Problems owners report
Complaints filed with NHTSA about the 1996 Ford Explorer, by the system named in each complaint. One complaint can name several.
- Tires570
- Vehicle speed control148
- Power train120
- Service brakes, hydraulic120
- Suspension97
- Engine and engine cooling81
- Seat belts78
- Structure63
- Electrical system47
- Visibility47
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 347 injuries and 51 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 57 1996 Explorer vehicles were involved in crashes on US public roads in which someone died; 46 people died inside them, and 29 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 1996 Ford Explorer failed the safety check 1.37% of the time — 6% less often than the average 1996 passenger car (1.47%). Median odometer at inspection: 143,722 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In the United Kingdom
0 cars built in 1996 were licensed for the road at the end of 2025, and 2 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
In New Zealand
13 1996 cars are on the New Zealand register; 15% arrived as used imports, 69% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 5 variants: combined 13.3–16.8 L/100 km (about 14–18 mpg US), CO₂ 306–386 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Explorer · Sport utility vehicle · Regular gasoline | 15.0 | 11.3 | 13.3 |
| Explorer · Sport utility vehicle · Regular gasoline | 16.7 | 12.1 | 14.6 |
| Explorer 4X4 · Sport utility vehicle · Regular gasoline | 16.3 | 12.5 | 14.6 |
| Explorer 4X4 · Sport utility vehicle · Regular gasoline | 17.4 | 12.3 | 15.1 |
| Explorer · Sport utility vehicle · Regular gasoline | 19.0 | 14.1 | 16.8 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
6 Transport Canada recalls for the 1996 Ford Explorer.
| 2009292 14 Oct 2009 | Other On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur ei… |
| 2000297 15 Dec 2000 | Suspension On certain vehicles, the front stabilizer bar link stud can fracture from bending fatigue. This can result in increased vehicle lean or the driver may sense a … |
| 1997172 8 Oct 1997 | Structure THIS VEHICLE MAY HAVE UNDERSIZED WELDS ON THE BRACKET THAT ATTACHES THE LIFTGATE ASSIST GAS CYLINDER TO THE RIGHT HAND BODYSIDE OUTER PANEL. THIS COULD RESULT … |
| 1997072 2 Apr 1997 | Engine WHEN OPERATED FOR EXTENDED PERIODS AT HIGHWAY SPEEDS AND TEMPERATURES BELOW -29 DEGREES CENTIGRADE, ICE MAY FORM AROUND THE THROTTLE PLATE RESULTING IN THE POTE… |
| 1997046 10 Mar 1997 | Emissions NOTE: VEHICLES EQUIPPED WITH 4.0 LITRE ENGINES. THESE VEHICLES DO NOT COMPLY WITH C.M.V.S.S. 1105 - EVAPORATIVE EMISSIONS. INCORRECT FUEL VAPOUR MANAGEMENT VAL… |
| 1996071 9 May 1996 | Structure THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S 206 - DOOR LATCHES, HINGES AND LOCKS. THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY N… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. UNDER CERTAIN CONDITIONS, A FRONT SWAY BAR LINK CAN FRACTURE.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. THE LIFTGATE ASSIST GAS CYLINDER BRACKET ON THE RIGHT HAND BODYSIDE OUTER PANEL WAS INCORRECTLY WELDED.
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.
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."
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."
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 1996 Ford Explorer: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 637922 | SOME VEHICLES BUILT PRIOR TO 9/15/2001 MAY EXHIBIT LOW LINE PRESSURE READINGS WHILE IN DRIVE, NO 2ND GEAR, NO 3RD GEAR, NO ENGINE BRAKING IN MANUAL 1ST AND SLIPPING SHIFTS AND / OR DELAYED ENGAGEMENTS. *TT |
| 637755 | SOME VEHICLES MAY EXHIBIT A NO 1-2 UPSHIFT, NO 2-3 UPSHIFT, A NO ENGINE BRAKING CONDITION IN MANUAL 1 OR DIAGNOSTIC TROUBLE CODE P0732 (GEAR 2 INCORRECT RATIO) OR P0733 (GEAR 3 INCORRECT RATIO). *TT |
| 636326 | SOME VEHICLES MAY EXHIBIT A SQUEAK, SNAP, RATTLE, OR CLUNK IN THE FRONT END WHEN TURNING OR GOING OVER BUMPS. *TT |
| 636235 | EXPERIENCING A CLICKING / POPPING NOISE FROM THE UPPER STEERING COLUMN AREA WHEN TURNING THE STEERING WHEEL. *TT |
| 636056 | CERTAIN VEHICLES WITH 4X4 OR ALL-WHEEL DRIVE MAY HAVE A FLUID LEAK FROM THE FRONT AXLE VENT TUBE. *TT |
| 635998 | LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT), SLIPPING SHIFTS AND / OR DELAYED ENGAGEMENTS WITH POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 SET ON VEHICLES BUILT BEFORE 12/1/2001. *TT |
| 635982 | SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT |
| 630515 | ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT |
| 628153 | OWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF WILDERNESS AT TIRES. *TT |
| 627752 | SOME 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. *TT |
| 625866 | INFORMATION REGARDING FRONT SWAY BAR LINK . *YH |
| 625794 | CONCERNS WITH HIGH BRAKE PEDAL FORCE TO STOP AFTER ROTOR MACHINING. *TT |
| 625715 | BRAKE SHIFT INTERLOCK.*JB |
| 623988 | INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC |
| 623944 | SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC |
| 620279 | INFORMATION ON REPLACING A GEM MODULE ON 4X4 VEHICLES EQUIPPED WITH 4.0L SOHC, OHV AND THE NEUTRAL TOW KIT. *TT |
| 619330 | CONCERNS WITH VEHICLES EXHBIT FLUID LEAKAGE FROM THE FRONT AXLE VENT TUBE. *TT |
| 619314 | SOME 4X4 VEHICLES MAY EXHIBIT A FLUID LEAK FROM THE FRONT AXLE VENT TUBE. *TT |
| 619276 | ON SOME VEHICLES, INCLUDING SPORT AND SPORT TRAC, THE FRONT AXLE LEAKS FLUID FROM THE VENT TUBE. *TT |
| 618546 | SUBJECT REGARDING CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS. *JB |
| 618536 | SUBJECT REGARDING ADDITIONAL COVERAGE PROGRAM FOR SWAY BAR LINKS. *JB |
| 618532 | SUBJECT PERTAINING TO SUPPLEMENTAL TIRE INFLATION LABEL. *JB |
| 616829 | SOME VEHICLES MAY EXHIBIT A MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION ALONG WITH A P0420 DIAGNOSTIC TROUBLE CODE (DTC) STORED IN CONTINUOUS MEMORY WITH NO DRIVEABILITY CONCERNS. *TT |
| 616531 | ON SOME VEHICLES, THE ACCELERATOR PEDAL BRACKET MAY BECOME LOOSE OR SEPARATED FROM THE DASH PANEL. THIS MAY BE CAUSED BY REPEATED EXCESSIVE FORCE ON THE ACCELERATOR PEDAL, RESULTING IN CRACKING OF THE DASH PANEL SHEET METAL AT THE ACCELERATOR PEDAL BRACKET. *TT |
| 616522 | SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
FRONT SUSPENSION STABILIZER BAR LINK
ACCELERATOR PEDAL
ELECTRICAL FIRE IN CENTER CONSOLE
NHTSA Office of Defects Investigation