Seven problems related to manifold/header/muffler/tail pipe have been reported for the 1996 Ford Explorer. The most recently reported issues are listed below.
I had to replace the intake manifold of the 1996 Ford Explorer at mile number 163400 on March 30, 2007. It was leaking at #1 cylinder. There was a 'ecret warranty' in effect. I beleived for Explorer's 10 years old and younger. Mine was just over the 10 year mark.
Knocking noise from engine manifold area. Dealer could not find any noticeable problem. Knocking noise would quiet down after the engine would heat up. Problem got worse over time. Independent mechanic found problem with the exhaust manifold gaskets leaking.
Went through an 18 inch puddle, the water came through the manifold and now the engine has ceased.
Exhaust manifold gaskets failed.
I purchased this Explorer the first year that the v-8 was available. The exhaust manifold fractured 4 times during the 12 years that I had the vehicle. The part cost over $300 and was on "national backorder" for over a year, so I had my nephew (certified welder) weld the piece together and reinstalled by an auto mechanic. My nephew stated that when you have "pot-metal" welded to steel, it will always fracture, so this part was never manufactured correctly. Ford denied my request for reimbursement, even after the 3rd time it fractured (persistent problem?) it released fumes into the car through the vents and floorboards. Now I see there is a problem with the newer Explorers and I feel that this has been a manufacturing problem for many, many years, but just now has caught up with Ford because it was investigated by news media, where I had no recourse back in the day for the correction on my vehicle.
Engine manifold cracked, causing the vehicle to make a loud noise. Dealer says exhaust header needs to be replaced.
Exhaust pipe melted into the bottom panel of the bumper.