Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
While traveling at 50 MPH 10:30p.m., without cause vehicle slid across highway to the left, rolled and flipped, and collided with a tree - vehicle landed on its side with roof in to the steering wheel: all windows broken and windshield shattered. Roof actually caved in on teenage driver -fatality from multiple brain injuries.
Sudden unintentional acceleration: on three different occasions, from years 1998-2015. The first incident occurred in town, 1998. I had to apply the emergency brake to disengage the surging accelerator. I had the vehicle towed to the dealer, who could find nothing wrong. Perhaps a floor mat problem, they said. I replaced the mats with an after market pair- SUV compatible and mud resistant with many, grippers on the underside. Within a year, I quit driving the vehicle and my husband took the Explorer as his daily driver. He never experienced the problem, I had had. I sold my car after retirement and on occasion now drive the 1996 Ford Explorer again. I have had two more incidents of sua within 2014-2015 - both on the interstate, both with the replacement mats. At the beginning of both trips, I ensured that the mat looked a safe distance from the pedals. …
Vehicle is an SUV with a rear liftgate / hatch that raises upwards when open. On this day I was loading some item is the rear of the vehicle when the liftgate suddenly fell and stuck me on the head. The liftgate is normally supported by a gas type strut on each side. There are ball type pins attached to the liftgate and the body for these gas struts to attach to. The upper pin on the right side of the lift gate snapped off and allowed the liftgate to fall. It appears it was rusting through, however there is no other rust on any portion of the liftgate. Only one gas type strut will not support the weight of the tailgate. In only two days I have found four other people who have experienced this same problem with 1995 & 1996 explorers.
Bought Ford Explorer in 1996, new. Filed a complaint with bbb regarding problems. Nothing was achieved. In November of 2002 was in an accident where the vehicle rolled over, my seat belt did not lock, nor did the air bags deploy, which resulted in severe injuries to myself. Broken neck (c-2, tbi tramic brain injury and broken bones. I beleive the failure of the seat belt, roof stability and airbags malfunction caused my injuries. The driver and other occupant received no serious injuries. Nothing was done to correct the failure as you can see in the numerous law suits againist Ford motor co.
Tl contact owns a 1996 Ford Explorer. The contact stated that the hatchback support gate would not properly support the glass. Also, the child safety locks do not work properly. The vehicle has not been taken to the dealer for inspection. She notified the manufacturer and they stated that her vehicle was not included in NHTSA campaign id number 97V137000 (structure:body:hatchback/lift gate:support device) or NHTSA campaign id number 96V070000 (latches/locks/linkages:doors:latch). The failure mileage was 120,000 and current mileage was 129,000.
Noticed that the recliner handle was bent on the drivers side. The next time I went to recline the seat the handle broke off at the rivet point. Common problem according to the dealer. The part can only be bought from Ford and the cost is $100. There was a service bulletin for this problem for a later year Explorer. Dealer said the new part is more heavy duty and made to replace the stock version that was light duty. No recall was issued and they have stopped making the part.
Tl contact owns a 1996 Ford Explorer. The contact stated that the liftgate assist gas cylinder bracket snapped at the welding point, which caused the liftgate to close without warning. As of October 16, 2007, the dealer had not inspected the vehicle. The dealer and manufacturer stated that his VIN was not included in NHTSA campaign id number 97V137000 (structure: body: hatchback/liftgate: support device). The failure mileage was 132,000 and current mileage was 134,000.
Gas pedal came off from its mounting to floor board driving while vehicle. Mounting plate seems to have only one bolt securing it to the floorboard. Their are three mounting holes for the peddle backing plate and three holes through floor board. Top hole had stressed metal indicative of what ever was used to hold gas peddle backing plate. Lucky us for just getting off the express way. Something bad could happen to me and my wife.
Approximately one day after truck was purchased, it was noticed passengers sitting in the back seats of the car could not open their doors. Child safety locks were looked at and reset, but doors still would not open. This is a safety hazard as passengers in the back would not be able to get our safely in the case of an accident.
1996 Ford Explorer rolled over in and accident. Consumer requesting information on risks for Ford explorers. The consumers daughter was driving when the vehicle rolled over. After the accident, the consumer learned of problems with the Ford Explorer's roof strength and unstable wheel base. Updated
Related recalls
Structure › Body › Hatchback/liftgate › Support device/strut
Vehicle description: multi-purpose passenger vehicles. The liftgate assist gas cylinder bracket on the right hand bodyside outer panel was incorrectly welded.
Remedy: Dealers will reinforce the bracket attachment with two pop rivets.
Body complaints in other Explorer years
Frequently asked questions
How common are body problems on the 1996 Ford Explorer?
NHTSA has 63 complaints about the body & structure of the 1996 Ford Explorer, 4% of the model year's 1,450 complaints. The component named most often is body › door (32 mentions).
Is there a recall for 1996 Ford Explorer body problems?
Yes — NHTSA recall 97V-137 (support device/strut, Aug 19, 1997). Recall repairs are free at authorized dealers.
At what mileage do 1996 Ford Explorer body problems start?
Half of the complaints with a recorded mileage happened before about 127,000 miles.
Is it dangerous?
Owners linked 5 crashes, 2 fires and 14 injuries and 5 deaths to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.