Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
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. …
Tl contact owns a 1996 Ford Explorer. The contact stated that dashboard lights were too dim. The gas cap was not secure on the tank and did she was unable to replace the gas cap on tight. The dealer advised her that the catalytic converter needed to be replaced because it added to the pollution. She received recall notice 09V399000,vehicle speed control and the dealer replaced the catalytic converter instead of the speed control deactivation switch. She called the dealer and the manufacturer but received no assistance. The vehicle had not been repaired at the time of the complaint. The current and failure mileages were approximately 157,000.
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.
Tl* the contact owns a 1996 Ford ranger. The contact stated the straps to the gas tank rusted and broke causing the gas tank to drop tank dropped onto driveshaft causing fuel leakage. The vehicle had not been inspected. The failure mileage and current mileages were 194,000. Updated 09/29/2011
During a routine transmission fluid and filter change I discovered a potential problem.during the refill and check of proper fluid level the dipstick gives a false indication that the fluid is at the correct level. It indicated to me that the level was over full. This was even verified by a certified ase technician at a local walmart. He noted the level was low. I discovered that you have to look at the opposite side of the dipstick to acquire the correct reading. By doing this I discovered the fluid was nearly 2 quarts low. The reading on the front side never changed where the cross hatched indicators are. This could be fixed by a simple change in the dipstick. This presents a problem of transmission failure due to improper fluid levels. I believe owners should be notified.
The dealer is been informing that they are working on fuel guage problem for almost 1 year and replaced the assembly in the fuel tank and contacted Ford several times. I also contacted them and spoke to shawn @ [phone] extn: 3066. He told me Ford will contact me, but, failed to contact. ABS problem came recently. Dealer reaplaced a part, but, did not resolve the problem. As per the dealer the Ford motors are aware of the fuel guage problem from the begining but, failed to come up with a recommendation.
Transmission failed twice under normal driving conditions. Lost power under certain circumstances. Same problem both times. Engine seized when vehicle hit a puddle of water at low speed. Air intake is mounted unusally low on this Explorer allowing water into the combustion chamber and causing hydrostatic lock. Ford motor company has been contacted and reads a scripted response when I have tried to get any additional information about what I consider a serious design flaw.
Fuel pump was being replaced. Townsend Ford performed the job. Tech broke cheap plastic clip requiring fuel filler neck to be replaced. It's defective. Will not seal. Gas vapor leak. Check engine stays on. Ford has problem with supplier. None in country told to me about a couple months ago. Still none now. Gas vapor leak is health hazard and unsafe in my opinion. They keep blowing me off on resolution. Can you help? -thanks-
Fuel pump broke. There was a recall for this problem, but this vehicle was not affected by recall although it has same problem. With cruise control engaged, vehicle won't stop unless consumer stomped on gas pedal several times, consumer states the gas pedal seemed stuck and acceleration wouldn't stop.
Gas gauge does not move when filled with gas or while driving. Cause unkown. Dealer cannot correct problem. The temperature gauge is erratic, dealer replaced a wiring harness, however this did not work, dealer can not remedy the erratic temperature gauge or the inaccurate gas gauge.
Fuel System complaints in other Explorer years
Frequently asked questions
How common are fuel system problems on the 1996 Ford Explorer?
NHTSA has 23 complaints about the fuel & propulsion system of the 1996 Ford Explorer, 2% of the model year's 1,450 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 1996 Ford Explorer fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 1996 Ford Explorer, though it has 6 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Ford Explorer fuel system problems start?
Half of the complaints with a recorded mileage happened before about 194,000 miles, and 25% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system 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.