IllustrationEXPERIENCED FAILURE OF HEATER/DEFROSTER IN COLD WEATHER. FORD DEALER IN ATHENS AL WANTED $1000 TO CORRECT FAILURE.*AK
1996 Ford Explorer
Owner reports · Recalls · Investigations
More warning signs than most Explorer years
Owner complaints for the 1996 Ford Explorer are substantially higher than the model-year median of 609.
About this comparison →How this year compares
Owner complaints by model year
Compare all Explorer years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 153 of 1,450 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Tires. Review the 570 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Vehicle Speed Control. Review the 148 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 120 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
195 crash reports37 fire reports179 injury reports
Visibility complaints
47 reportsTHE PLASTIC BLEND DOOR BREAKS AND YOU HAVE NO CONTROL OF HOT/COLD TEMP ON TRUCK. *AK
PART THAT SWITCHES HEAT TO AIR CONDITIONER IS WARPED ,CAUSE UNKNOWN. PLEASE GIVE FURTHER DETAILS.*AK
WHEN DRIVING THIS FALL I FOUND THAT WHEN USING THE VENT I GOT NOTHING BUT HOT AIR, THEN THE AUTOMATIC SETTING ON THE HEAT/AIR TEMPERATURE CONTROL WOULD NOT REGULATE PROPERLY. IT WOULD GO TO EXTREMES TO 85+ DEGREES, THEN DROP OFF AND BLOW UNTIL IT WAS DOWN TO 60 AND THEN BACK UP TO 85 CONTINUOUSLY. I WENT ACCORDING TO THE OWNER'S…
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WHEN DRIVING THIS FALL I FOUND THAT WHEN USING THE VENT I GOT NOTHING BUT HOT AIR, THEN THE AUTOMATIC SETTING ON THE HEAT/AIR TEMPERATURE CONTROL WOULD NOT REGULATE PROPERLY. IT WOULD GO TO EXTREMES TO 85+ DEGREES, THEN DROP OFF AND BLOW UNTIL IT WAS DOWN TO 60 AND THEN BACK UP TO 85 CONTINUOUSLY. I WENT ACCORDING TO THE OWNER'S MANUAL, WHICH STATED I NEEDED TO HAVE IT PUT ON THE COMPUTER AND CHECKED AT THE DEALER. AFTER THEY KEPT MY CAR 2 X AS LONG AS PROMISED AND CHARGING ME $100 TO CALL THE ENGINEERS AT FORD ITSELF, THEY TOLD ME IT WAS THE BLEND DOOR IN THE HEATER PLENUM. THIS DOOR IS APPARENTLY MADE OF PLASTIC AND BREAKS. IN MY CASE IT WORKED FOR A LITTLE WHILE, BUT VERY SLOWLY, AND WAS IN THE PROCESS OF BREAKING. IT CURRENTLY DOES NOT WORK AND IS STUCK IN THE AIR CONDITIONING SIDE. I GET NO HEAT AND CAN'T DEFROST MY WINDOWS. I LIVE IN WISCONSIN AND WE ARE EXPECTING FREEZING RAIN TODAY, NOT TO MENTION SNOW LATER THIS WEEK. THE DEALER HAS TOLD ME THAT THE ENGINEER THEY TALKED TO SAID THIS HAS HAPPENED BEFORE. IF IT IS A BAD DESIGN, BUT BECAUSE IT IS NOT OFFICIALLY A DEFECTIVE PART ON THEIR LIST, THEY COULD NOT FIX IT WITHOUT CHARGING ME ANOTHER $700 ON TOP OF THE $100 ALREADY SPENT TO DIAGNOSE THE PROBLEM. I HAVE FOUND ON THE INTERNET THAT I AM NOT THE ONLY ONE THIS HAPPENED TO (SEE MIGHTYAUTOPARTS.COM, ON THE LINE WITH LARRY HAMMER - EXPLORING THE LIMITS OF PATIENCE). THE NEWLY DESIGNED DOOR IS MADE OF NYLON THAT IS STRONGER AND LESS SUSCEPTIBLE TO BREAKING. WHEN CONTACTING FORD CUSTOMER 1ST TO LET THEM KNOW ABOUT MY VISIT, THEY SAID AN ADVISOR WOULD BE ASSIGNED TO ME AND WOULD CONTACT ME THE NEXT DAY, THAT WAS 2 WEEKS AGO. I FEEL I AM BEING GIVEN THE RUN-AROUND. I AM DRIVING IN AN UNSAFE VEHICLE. FORD WILL NOT TAKE ANY RESPONSIBILITY FOR THE BAD DESIGN. I FULLY APPRECIATE AND ACCEPT THAT THINGS WEAR OUT ON VEHICLES AND NEED TO BE REPLACED, BUT DEFECTIVE DESIGN SHOULDN'T BE AT MY EXPENSE, IN DOLLARS OR SAFETY.
LEFT FRONT SEAT ROCKS IN FULL ELEVATED POSITION, DEALER SAID IT WAS NORMAL PLAY IN THE POWER SEAT TRACK. NLM
DUE TO DEFECTIVE REAR DEFROSTER, CAR BURNED AND WAS COMPLETE LOSS. FORD WAS CONTACTED BUT CLAIMED THAT THEY WERE NOT LIABLE BECAUSE NO OPEN RECALLS EXISTED. THE REPRESENTATIVE IN THE CONSUMER AFFAIRS REFUSED TO GIVE ME THEIR NAME AND REFUSED MY REPEATED (3X) REQUESTS TO SPEAK WITH THEIR SUPERVISOR. *AK
DESIGN OF CONSOLE CAUSES REARVIEW MIRROR PLACEMENT TO BE TOO LOW. THIS CREATES A BLIND SPOT FOR DRIVER WHEN TRYING TO MERGE RIGHT. VEHICLE WAS TAKEN TO DEALERSHIP. DEALERSHIP SEEMS TO RECOGNIZE THAT THIS IS A DESIGN FLAW. FORD HAS AGREED TO LOOK INTO THIS MATTER. PLEASE PROVIDE ANY FURHTER INFORMATION.*AK
GLASS IS SOFT - PITTING AND CHIPPING OCCUR EASILY
FORDS SERVICE BULLETIN 99-8-8 ADMITS TO DEFECTIVE AIR PLENUM. CONSUMER COST TO REPLACE IS $700-$1000. HAS BECOME A DEALER STOCK ITEM. WHEN THE AIR DOOR BRAKES THERE IS NO AIR FLOW HOT/COLD/DEF CONTROL. CAN'T SEE WHERE YOU ARE GOING WITH FOGGED WINDOWS. FORD REVISED THE PLENUM OUT OF NYLON (#F87Z-18471-DA) CLAIMING IT WOULD NOT B…
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FORDS SERVICE BULLETIN 99-8-8 ADMITS TO DEFECTIVE AIR PLENUM. CONSUMER COST TO REPLACE IS $700-$1000. HAS BECOME A DEALER STOCK ITEM. WHEN THE AIR DOOR BRAKES THERE IS NO AIR FLOW HOT/COLD/DEF CONTROL. CAN'T SEE WHERE YOU ARE GOING WITH FOGGED WINDOWS. FORD REVISED THE PLENUM OUT OF NYLON (#F87Z-18471-DA) CLAIMING IT WOULD NOT BREAK LIKE THE PLASTIC WHICH WAS ORIGINALLY INSTALLED. CONSUMERS SHOULD NOT HAVE TO PAY $1000 FOR A FACTORY DEFECT. CRASHES WILL OCCUR WITHOUT DEFROSTERS. THEY ADMIT IT IN THE MENTIONED SERVICE BULLETIN BUT REFUSE TO MAKE THE REPAIRS.
DUE TO FAULTY DESIGN OF AIR PLENUM DOOR WHICH WAS MADE OUT OF PLASTIC, IT CAUSED A LOSS OF ABILITY TO CONTROL DEFROSTER/ HEATER AND AIR CONDITIONING. FORD HAS SENT A TSB (99-8-8) FOR DEFECT. A NEW REDESIGNED PLENUM WAS MADE OUT OF NYLON (F87Z18401DA). *AK
Official recalls
609V399000 · Vehicle Speed Control
Oct 13, 2009
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence & remedy
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
00V402000 · Suspension
Nov 28, 2000
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. UNDER CERTAIN CONDITIONS, A FRONT SWAY BAR LINK CAN FRACTURE.
Consequence & remedy
Consequence: VEHICLE HANDLING COULD BE AFFECTED, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE BOTH THE LEFT AND RIGHT FRONT SWAY BAR LINKS.
97V137000 · Structure:body:hatchback/liftgate:support Device/strut
Aug 19, 1997
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. THE LIFTGATE ASSIST GAS CYLINDER BRACKET ON THE RIGHT HAND BODYSIDE OUTER PANEL WAS INCORRECTLY WELDED.
Consequence & remedy
Consequence: THE GAS CYLINDER BRACKET MAY NOT PROPERLY SUPPORT THE LIFTGATE INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL REINFORCE THE BRACKET ATTACHMENT WITH TWO POP RIVETS.
97V074000 · Vehicle Speed Control
Apr 30, 1997
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH 5.0L ENGINES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE STATES OF ALASKA, IDAHO, IOWA, MAINE, MICHIGAN (UPPER PENINSULA ONLY), MINNESOTA, MONTANA, NEBRASKA, NEW HAMPSHIRE, NEW YORK, NORTH DAKOTA, SOUTH DAKOTA, VERMONT, WISCONSIN, AND WYOMING. THESE VEHICLES, WHEN OPERATED FOR EXTENDED PERIODS OF TIME AT HIGHWAY SPEEDS AND TEMPERATURES BELOW -20 DEGREES FARENHEIT, DO NOT RETURN TO IDLE DUE TO ICE IN THE THROTTLE BODY.
Consequence & remedy
Consequence: ALTHOUGH THE VEHICLE CAN BE CONTROLLED BY EITHER APPLYING THE SERVICE BRAKES OR SHIFTING THE TRANSMISSION TO NEUTRAL, INCREASED BRAKE PEDAL EFFORTS OR SOME INCREASE IN STOPPING DISTANCE CAN RESULT.
Remedy: DEALERS WILL INSTALL A REVISED PCV SYSTEM WITH WATER HEATED VACUUM SOURCE.
96V161000 · Equipment:other:labels
Aug 29, 1996
THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Consequence & remedy
Consequence: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .
Remedy: OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.
96V070000 · Latches/locks/linkages:doors:latch
Apr 22, 1996
WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."
Consequence & remedy
Consequence: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3PE00039 · Front Suspension Stabilizer Bar Link
Opened Sep 20, 2000 · Closed Nov 30, 2000
Status: closed (inferred from source dates) · Suspension
There is no summary currently available
PE99068 · Accelerator Pedal
Opened Nov 1, 1999 · Closed Mar 9, 2000
Status: closed (inferred from source dates) · Power Train
There is no summary currently available
PE97010 · Electrical Fire In Center Console
Opened Mar 13, 1997 · Closed Sep 4, 1997
Status: closed (inferred from source dates) · Electrical System
THIS INVESTIGATION REVEALED THAT CONSOLE FIRES IN THE SUBJECT VEHICLES MOST OFTEN OCCURRED WHILE VEHICLES EQUIPPED WITH THE LAMP OUTAGE MODULE (LOM), WHICH IS PART OF THE MESSAGE CENTER, WERE TOWING A TRAILER AND WHICH HAD BEEN MODIFIED BY ADDING AN AFTERMARKET TRAILER WIRING HARNESS INTO THE VEHICLE'S TAILLIGHT CIRCUITS.THE OWNER'S MANUAL STATES NEVER AND MORE THAN OTHER TRAILER LIGHT BULB TO ONE CIRCUIT HOWEVER TRAILERS FREQUENTLY CONTAIN SEVERAL BULBS.THE RESULTING EXCESS CURRENT PASSING THROUGH THE LOM COULD CAUSE IT TO OVERHEAT RESULTING IN A FIRE.PROPER AFTERMARKET INSTALLATION OF TRAILER WIRING REQUIRES THE USE OF A BYPASS MODULE, WHICH OBTAINS POWER FOR THE TRAILER LIGHTS DIRECTLY FROM THE BATTERY RATHER THAN FROM THE VEHICLE'S TAIL LIGHT AND STOP LAMP CIRCUITS, OR THE USE OF THE MANUFACTURER'S WIRING HARNESS.IN A LETTER DATED SEPTEMBER 2, 1997, FORD NOTIFIED ODI THAT IT INTENDS TO TAKE ACTION TO PRECLUDE FURTHER INCIDENTS INCLUDING ISSUING A TECHNICAL SERVICE BULLETIN TO ITS DEALERS, NOTIFYING TRAILER RENTAL ASSOCIATIONS AND AGENCIES WHERE KNOWN, AND ADVISING OWNERS BY LETTER OF THE PROPER METHOD FOR CONNECTION OF TRAILER TOW WIRING ON THE SUBJECT VEHICLES.THERE WAS NO DEFECT TREND IN THE SUBJECT VEHICLES IDENTIFIED AS A RESULT OF THIS INVESTIGATION, AND FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT WARRANTED TO CONTINUE THE INVESTIGATION.