the engine has never completely stalled. the vehicle has been seen by the service dealer several times, but the problem could never be duplicated. updated 06/07/2006. *ak *ts
09/27/2003110000105/17/1997
 Engine crank broke off at pulley. no previous warning, it happened while driving at low speeds. 110 miles on engine at time of catastrophic failure. dealership laughed at request for repairs, warranty expired. i paid for new rebuilt engine cost= $3000.00. *nm
07/03/2005120000812/21/1998
 1997 ford explorer, 5.0 l engine, automatic transmission. the car's engine unexpectedly races to the point that its brakes will not hold it back. this sometimes happens when backing from a cold start and sometimes when braking for a stop at an intersection. the only way to stop the vehicle is to shift into park and turn off the engine. the effect is like being slammed into by a large vehicle. it almost killed my pregnant daughter and me earlier this month when it happened as i was braking for a traffic light. it felt like we had been hit from the rear, but it was the engine pulling its old trick again. the local ford dealer has been unable to diagnose and repair the problem. one year ago he said that it was the pcv valve and he replaced the valve. the car then behaved for about one year. then, without warning, with my wife at the wheel, the car, in reverse, raced out of our garage into the street. it was unstopable. later it did the same thing, while in drive, at intersections. i returned it to the dealer who could find nothing wrong. it then happened to me and my daughter and i returned it to the dealer who tested it for a week without results.
01/01/20011
 Ford explorer 1997, consumer paid for replacement of engine prior to ford recall. *bf the consumer was denied reimbursement under the recall because the replacement engine was not purchased from ford. *nm
01/01/20012
 Replacement of engine due to defective parts; throttle body plate and cam chain guide on motors. *bf the engine throttle plate stuck while the consumer was warming the vehicle on a cold day. recall #00v422000. the consumer requested reimbursement for the defective engine. the starter did not kick in per invoice. *sc
01/03/200315743108/05/1997
 First evidence of noise reported to dealer on 7/22/98. they said there was no problem. noise became unbearable and engine began lossing power. took it to dealer on1/2/01 and found out the front cam tensioner disintegrated causing severe metalic noises from the engine compartment. bankston ford supposidly did the well known recall. my paperwork shows they replaced the tensioner cassette and changed the oil. i obtained their own proceedures for this issue because many engines have had to be replace due to the pieces of the broken tensioner clogging oil passages and destroying the engines. the instructions they should have followed included inspecting the heads for clogged passages and other things. i believe they should have replaced the engine then, but they made me take it. as soon as i left dealer, the noise was back. called them and they said to give it a week and see if it goes away. it got worse and i brought it back in to the dealer. this time they said it was the rear tensioner (the one not coverered by their recall since it requires removing the engine. same part- same defect, but not covered due to cost). since ford was losing too much money on their defect replacing engines, they stopped helping their customers. the dealer offered a $500 and 75,000 mile warrantee dealer concession, but i expected it to be taken care of like everyone else. the defective part ruined the engine and it should be replaced, or at least repaired properly. have been at a stand-still for almost 2 years now with a non-funcioning vehicle. ford customer service will not do anything and the dealer now wants $5000 for a new engine.*ak
08/15/20045200012
 I have had my1997 ford explorer for two years, the same problem keeps recurring. it becomes suligish on the on set, than the check engine light comes on. 12 times now i have had to replace the spark plugs, 3 times i have done fuel enjection cleans, 2 times i have changed the o2 sensor. i have talked to other owners that speak of the same problems.*ak
12/15/2002900001
 Type e motor failure at only 90,000 miles resulting in replacement motor. *ak
1300001
 While driving at 65 mph vehicle suddenly started to decrease in speed without warning. engine had blown.*ak
07/11/2003139280103/15/1999
 I have experienced loss of power in the engine in my 1997, fordexplorer(purchased used, in june of 1999) causing me to lose my brakes while driving, i have taken this vehicle to several mechanics (for diagnosis) and have been told that this is a recurring problem, that ford knows about, and that there is something defective in the timing system, and i should take it to the dealer, for further diagnostics, after taking it to the dealer i was told, that the timing chain and timing casette had went and that there had been a service bulletin out pertaining to this problem and that owners had been notified, however i was never notified that there were problems with the engine in this vehicle, the dealer also told me that it would cost me $4500.00 for a remanufactured engine-replacement because the car was beyond the milage of the service bulleten. after paying $28,000.00 for a vehicle, as a consumer i would not expect to be subject to repetitive safety concerns for self, family and the public at large, especially when the manufacturer knows of the defective product (1997 explorer), and then told that i must pay the amount it would cost fora down payment ($4500.00) on a new vehicle, just to keep my investment safely on the road. everytime i have taken this vehicle to the dealer i have been robbed of my finances and dignity. i should not have to keep paying for repairs of this car, when ford knows they have manufactured a defective product. this is not the first time i have had to take this vehicle to the dealer for expensive repairs for defects that ford knows about and refuses to take responsibility for.merican auto manufacturers want to know why the american citizen has stopped buying american cars? well the answer is simple. we want to get what we are paying for ($28,000.00 worth)!! and ford auto manufacturer, is not giving us what we are paying for... instead they are taking us to the cleaners financially.. *ak
04/12/200356777106/10/1998
 Idle not returning after cruise control was disengaged and brakes would not work. cruise control kept accelerating. my three children were in the car, was able to stop the car by putting it in neutral, at that point the brakes worked. pulled to the side of the interstate and shut the car off. when trying to start car again, engine revved to the point where it sounded like it was going to blow up. *nlm
02/14/2003
 Head gasket - leaking anti freeze
11/21/20010
 Backed out of driveway and proceeded down street at about 10 mph. engine made a thunk noise and went into a no start condition. my '97 explorer was towed to the dealer who diagnosed the problem as a snapped crankshaft. at 103k miles the dealer did not acknowledge that this was any sort of manufacturing defect and emphatically stated that they'd never heard of this problem. they refused customer request that they review nhtsa webiste for history of prior reports. the dealer stated that the engine was only designed to last 100k miles but that might be extended with regular oil changes. this customer asked if engine replacement at 100k miles was an expected event and the dealer repeated that it could be. ford's national customer service was no help. the zone manager would not meet to discuss the problem. customer paid $4,800 to replace the engine. customer kept the broken shaft which shows multiple internal surface textures. to date there have been other complaints about this same problem without a response on this safety and manufacturing issue from ford. other websites report ford employees aware of this problem, loosely referred to as a stacking of tolerences whereby the tolerences exert pressure on the crankshaft just behind the key where it attaches to the dampner. this is reportedly not a condition that the owner can prevent, diagnose or otherwise be aware of until the crankshaft breaks. ford reportedly cannot make a prior determination either, seemingly leaving it to chance whether a vehicle will have problems. certain engine compnents are expected to fail during engine life such as water pumps, alternators and so forth but major components should not. ford should address this issue by revealing the design life of the crankshaft. j.d. powers relayed to this customer that crankshafts are routinely designed to last 200 - 250k miles, contrary to dealer assertations. the nhtsa needs to investigate this issue and take appropriate action.
12/18/20021250001
 Broken crankshaft on a 97 ford explorer.crank broke while driving on the interstate at 55 mph. all dash lights came on and engine quit.ford dealer confirmed crank was broken and new engine was needed at a cost of $4400.00.
05/01/20021
 The consumer stated, while driving, the crankshaft sheared off. the consumer contacted the dealer and was told that there was nothing they can do.*scc
07/30/2002105/01/2097
 When starting up the car, a loud noise came from engine. my personal mechanic advised it was a timing chain. ford towed it to the dealership and i found out that there was additional warranty coverage for this part. it was a failed timing chain guide. they are now in the process of reviewing it for ford to pay for repairs. entire engine may need replaced.*ak
1
 While in motion, the vehicle developed a problem with the engine. the cause of the vehicle failure was the crankshaft. the crankshaft had a crack half way through which has been there for a while due to weathering on the area. *jg
06/02/2001105/01/2001
 Timing chain was making a rattle noise and we had it checked out and they said that they had a safety recall .*ak
05/01/2001
 There is a constant rattling noise when driving. dealer determined it was the timing chain. please provide additional information.*ak
05/03/2002104/01/2099
 I was making a left turn in my 1997 ford explorer. all of a sudden the car engine just died and i lost steering power and the car would not start again. after having it towed to the dealer they examined the vehicle and told me that the crankshaft had broken and that it was unrepairable, and that my only option was to have the engine replace. from my understanding if i had been travling at a high rated speed i could have been seriously injured from that piece breaking off.*ak
04/01/2002107/01/1997
 While driving crankshaft sheared off. vehicle then completely shut down. consumer contacted the dealer. however, problem has not been resolved as of yet. *ak *tt
 Cranckshaf/pulley disconnected from engine. *ak
12/01/2001
 Drivers door lock not working properly, gasket cylinder front cover, torque converter shudder, catalytic converter, rt bank exhaust manifold; these problems have been corrected, but new ones mount every week. now there is a problem with the steering, being checked tomorrow. *ak
02/04/200210/01/2000
 While backing out of our yard , the engine just stopped working. had it towed to a local automotive repair service. was told that the crankshaft was sheared off . ford motor co. will not admit any equipment fault, leaving me with a $4200.00 price tag to get it fixed.. i have been told that crankshafts do not just shear or break off by other mechanics that i have talked to. looking at your site has shown me that this is not just an isolated case and it should be looked into by ford. i am thankful that this didn't happen while traveling at highway speeds which could have caused injury.thank you.*ak
11/01/2001
 While driving vehicle completely shutsdown without warning, cause unknown. please give any further details.*ak
11/03/2001101/01/1997
 Cylinder heads or head gasgets failed causing coolant leak into cylinders and out exhaust. suspect faulty heater valve leaked coolant causing engine to overheat and damage heads or gasgets.
06/27/2001107/01/1999
 The crankshaft fell out while driving, as the crankshaft fell out it caused the vehicle to lockup resulting in the vehicle not steering or braking very well. nlm
09/17/2001
 Cam tensioner broke. metal piece from tensioner ran through engine and damaged it. there was a recall on vehicle's make/model; but, consumer's vehicle was not included because it exceeded 100000 mile warranty. consumer bought vehicle and didn't know recall.*ak
05/01/1997
 Ford definitely has an engineering problem. is the nhtsa gonna deal with it or, are we going to wait till we have another wilderness tire issue. my explorer has consistently shown severe skip/miss for the past 2-months. at first indication....i scheduled it in to my local dealer (rochester auto collection - a divison of ford), who determined that it needed new ignition wires. (mind you, this vehicle only has 42,000 original miles, as i bought it new). three hundred bucks later, i notice the vehicle performing no better on the day i picked it up. so....we schedule a second visit. during that visit, they dink around with the throttle. again, the day i picked it up, i noticed it was no better. so....in we go for a third visit. during that visit i am advised that the timing chain tensioner has broken off and that they will need to pull the engine out to repair. so, we schedule that 3-day service visit. and here i am today.....after having picked up the vehicle, and now it is worse!! this is a $30,000 vehicle with 43,000 miles that runs worse than my son's '95 cavalier. as i review the database of consumer complaints, i note many, many issues relating to this timing belt tensioner. so......when is the nhtsa gonna step up to the plate, and make ford get their ducks in a row and fix this issue. as it is right now, between the tire incident and then this, i sincerely doubt i will ever buy a ford again.
01/01/2000102/21/2001
 When vehicle is sitting or moving there is a ticking noise coming from engine. vehicle was at repair shop, and mechanic told consumer that vehicle needed a cam chain guide. dealership was aware of problem.*ak dealer replaced the timing chanin, also the brake light was inoperative.*jb
08/12/200110/01/1999
 An unknown cause lead to the head gasket cracking and the cyclinders blowing-out on the vehicle, which now requires a new engine. vehicle was purchased with 46m miles and the return of a lease orignated with the delaership that sold the same vehicle to us. this was ford certified lease vehicle we were told, which means it supposedly wnet through the highest inspection upon it being turned in from the lease. the vehicle broke-down on 8/12/01 on busy interstate 84 at the juction of the merge of interstate 91 and 84, stranding my wife ( who ws driving) between two heavily used highways. both the dealership and ford have refused to take responsibility for the inherent defect in the manufacturing of the vehicle. acordig to the dealership a their ford representative, taryn, stated ford refuses to pay fany part of the repair becuse the vehicle was bought used and we did not do our service (oil changes) with the dealership, although we did do so at other places. we want ford and the delearship to pay for the full cost of repairing this vehicle.*ak
08/01/2000106/01/1997
 Ever owner i know who owns a ford explorer has a failure on this valve. i feel this should be recalled by ford.*ak
 While driving vehicle heard a loud noise and vehicle stalled. also, opened hood to check, and found a hole in engine block, size of a silver dollar. consumer had gotten notices for camshaft guide and retentioner, but was not honored because vehicle had gone over the mileage. contacted dealer, could find nothing, but did see metal shavings.*ak
05/01/1999
 Ford is aware of a recurring problem, the particular problem being a worn or broken cam chain guide which creates a noisy symptom which my vehicle has, then ford should be willing, if not liable, to fix it.
06/14/2001
 Vehicle had shutdown while driving. dealer was notified, and informed consumer that camshaft had failed. part was not covered under a manufacturer's recall, and was out of its warranty. feel free to provide any further information.*ak
06/02/2001106/01/2000
 30 mph, camshaft breaks. dealer says new engine required, $4500 est. ford contacted and offers $2000 assistance. this should be a safety recall and ford should be forced to pay for all damages b/c the forceful stop caused by engine failure could have caused serious injury to passengers or other vehicle due to skidding. this is not normal wear on a vehicle, is obviosly a ford defect.
 Consumer was starting to accelerate almost reaching speed of 25-30mph when engine shut off due to crankshaft that fell off. no prior warning . dealer has to replace motor, but cannot determine cause. *ak
02/12/2001101/01/1997
 While traveling at low speed, engine seized and car stopped abruptly, consumer had vehicle towed and was advised by mechanic that crankshaft broke and a new engine was needed. (check odi # 740940) *jb
05/03/2001
 Timing chain belt broke while travling at 35 mph with no prior warnings . has not contacted dealer. *ak
03/22/20010
 While driving about 65 mph engine malfunctioned. then, stopped and found that crankshaft was out of engine. vehicle had to be towed, and engine had to be replaced at dealer.*ak
02/27/2001
 Consumer was driving less than 30 mph and stalled. all lights came on. towed to dealer who found crankshaft had broken. crank pulley had broken off engine. no prior warning. *ak
03/04/2001
 While driving all lights on dashboard came on, humming sound, had vehicle towed. crankshaft had broken.*ak
08/28/20002
 Consumer was informed by dealer that the chain tensioner broke and the engine needed replaced, consumer had used engine put in vehicle, consumer received a letter (o00m12) extending the warranty on the camshaft chain tensioner (00m12) and lower intake manifold gaskets, if any repairs were performed because of a faulty camshaft chain prior to december of 2000, ford would give a full reimbursement, the used engine that was installed has the same defect and consumer is requesting a new engine be installed plus refund of the used engine, ford stated they would not replace the engine, only give reimbursement for the used engine. *slc
02/12/2001107/01/1997
 While traveling at low speed in light traffic, the crankshaft on my 1997 ford explorer broke causing the vehicle to stop quite abruptly. the motor must be replaced at a cost of $4500. this is a part failure that places individuals at considerable risk. had this incident occurred at high speed in relatively heavy traffic, e.g. freeway traffic at 55 mph or higher, there would certainly have been serious injuries and probably fatalities. to date, ford motor company steadfastly refuses to acknowledge any responsibility for the problem and, further, refuses to participate in paying for any portion of the necessary repairs or associated costs such as towing bills and car rentals while the necessary repairs are being made. *ak also see 560357.
02/12/2001107/01/1997
 While accelerating from a traffic signal, the engine siezed and the vehicle came to an immediate stop. unable to restart the engine, i had the vehicle towed to a service station where inspection by a mechanic revealed that the crankshaft had broken. the vehicle was then towed to conlon-collins ford in crystal lake, il where they confirmed that the crankshaft was broken and the engine must be replaced at a cost of approximately $4,500. i reported the matter to ford motor company's customer assistance center. they indicated that this problem has not been reported previously and no recall notices or service bulletins have been issued with regard to this problem. ford motor company has been reluctant to discuss bearing any part of the cost for repairs or incidental expenses such as towing or rental of a replacement vehicle while repairs are under way. a crankshaft should never break and one certainly should not expect it to fail after only 52,000 suburban miles. in my opinion, this represents a significant safety hazard. there is no question that had this incident occured at high speed or in heavy traffic, there would have been injuries and/or fatalities. *ak
09/02/20001
 While driving the tensioner failed causing the engine to stall without warning or indication of trouble, consumer request reimbursement. nlm
10/07/2000112/01/1996
 I heard a noise while leaving parking lot. immediately there was a rattling sound in the motor, then the truck stalled.. the vehicle was towed into the dealership. their diagnosis is the engine needs to be replaced because of a timing chain failure that jumped loose and knocked a hole in the left valve cover. there was no prior warning or occurence before this happened.
07/07/2000110/01/1997
 While driving about 25 mph and all of a sudden vehicle just died. this happened without any warning. vehicle would not restart. this was due to a broken time chain tensioner. entire engine was being replaced. ford refused to help consumer with this matter. *ak manufacturer changed the design due to timing chain tensioner problem with this make of vehicles. *yh
10/02/20000
 Engine crankshaft broke. while sitting in vehicle heard a funny noise. then, vehicle died, and would not start again. consumer felt this was a manufacturing defect because of the way the crankshaft fell off.
1
 When driving consumer noticed a rattling noise coming from engine comparment. vehicle cut off without prior warning. consumer contacted dealer, dealer noted that engine had a hole which was caused by the timing belt that came off. engine needed to be replaced. *ak
06/24/1998104/01/1997
 Timing chain accesories are made of a poor material causing it to break . whats worry all the costumer is that the people the have does not know how to deal with this situation in time(warraty time) making this problem prolong so much that the costumers have to deal with the problem and it cost having the situation during the warranty time.
02/22/20001
 Engine crankshaft failed. *et
09/10/2000111/01/1996
 4.0liter sohc has defect in the design of timming chain idler . this caused engine to stall and severe valve damage . ford is recomending complete engine replacement ( $4,800 ) with 2000 model. ford is obviously aware of the defect but i was never notified. *ak
07/12/2000111/01/1997
 Timing chain needs replacement? $1,700 and truck isn't even 3 years old.*ak
06/29/2000103/17/1997
 Stopped for a red light and all of a sudden engine shutoff and all of the lights on the dashboard came on. looked under the hood belt, came off, and noticed the pulley was laying against the radiator. towed the car to the dealer. *ak dealer notice crankshaft broke outside of the engine. *yh
01/21/2000102/01/1997
 1-21-00 took car into magic ford in santa clarita, ca. for warranty work, replace catalytic converter. i was informed by tim heming that the timing chain tensioners were bad. about $1500.00 to fix. i asked if it was a warranty item. he said no, but i can call the ford customer assistance guide to see if i can get finacial help. i did and they said no. 1-27-00 i had my own service tech. pick up car and start the repairs. 2-1-00 my service tech., ken wagner lic.#0706-121676 informed me that the timing chain tensioners were broken and sucked up in the engine and desstroyed the engine. he also informed me that the timing chain tensioners have been upgraded from some kind of plastic material to metal. he also informed me that the dealer he ordered the parts from has ordered 104 of them. the dealer is antelope valley ford lancaster, ca. the cost to buy and install the new engine was $4000.00 i had to pay to ken wagner. i think that do to the fact that the parts have been upgraded and so many are being ordered that ford is aware of this problem and i should be reimbursed for my out of pocket expense. *ak
03/23/2000109/01/1998
 Mechanic stated metal used in making crankcase too soft. this problem shouldnt occur with the mileage and year of this vehicle. *ak
01/04/2000
 The timing chain broke off and knocked a hole in the valve cover tensioner. could smell oil burning prior to problem with timing chain. vehicle was towed to dealership for repairs of timing chain. *ak
07/26/19993
 The timing chain tensioners do not support the guides as it was designed to do causing loud rattling. nlm
1
 The timing chain and tensioner failed due to design problems causing the vehicle to idle rough and make alot of noise upon startup and while stopped at a light. nlm
12/13/1999
 Tensioner plastic piece wich supports the timing chain broke, caused the vehicle to stall while driving which may cause a crash. please provide further information. *ak
 Timing chain broke, causing the engine to blow up. dealer replaced the engine. problem with timing chain has occurred again. *ak
07/07/1999302/01/1999
 Engine- vehicle began making knocking/ticking noise from engine at 30000 miles, took into dealer to report it, and they said no problems. noise was at start ups and after vehicle had set for brief time. noise became louder and longer in duration, took back into dealer at 35000 miles, again, they said no problems-normal noise. at 41900 miles, vehicle became undriveable, noise was extremely loud and metallic in nature. took to different dealer who stated that they had numerous problems with 1997/98 explorers with 4.0sohc engine timing chain tensioner failures. most were under warranty and they sent entire engine back to manufacturer to repair. now my vehicle was out of warranty and the reapai cost me $700.00. the vehicle went back 3 days later with same problem, another $300.00. i feel that i reported my problem while the vehicle was still in warranty and that ford should cover the repairs. i also think thatford is fully aware of a widespread problem with these 4.0 sohc engines and the timing chain/tensioner defects. i have talked with many dealers and individual owners who have stated the defect is not isolated. had my family and i been traveling at high speed when this thing went bad and the engine quit,there could have been an accident. there needs to be a formal investigation into this issue, it is too widespread and ford certainly is aware of the problem, but unwilling to address it and compensate consumers who are suffering with this. fuel system- there is also a hesitation/stalling that occurs on same vehicle that has been into teh dealer on several occasions to fix, but can not be diagnosed or repaired. this is very dangerous especially when pulling into intersections or turning at traffice lights. my wife has had several near misses due to this. again, this appears to be widespread with this 4.0 sohc engine. please let's have something done about this before someone is hurt. ford's army of engineers surely are aware this exists. mark ditto
11/01/1997
 Cam chain tensionners replaced at 19004 miles dec. 1998 but still making rattling noise when starting
10/27/1999108/01/1997
 While traveling about 35mph, check engine light appeared. took vehicle to dealer who indicated that the intake gasket was loose and resulted in the check engine light coming on. dealer noted that the gasket allowed dirt to enter the engine.
12/15/1998107/28/1997
 Rocker arm cover out of order.
102/01/1997
 Oil pump failed. *yc
 Timing chain broke, causing vehicle not to run at all. dealer said itwas defective, and the manufacturer doesn't make part anymore. *ak
04/01/1998108/01/1997
 Check engine light came on, due to engine sensor failure. *yc
06/22/199910/01/1997
 There is a faulty timing chain with the ford explorers. ford has admitted that they know there is a problem. they also said there is no fix right now. this has been going on for over a year. the problem has gotten so bad that they are replacing the engine. they can not guarentee me that this problem will hapen again. *ak
05/17/1999
 Consumer was at stop sign when there was a loud popping sound and the engine shut down. timing chain broke. consumer was hearing popping noise for years, took to dealership and they never were able to duplicate noise. *ak
06/01/19984
 Was traveling approximately 40mph when vehicle stalled. took to dealer & informed defective engine & needed to be replaced. had no anti-freeze. received another engine off manufacturing line. engine lasted 2 weeks. had paid half. the 3rd engine replaced free. there is some stalling in this engine as well. *ak
08/06/1997102/12/1997
 Pinion seal leaking.
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
10/01/1999
 My '97 explorer sport makes a diesely noise. i have seen many complaints on the ford enthusiasts message boards. i have had several repairs done and it hasn't fixed the problem. i've heard belt tensioner, cat converter, heat sheild, lifters , bearings, arm rockers, and even rod knock. ive also heard there was a batch of '96- early '98 explores made typically the sohc. i want some answers. i am fed up with having unnecessay repairs done to my truck. please contact me. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
01/03/200315743108/05/1997
 First evidence of noise reported to dealer on 7/22/98. they said there was no problem. noise became unbearable and engine began lossing power. took it to dealer on1/2/01 and found out the front cam tensioner disintegrated causing severe metalic noises from the engine compartment. bankston ford supposidly did the well known recall. my paperwork shows they replaced the tensioner cassette and changed the oil. i obtained their own proceedures for this issue because many engines have had to be replace due to the pieces of the broken tensioner clogging oil passages and destroying the engines. the instructions they should have followed included inspecting the heads for clogged passages and other things. i believe they should have replaced the engine then, but they made me take it. as soon as i left dealer, the noise was back. called them and they said to give it a week and see if it goes away. it got worse and i brought it back in to the dealer. this time they said it was the rear tensioner (the one not coverered by their recall since it requires removing the engine. same part- same defect, but not covered due to cost). since ford was losing too much money on their defect replacing engines, they stopped helping their customers. the dealer offered a $500 and 75,000 mile warrantee dealer concession, but i expected it to be taken care of like everyone else. the defective part ruined the engine and it should be replaced, or at least repaired properly. have been at a stand-still for almost 2 years now with a non-funcioning vehicle. ford customer service will not do anything and the dealer now wants $5000 for a new engine.*ak
06/01/20041308/16/2003
 I had purchased a 1997 ford explorer xlt from mk auto in auburn, ca and the car fax i recieved said there had been no recalls and no accidents on the vehicle. the owner from mk auto assured me many times that the fehicle was in good running condition. the day after i baught the vehicle it broke down in me. mk auto took it back 3 times in hopes they could fix it, but never did. 10 months later the cam chain guid broke in the engine. my husband and i looked on the internet and found there had been 13 recalls on my vehicle i never knew about. this car in very unsafe for my family and i am outraged i was never notified! i have now tried to buy another car, but the ford explorer is worht so little and now i have so much negative equaty its hard.......i finally found a car, but am paying dearly for it because of the explorer which has been sitting in the car lot of a ford dealership for over a month!*ak
11/15/20011
 Engine is a 1997 4.0l sohc. there is a very noticible miss in the timing at idle. when the vehicle is sitting still, it bucks and shudders the whole truck, but the idle speed never varies more than 100 rpm. had same problem with 1991 explorer 4.0l. dealer ran on the vehicle and could not find any problems. mechanic said this is common with these engines. dt
10/03/2000108/01/2000
 My vehicle suddenly started accelerating when i was proceeding down the interstate. i could slow the vehicle down somewhat by aggressively applying the brakes. however, this would just get me slowed down a little until i would release the brake. the vehicle would suddenly speed up again. i was traveling on a fairly busy stretch of interstate at the time of the incident. i luckily did not have a need to stop quickly while this problem occurred. i tried hitting the accelerator a few times to get it to stop sticking in the wide open position. i even tried manipulating the cruise control (which was off). after several failed attempts to remedy the problem, i started trying to think of a quick game plan to get out of this potential disaster. i am very thankful that my wife was not driving at the time and that i did not have others in the car during this nightmare. i was finally able to find a shoulder where i could pull off the road. as i said, the road was extremely busy and i was very worried about getting off the road safely with a semi-truck not far behind me. i pulled toward the shoulder and put the car into neutral. the rpm's, which had been running extremely high for about 3 minutes, moved even higher at this point. the rpm's were pegged to the top of the gauge for about 30 seconds. as soon as i felt i was off of the roadway enough, i turned the key to the off position. when i got out of the car there was a horrible burning odor coming from the front of the car. i am not only concerned about the problem that may have triggered this incident, but i am also very worried about collateral damage that this undoubtedly caused. i feel that this caused an excessive amount of wear and tear to the engine and the braking system. on top of all of the physical damage done to the car, the experience was scary to say the least. my wife refuses to even get in the car at this point. needless to say, she doesn't want my kids to ride in it either.
203/01/1997
 Consumer states that there is a significant safety hazard with this vehicle. the vehicle is experiencing revving and stalling. consumer feels that the vehicle is unable to be corrected. the problem has been able to be fixed temporarily to reduce the severity of the problem, even in consultation with ford motor company engineers. consumer has continued to experience several unexpected surges in the engine revs in different situations. *scc
11/01/1999207/01/1997
 The engine locked up and was replaced twice, the dealership refused to pay for any repairs. *mj
06/05/2002110/01/2099
 No summary listed for above vehicle. *ak
12/10/1999311/01/1999
 Consumer stated when vehicle was being started it sounded like a diesel engine, the engine light was appearing on the dashboard, consumer was informed that a new engine was needed, consumer states vehicle is now on its 3rd engine. *jb
10/01/200111/01/2000
 I ha d a warranty through ford motor co. they will not honor it nor will the dealership i complained about this loud metallic rattling noise they (the dealerships service writers) said that the problem was fixed back in october it was not nearly a half a year later there was enough engine damage that it needed to be replaced my extended warranty states if the front cam chain guide is not functioning properly it will be replaced by ford free of charge any other engine damage clearly resulting from a worn or broken front cam chain guide is also covered by this extended coverage again this extended coverage is not being honored by ford or the servicing dealership. *ak
12/10/1999311/01/1999
 Consumer stated when vehicle was being started it sounded like a diesel engine, the engine light was appearing on the dashboard, consumer was informed that a new engine was needed, consumer states vehicle is now on its 3rd engine. *jb
07/29/2001107/01/2000
 While driving pressed on gas pedal to accelerate, and vehicle would die. when car was in park it did not cut off. but, soon as consumer pressed gas pedal it shut off. *ak *jb
1
 Check engine light illuminated, possibly engine related. *slc
05/13/2001107/01/1997
 Cam chain tensioner failed, as described in technical service bulletins 00m12, 01m01, 12150, 6926. ford customer relations refuses to cover the repair. they claim this is not a safety issue. i claim it is. when mine failed, i was nearly run over by a semi tractor trailer following behind me due to instantaneous loss of power without warning. ford should be compelled to issue a general recall on all such engines with this known defect.*ak
205/01/2000
 While driving the vehicle shut down and lost all power, the dealer replaced the timing chain, 2 days after this repair the vehicle broke down again, this time it was determined that the vehicle needed a new engine. nlm
04/26/20011
 After cutting car off and parking for a while, consumer tried to restart car and it would not start. *ak *jb
05/10/20001
 Faulty serpentine belt causes squealing noise at times, there is also an oil leak from the vehicle. nlm
 Engine failed while driving, causing vehicle to stall due to overheating. cause unknown, dealer does not know why vehicle overheated. complete engine needs to be replaced. *ak
02/25/2001
 Ongoing problem with defective engines. dealer / manufacturer notified, and replaced engine. later on, problem reoccurred again. engine needs to be replaced again. feel free to provide any further details on this matter. *ak
12/05/2000106/01/1997
 I am sending this information as requested but my major concern is that i have not been personally informed for the recalls to the ford xlt explorer except the one for the firestone tires and the one for the motor oil pump. my wife and myself contacted bayamon ford dealer for information on other recalls that appeared in the news and no response was received from the dealer. could you update me in this issue? should i contact the ford company? *ak
12/15/200004/01/1998
 On 12/18/00-i had my car towed to romeo ford,because my motor died sitting at a red light waiting to turn ,romeo ford informed me that something in the upper half of the motor let go and that ford motor company did not recomend the motor be repaired-that a factory rebuild is recomended-my cost would be 1,600.00-and that ford would pick up the rest-i thought great a new motor for 1,600.00 dollars-i said fix it-i got the car back 01/18/01-runs great-on 01/24/01 i get in the mail a safty recall packet from ford motor company-in this packet is a warranty extension on the camshaft chain tensioner-(thats what let go to kill my motor) i thought great my new motor is covered under warranty-i get my $1,600.00 back! -nope- romeo ford -ford motor company-will not honor the warranty extension-can you help me?*ak
11/27/200006/01/2000
 No summary listed for above vehicle. *ak
04/26/2000106/01/1997
 While driving at 50 mph heard a loud noise, and then saw smoke coming out of engine. vehicle was totalled. *ak
03/01/2000203/20/2000
 Consumer hears a tapping in the engine when foot is on the gas. *slc
10/20/19972008/01/1997
 My 1997 explorer will temporarly stalls without warning since new, usually when pulling out into a stream of traffic.this causes a severe safety problem for the occupants of the car. i have taked the vehicle to tallahassee, ford, tallahassee, florida several times (remaining overnight there for over 10 days) and the only effort to fix this problem was to install a set of spark puugs. the service manager advised me not to bring the car back since the problem is intermittent and can't be fixed. i feel no one has taken my complaints seriously and no real effort has been made to fix this problem. the vehicle continues to have the problem, noticibly worse in hot weather and i have no more support from ford motor comapny despite writing and calling ford's consumer complaint division. the car remains to be hazardous to drive and i hope you can help me with this problem. i am really suprised at ford motor company for placing a long time customer in a dangerous vehicle with no support in making necessary repairs.
08/30/2000101/01/1999
 Engine making ticking noise where time chain is. after disassembly by mechanic found tensioner with timing chain was defective. new tensioner and timing chain installed( dot number: )
07/28/200004/01/2000
 Engine stopped. never started again. plastic cassette guide failure in engine?? said dealer. timing / valves all went.
07/31/2000101/01/1999
 I have a big question conserning the 4.0 sohc plastic cam tensioner. i have had my explorer in a local shop for 4 weeks diagnosing me check engine light problem. today i find out that i have a totally wrecked 48,000 mile engine due to the fact that ford installs plastic cam tensioners from the factory only to replace them later with steel units. i also found out today that i am going to have to purchase a new engine for the low, bargain basement price of $5400. my god that makes me happy. there are 4 explorers in my local dealership with the same problem. i am beginning to see a trend here! could somebody please tell me what's up with these engines. i was also told that the new engine, which is a 2000 model, has been redesigned.
 When depressing brake pedal vehicle would stall without any indication. please provide further information.*ak
12/27/1999
 Started vehicle in mornings, and it ran rough. also, motor stalled. contacted dealer. dealer indicated that intake manifold gasket needed to be replaced. was told by dealer that they were on national backorder. *ak
04/01/2000301/01/1997
 Car stalls at speed.. premature failure of intake gaskets..ford may have redesigned but no recall.. caused loss of control 17 year old driver. *ak
 While traveling 0-25 mph after stopping vehicle shutdown without any indications. also, engine check light flashed. dlr has been notified. please provide further information. *ak
10/01/199903/01/1999
 Engine ticks primarily at cold startup. problem becoming more prevelant however, now it occurs also at a warm startup. engine also hisses at low speeds to idle. rear end leaks fluid and also shudders at high speeds. clunking noise often heard and felt from rear end when vehicle stops.
 Upper and lower engine intake gaskets are leaking, causing air to enter into the cylinder, resulting in engine idling erratically and eventually no start. please give any further details. *ak
12/22/1998
 Consumer was driving the vehicle on the road at approximately 40 mph when she heard a grinding noise and noticed engine smoking. dealer noticed, and informed consumer that the repairs would be the consumer's responsibility. *ak
1
 Chain tensioners have deteriorated and broken up. engine now rattels and grinds. i have fear of major engine damage. after talking to ford dealers in reno nv and one in susanville ca i have been told every thing from your on your own to ford is working on a permanant fix so be patient. is ford going to fix my problem . i understand this to be a major widespread problem.
09/01/1999111/01/1996
 Ford acknowldges problems in their service bulletins relating to this particular part. the service alerts warn of catastrophic engine failure which is what happened to my vehicle. this defect cost me $2178.68. ford refuses to cover any of these costs. *ak
09/17/1999
 Engine misses and stalls in various situations including highway speeds and from a stop. dealer has been unable to repair after replacing ignition wires and vaccuum assembly. i consider this to be a very dangerous situation because of loss of power steering and brakes. it also causes the vehicle to act as if the brakes have been applied causing a stop from high speeds.
08/03/1999
 I know that ford is fully aware of the problem. the replacement parts reflect that. those who experience failure during warranty are fortunet to save hundreds of dollars. i still as of yet not claimed my vehicle .
11/18/1996
 Engine is noisy.
08/20/1999
 While traveling at any speed vehicle will stall and hesitate without prior warning, causing loss of power steering and power brakes . consumer has contacted the dealer, dealer has replaced parts. please provide any further details. *ak
05/01/1998108/01/1997
 Engine seal leak. *yc
805/19/1997
 Intermittently when making a quick left turn the truck loses power. the problem has been reported to the dealership. dealer cleaned speed sensor and replaced idle air control, but the problem still exists. *ak *ml
06/25/1999
 Check engine light came on while dirving 25-35 mph. vehicle had no power/ brakes. vehicle coasted to a parking lot to avoid an accident. was not able to steer car. *ak
6
 On-going problem with vehicle vibrating in front, vibration would commence whenever taking off from a stop position or whenever transmission would shift gear. vehicle has been in and out of the shop on five occasions,condition still unresolved. the check engine light also illuminated, had dealer check vehicle and found the cv solenoid, ftp sensor and the o2 monitor were bad. *jg
05/27/1998105/01/1997
 Was driving and car stopped with a clicking sound. no prior warning with engine lights, etc. dealer claims failure to change oil resulted in engine failure and that engine needs replaced and ford also denied claim to replace said engine. *ak
02/19/1999801/01/1999
 No summary mentioned for this vehicle. ak
 Have had a intermittent valve tap since a recall was done ,it's getting progressly worse. dealer has replaced tappets once and the timing chain tensioner thinking it was that .now i see two tsbs' nhtsa #sb051948 and #sb051128 and was wondering if they might apply and can i do anything to get the problem resolved ? thankyou for any help ,shannon
08/01/1997
 Repeated failed attemps to correct ping/tick when engine is below 30 degrees f
04/22/1999112/01/1996
 Engine failure due to oil pump drive assembly failure(ford recall campaign #97b12). manufacturer refuses to cover under warranty.
10/01/1997
 When engine is warm and vehicl is at a stop, driver attempts to accelerate hard to get into traffic the engine will stall or hesitate. *ak
06/20/19981005/01/1997
 Vehicle has been brought back to dealer several times with same complaint, dealer complies ,has acknowledged ford has problems. however, nothing has been done that seems to rectify the problem. vehicle has had problem since the first year, and it continues to get worse. investigation control number was issued #118268bh (11/30/98). ramp ford has been helpful to us in this matter, but it seems that ford has not provided the dealership with a way to fix this problem. *ak
03/23/1999
 Vehicle caught on fire in the engine after sitting for over an hour. also caused the house to catch on fire. *ak
01/07/19982505/16/1997
 Engine o-rings and computer program faulty causing continued engine stalling.
05/27/1997102/12/1997
 Motor failed.
06/09/19989
 When parking the vehicle or leaving vehicle overnight, the vehicle does not start, and this is a problem for the consumer. manufacturer was contacted. *ak
06/29/19981
 Consumer was driving on highway at 55 mph under normal road conditions, consumer heard something popping. then noticed a gas smell. within a few seconds later other motorist was signaling for consumer to pull over. pulled over and found engine on fire. dealer notified and informed consumer that they do not do fire repairs and the vehicle was not under warranty. *akthe vehicle was under warranty but the warranty did not cover fire related failure. *nlm
01/22/1999312/01/1998
 When starting cold engine races and gas pedal sticks, i live in florida so it doesn`t happen unless its 50 deg or less, engine also almost stalls, dealer could not find the problem. *ak
01/10/1999311/01/1998
 Engine stalls and almost quits entirely during acceleration. most noticeable at speeds 50 - 55 mph. may be in conjuction with a slight turn of the left (during lane change on the freeway.)
01/19/19992507/01/1997
 Engine stalls sometimes when turning left after stop. very dangerous in traffic. taken in to multiple dealers who can never reproduce the failure. stalling problem seems common among people with 4.0 sohc engine (based on internet discussion). truck was bought/registered under my wife's name: kathleen.
07/04/1998608/01/1997
 When accelerating to turn left with my s.o.h.c v6 explorer, the engine will sometimes cut out and almost stall in the middle of the intersection with cars bearing down on me. it goes for 2 seconds and then cuts out for 2 seconds. it will then take off again. at first i thought it had to do with the heat outside, but it happened this january. i have always been turning left under quick acceleration. has happened with 1/4 tank of gas to nearly full. i did a search in dejanews and found approx. 20 other similar cases. it is very scarry to have your vehicle almost die in the middle of an intersection with cars coming at you. it happened twice in the summer of 97, 3 times in the summer of 98 and once in january 99.
11/24/19983
 Early in 1998 consumer saw oil in driveway, she took vehicle for oil change in february. a week later the oil spot was bigger. took vehicle back to dealer in june 98, and they saw no leak. the oil leaks got bigger. consumer has taken vehicle to dealers three times. banner ford--1665 scott blvd. decatur, ga---404-633-4005. vehicle is still leaking oil today. *ak
08/02/19983
 When vehicle comes to a stop the motor races with the rpm's going up to 6000, idle arm sensor replaced, but still idling high.
111/13/1997
 Vehicle experiences continued hesitation.
808/28/1997
 Engine turns and vehicle moves on slight incline with engine off and manual transmission in first gear. resulting in crash.
504/11/1997
 Ford was never able to determine cause of problem (engine cut out and or stalled upon moderate to hard acceleration, on most occasions from a stop) with vehicle after 5-6 repair attempts on parts listed above. vehicle was replaced by ford with a 1998 explorer that turns out to be exhibiting the same problem that the 1997 explorer did.
07/09/19974
 Engine stalls
03/26/19980
 While driving vehicle about 45 mph after leaving from a gas station, smelled somthing burning. stopped and looked under the hood, but did not see anything. when parked vehicle on the bank parking after coming from inside, found her vehicle on fire. dealer and manufacturer were contacted. *ak
02/03/199811/07/1996
 While driving at 40 mph the engine caught fire.
103/01/1997
 While driving the engine cut completely off. dealer replaced engine. *ak consumer states that after engine replacement, oil pump assembly failed and then oil was leaking again after that was replaced, dealer has agreed to replace consumer's explorere with a 1998 model. rack and steering was replaced, due to lost fluid in front end. seat bracket failed. *slc
09/15/199730
 Consumer was going to pull out into traffic, merged into lane when vehicle completely stopped/no motion, but engine was still on/running/and in gear. pushed pedal to the floor, heard noise, no response. gradually picked up speed after waiting about 30 seconds to 1 minute. dealer could not duplicate same problem. *ak
07/13/19970
 While driving on highway at 65 mph suddenly the engine light came on and the engine cut off. the vehicle was taken to the dealer, and the dealer said that the engine needs to be replaced. *ak
01/11/1997112/26/1996
 The engine races from 55 to 70 mph.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
07/27/200460000209/19/1999
 1997 explorer 4.0 sohc purchased in 1999.made knocking noise went to dealership several times under warranty and was told my motor was pulled and tensioner (pulley, cam tensioner) was replaced.after recieving notification from ford of in warranty service bulletin,different dealer said it hadnt been replace or documented by previous service.so,it was supposedley replaced again (2 time).still making the noise after so long, and told several times we cant find anything wrong kept driving.now, i am in dealership for about 10th time and my tesnioners,possibly my timing chain,and possible other components (hopefully not motor)need to be replaced again(3time,more damage)??!!this time theres no warranty or reason why i shouldent have to pay so it is costing me $1600 so far...possibly more if there was more damage.this must be documented because i have tried in good faith and numerous,tiring efforts to repair this from day one!do not want to have to replace motor in near future like others.*ak
04/10/200486000108/08/2002
 Without any warning, lost all power, engine totally shut off at 45 mph. had towed and was told crankshaft broke. ford knows of problems with the crankshaft and has actually replaced some but as more are breaking, refuses to deal with the problem. had this happened the previous weekend while traveling rt. 95 this could have had serious consequences. please look into the numerous complaints about the 1997/1998 ford explorer crankshaft problems. *jb
2
 While driving serpentine belt came off, and driver lost control of the vehicle. also, when braking there was a grinding noise. *ak
07/21/20031
 Consumer took vehicle into inspection station and didn't pass inspection because of the timing belt was making noise. dealer stated it would cost about $1500.*ak
07/11/2003139280103/15/1999
 I have experienced loss of power in the engine in my 1997, fordexplorer(purchased used, in june of 1999) causing me to lose my brakes while driving, i have taken this vehicle to several mechanics (for diagnosis) and have been told that this is a recurring problem, that ford knows about, and that there is something defective in the timing system, and i should take it to the dealer, for further diagnostics, after taking it to the dealer i was told, that the timing chain and timing casette had went and that there had been a service bulletin out pertaining to this problem and that owners had been notified, however i was never notified that there were problems with the engine in this vehicle, the dealer also told me that it would cost me $4500.00 for a remanufactured engine-replacement because the car was beyond the milage of the service bulleten. after paying $28,000.00 for a vehicle, as a consumer i would not expect to be subject to repetitive safety concerns for self, family and the public at large, especially when the manufacturer knows of the defective product (1997 explorer), and then told that i must pay the amount it would cost fora down payment ($4500.00) on a new vehicle, just to keep my investment safely on the road. everytime i have taken this vehicle to the dealer i have been robbed of my finances and dignity. i should not have to keep paying for repairs of this car, when ford knows they have manufactured a defective product. this is not the first time i have had to take this vehicle to the dealer for expensive repairs for defects that ford knows about and refuses to take responsibility for.merican auto manufacturers want to know why the american citizen has stopped buying american cars? well the answer is simple. we want to get what we are paying for ($28,000.00 worth)!! and ford auto manufacturer, is not giving us what we are paying for... instead they are taking us to the cleaners financially.. *ak
04/14/2003
 The vehicle was serviced on 4/1/03 for the check engine light. on 4/14/03 consumer entered a parking lot and turned off vehicle ignition. consumer restarted the vehicle, heard a thump, and noticed the battery indicator light was illuminated. the dealer diagnosed that the serpentine belt popped. *nlm
12/23/2000305/01/2000
 New engine needed. i have had ford replace the cam tensioners, only to have had it fail now for the 3rd time in 8 mos. i am going to request the engine be replaced at dealer cost, as it was a recalled part. the warranty was extended to 72k miles back in jan 0f '01. i now have 90k and the problem has reocurred. the problem was never really corrected, so its my opinion that ford is obligated to correct this. was told engine needs replacement. have had a constant 'ticking' since purchased. now very loud clattering and 'rapping' noises in timing chain area. i was told there are 6 chains on this engine and they only replaced the front, saying if the back ones are bad, the engine needs to be replaced...and that that is the problem since the first 2 replacements have gone bad again.*ak
06/11/20011
 Consumer was starting vehicle in the morning and there was a loud boom with a toxic smell. there were no flames. started it again, and it didn't do anything. there was a small mini explosion underneath hood. dealer stated that uper intake had blown to pieces. undetermined of the cause, but assuming a missed fire. *ak right rear gasket intake manifold failed and was replaced. spark plugs were replaced. the fan belt were replaced. *yh
05/10/20001
 Faulty serpentine belt causes squealing noise at times, there is also an oil leak from the vehicle. nlm
12/15/1998107/28/1997
 Tensioner failed. yh
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
11/18/2000105/01/1997
 Engine check light came on and stayed on when weather got cold. the ford service said the the air intake valve gaskets shrank and was letting in too much air and carbon monoxide into to the gas tank. i've never seen or heard of this happening with truck under 100,000 miles.*ak
11/01/1998
 I purchased this vehicle in november of 1998. at the time it had 10,000 miles on it. i noticed the vehicle had what seemed to be a shutter or vibration. i took the vehicle back to the dealership and the service manager drove with me for many miles. he stated that this was a normal characteristic of the vehicle. everything is a normal characteristic of the vehicle. i have taken the vehicle to a certified transmission repair/replacement shop and have found that this problem is actually an emissions problem, and that the computer needs to be flashed to change the strategy of the torque converter. i would like this issue addressed as it causes my vehicle to vibrate and at highway speeds the vehicle feels very unsafe.*ak
03/23/1997
 Vehicle vibrates at idle in drive or park at 625 rpms. dealer replaced the exhaust system per ford, however the problem remains.
701/08/1997
 Vehicle experienced misalignment. in addition, replaced fuel gauge sendin gunit/air bypass valve/ water pump/seat release/passenger's door and computer. *ak
1
 Emissions control system failure.
10/22/1996
 While running engine emitted an awful odor, dealer has been unable to determine source. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
10/31/2000205/01/1997
 Onboard diagnostics indicated oxygen sensor error--common problem. *ak
07/18/1999209/01/1996
 I was driving down the road and when going down a hill the veh. stared to make a grinding noise. i had to get up out of the hole to pull off and i noted that when i steped back on the gas it stoped. it only does this when coasting or braking. i took it to the shop and they said it was a failure in the transfer case. i started looking for a new one on the net and found alot of other people describing the same problem to a t. one guy stated that his mechanic said that the gem control module had failed or partially failed and commanded the tranfer case to disengage causing damage to the case. it appeared to be a ford electronic defect not having a fail safe mode but instead ordering the tranfer case to self destruct. the oxygen senors i replace them and they go right back out.
07/07/1999
 Vehicle experiencing ongoing problem with fuel vapor smell coming inside the vehicle. dealer notified, and was unable to locate the problem. also, seat moves back and forth, and driver's shoulder belt would not latch properly. dealer notified. *ak
12/15/1998107/28/1997
 Intake manifold failed. yh
09/01/1997101/01/1997
 Emmission/exhaust control sensor failed causing the check engine light to illuminate. mjs
11/02/1998111/01/1997
 Oxygen sensor failed.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
12/01/2001
 Drivers door lock not working properly, gasket cylinder front cover, torque converter shudder, catalytic converter, rt bank exhaust manifold; these problems have been corrected, but new ones mount every week. now there is a problem with the steering, being checked tomorrow. *ak
1
 Catalytic converter was replaced. *slc
01/21/2000102/01/1997
 1-21-00 took car into magic ford in santa clarita, ca. for warranty work, replace catalytic converter. i was informed by tim heming that the timing chain tensioners were bad. about $1500.00 to fix. i asked if it was a warranty item. he said no, but i can call the ford customer assistance guide to see if i can get finacial help. i did and they said no. 1-27-00 i had my own service tech. pick up car and start the repairs. 2-1-00 my service tech., ken wagner lic.#0706-121676 informed me that the timing chain tensioners were broken and sucked up in the engine and desstroyed the engine. he also informed me that the timing chain tensioners have been upgraded from some kind of plastic material to metal. he also informed me that the dealer he ordered the parts from has ordered 104 of them. the dealer is antelope valley ford lancaster, ca. the cost to buy and install the new engine was $4000.00 i had to pay to ken wagner. i think that do to the fact that the parts have been upgraded and so many are being ordered that ford is aware of this problem and i should be reimbursed for my out of pocket expense. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
08/30/200266502102/13/1999
 Egr valve failed at cost of over $250. this is part of the emissions system and is covered by an extended warranty. i requested warranty status for this part from ford motor co. customer relations center in letter of 7/17/03 with 76,172 miles on vehicle. initial check engine light for this failure was at about 66,000 on 8/30/02. ford did not answer my inquiry, instead referring me to their customer service reps in india, against my wishes. *jb
03/01/2000203/20/2000
 Egr valve pipe has a crack, consumer feels dealer should pay for this repair due to the number of miles on the vehicle.
06/01/1998102/17/1997
 Exhaust gas recirculation valve tube failed. *yc
 Recall 97v074000. the dealer has no parts. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
01/01/20041000001
 My 1997 ford explorer has an intake manifold failure. i understand by reading many message boards and other complaints on the internet that ford has recalled this item on some vehicles but not all. i really can't believe that ford would actually use a plastic intake on anything. i believe it is a break down in judgement and ford should be responsible for the replacement of this part.*ak
01/01/1901781321
 Consumer is a victim of odometer fraud, encountering problems with the vehicle that's uncharacteristic for the mileage on the vehicle. (nar) *ph exhaust system, ball joint, and instrument panel had to be replaced. *cb
03/05/2003111/15/2002
 Engine surging when cold. i have had the codes read and will not tell what the problem is. poor gas mileage. valves rattling when start up of engine for several secounds and then stops rattling. black sutt in exhaust pipe.*ak
12/01/2001
 Drivers door lock not working properly, gasket cylinder front cover, torque converter shudder, catalytic converter, rt bank exhaust manifold; these problems have been corrected, but new ones mount every week. now there is a problem with the steering, being checked tomorrow. *ak
04/01/2000301/01/1997
 Car stalls at speed.. premature failure of intake gaskets..ford may have redesigned but no recall.. caused loss of control 17 year old driver. *ak
 Upper and lower engine intake gaskets are leaking, causing air to enter into the cylinder, resulting in engine idling erratically and eventually no start. please give any further details. *ak
01/18/2000
 Intake manifold and the exhaust gas sensors had to be replaced prematuraly.*ak
11/18/1998
 Tail pipe separated from muffler and there was a loud noise coming from under the vehicle. there was some metal rubbing against the vehicle. *ak
11/18/1998
 Tail pipe separated from the muffler, causing vehicle to make a very loud noise. there is a noise like metal piece of object is hanging from vehicle. *ak
11/18/1998
 Tail pipe is separating from muffler, and the vehicle is making a loud noise. there is metal type of noise coming from the vehicle. *ak
11/18/1998
 Tail pipe separated from the muffler. causing vehicle to make loud noises there is some metal under the vehicle that is making alot of noise. *ak
05/13/1997102/12/1997
 Exhaust manifold failed.

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