Five problems related to other fuel system have been reported for the 1996 Ford Explorer. The most recently reported issues are listed below.
While we were driving on I-84 near middleton, id, our gas pedal (throttle pedal) un-welded (fell off) completely. We got to the side of the road (it slowed down--wasn't "stuck" at any speed) and didn't have an accident. We were towed to caldwell, id, where a mechanic repaired it. I think he put in 3 nuts/bolts to keep the pedal affixed. I have called Ford motor CO. (did on 8/16/10), but obviously this could've been very dangerous. We got lucky. I wonder if other Fords have had welded parts fall off/un-weld while driving.
Strong odor of fuel inside vehicle.
Fuel switch connector failed.
Extreme fuel fumes inside vehicle.
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.
| Other Fuel System problems | |
| Other Fuel System Fuel Gauge problems | |
| Other Fuel System Hoses Lines/piping, And Fittings problems |