Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
Tl contact owns a 1996 Ford Explorer. While driving between 45-55 MPH, the vehicle began shaking and could not be steered. The vehicle flipped and rolled over. The contact and her baby received minor bruises. The vehicle was destroyed and a police report was filed. The contact has pictures available. Her VIN was not included in NHTSA campaign id number 00V402000 (suspension). The powertrain was unknown. The current and failure mileages were 140,000.
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.
Explorer sport (4x2),( manual transmission)(18,462 miles) dodging truck tire retread on interstate was oversteered. Then oversteered back when left rea hub assembly broke off. Then car fliped 6 times. When the car lost the rea wheel, control was lost.
I replaced the front hub assemblies in December 2011 with parts purchased from autopartsmidwest.com. On December 18, 2012, the left hub assembly failed and the wheel came off. The outer portion of the ball bearing race came off the splined hub. I was going very slowly at the time the failure occurred and there was no injury or damage other than to the hub assembly, caliper bracket and some other brake parts. The total cost of repair parts not including labor is about $500. I have no knowledge of the manufacturer of the hub assembly. It should be reasonable to expect a critical part like a hub assembly to last more than about 6000 miles. If the hub assembly had come apart two minutes or a half mile earlier, I might not be filing this report. I have asked autopartsmidwest to refund the purchase price of the defectuve hub assemblies as well as the cost of replacement parts. …
On dec. 13, 2000, my 22 year old son totalled this vehicle after hitting a patch of "black ice" while traveling at a speed of approximately 45-50 MPH. The vehicle rolled according to an eyewitness 4 times and landed on its roof. My son was, thank god, wearing his seatbelt! He was able to release his seatbelt and crawled through the driver's window which had been broken out. He escaped without any injuries! My concern is so much emphasis has been placed on the rollover possibilities when a tire blows, why not the possibility of flipping when hitting ice? Is anything being investigated to correct the top heaviness of the vehicle, especially the 2-door models. More emphasis needs to be placed on the necessity of wearing seatbelts to survive a rollover..
Consumer has experienced various suspension problems, installation of the caster/camber kit was necessary to properly align the vehicle, however consumer was in an accident due to possible suspension problems which caused the vehicle to fishtail and crash into a utility pole, two injuries due to collision. The consumer now believes the accident was due to the advisiory to inflate all 15 inch tires to 26 psi, the consumer had 45 psi on rear tires and the dealer deflated them to 26 psi which she believes caused the vehicle to spin out of control. Nlm
In feb 04 the vehicle was taken in for the sway bar replacement. Since that time, it has been riding worse and making rattling noises when going over bumps. Talked to dealership that fixed it the first time and they said it most likely is not the same thing and will charge $35-$68 fee to inspect the front end. The did not do a diagnosis the first time the vehicle was brought in according to their rep walt. Therefore my question is, has there been any other front end problems with this vehicle that has a pending recall on it?
The driver of the vehicle was involved in a accident, the vehicle was hit on the rear left side which caused the driver to loose control of the vehicle resulting in it rolling over 3 1/4 times, the passenger was killed and the driver sustained extensive injuries including a broken neck, the consumer believes that the recall 00v-402 for front sway bars May or May not have contributed to the accident and was received after the accident occured, during the accident neither air bags deployed. Nlm
Consumer stated problems with the ball joints. Manufacture was contacted and stated that they will pass the information to the engenieers but has been 8 days and he has not heard about them. The rubber boots fell apart causing dirt and water to enter the ball joints. Consumer is aware of other complaints on the internet regarding this condition. However a month has pasted and consumer has yet to hear from manufacture.
I bought my 1996 Explorer new on 01/19/1996 from wade Ford smyrna ga. I have not had any other mailing address other than the one where I lived at time of purchase and I still live there today. Ford did not send me a notice of NHTSA id # 00V402000. Can you please have Ford send a notice that I can take to a Ford dealer for the specified repairs? I learned of the recall 10/3/07. Thank you. Updated 12-12-07. Updated
Related recalls
Suspension
Vehicle description: sport utility vehicles. Under certain conditions, a front sway bar link can fracture.
Remedy: Dealers will replace both the left and right front sway bar links.
NHTSA investigations
Front suspension stabilizer bar link
There is no summary currently available
Suspension complaints in other Explorer years
Frequently asked questions
How common are suspension problems on the 1996 Ford Explorer?
NHTSA has 97 complaints about the suspension of the 1996 Ford Explorer, 7% of the model year's 1,450 complaints. The component named most often is front (37 mentions).
Is there a recall for 1996 Ford Explorer suspension problems?
Yes — NHTSA recall 00V-402 (suspension, Nov 28, 2000). Recall repairs are free at authorized dealers.
At what mileage do 1996 Ford Explorer suspension problems start?
Half of the complaints with a recorded mileage happened before about 140,000 miles, and 8% before 25,000 miles.
Is it dangerous?
Owners linked 15 crashes, 1 fire and 20 injuries and 5 deaths to suspension 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.