1996 Ford Explorer engine and engine cooling problems

“I OWN A 1996 FORD EXPLORER SPORT 4X4, 4.0 LITER V6 WITH 5 SPEED MANUAL TRANSMISSION. THIS IS A MOTOR MADE IN GERMANY AND THE TRUCK, IN THE LOUISVILLE, KY. FORD PLANT. RODENTS TOOK UP RESIDENCE IN THE HEATING SYSTEM, AND FILLED THE HEATER BLOWER ASSEMBLY AND DUCTING WITH SCAVENGED MATERIALS, WHICH TOOK UP APPROX. 1 CUBIC FOOT OF SPACE, ONCE EXTRACTED. MUCH TO MY BENEFIT, THE MATERIAL JUST SO HAPPENED TO BE FIRE RESISTANT STUFFING FROM MY ARCHERY TARGET, STORED IN THE SAME BUILDING. I STARTED MY VEHICLE AND IMMEDIATELY UPON TURNING ON THE HEATER, I HEARD A TERRIBLE NOISE WHICH ENDED ABRUPTLY. MY HEATER STOPPED WHEN THE NOISE STOPPED. IN AN EFFORT TO DIAGNOSE THE PROBLEM I INSPECTED THE ENGINE COMPARTMENT. I THEN NOTICED A BURNT SMELL, BUT SAW NO SMOKE. UPON REPLACING MY BLOWER MOTOR I INSPECTED THE OLD ONE, WHICH HAS CHARRED REMNANTS OF THE FOREIGN MATERIAL INSIDE AND WRAPPED AROUND THE ELECTRICAL COMPONENTS. THE ONLY OPENING TO THE INNER COMPONENTS OF THE BLOWER MOTOR IS ABOUT 1" IN DIAMETER AND HAS A RUBBER TUBE PLUGGED INTO IT. IT APPEARED UNDISTURBED AND WAS CONNECTED WHEN I FIRST SERVICED IT. I ALSO DISCOVERED AN OPENING ON THE LOWER SIDE OF THE BLOWER FAN…”

“1996 EXPLORER, HAS BEEN A GREAT VEHICLE. STARTED LOOSING POWER AND SHIFTING DOWN AND STRANGE TIMES. THEN THE O/D FAIL LIGHT STARTED TO FLASH. I UNDERSTAND THIS IS A COMMON FAILURE AND FORD KNOWS ABOUT IT BUT REFUSES TO ACKNOWLEDGE THE FACT OR ACCEPT RESPONSIBILITY. THEY NEED TO RECALL THESE TRANSMISSIONS. *TR”

“FIRST MY ENGINE SEEMED TO OVERHEAT A BIT THEN EVERY ONCE IN A WHILE IT WOULD SOUND LIKE THE ENGINE WAS GRINDING ON SOMETHING AND WOULDN'T STOP.. SOUNDED LIKE A BUNCH OF CHAINS IN MY HOOD. BUT THEN ON OCCASIONS THE STUPID THING WOULDN'T SHUT OFF WHEN IT WAS MAKING THE CHAIN SOUND, EVEN WITH MY KEY OUT. IT JUST HAPPENED AGAIN AND NOW THE THING SMELLS LIKE SOMETHING IS BURNING AND I HAVE NO POWER WHAT SO EVER IN MY VEHICLE. BEFORE WHEN IT FINALLY SHUT OFF IT SOUNDED LIKE IT WAS ABOUT TO SPARK. THEN IT WAS MAKING A CLICKING NOISE THAT WASN'T COOL. *TR”

“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. *AK”

“DT*: THE CONTACT STATED THAT THE SPEED CONTROL DEACTIVATION SWITCH WAS LEAKING FLUID. THERE IS A NHTSA RECALL ON OTHER FORD VEHICLES. THE VIN WAS NOT INCLUDED IN THE RECALL. WHEN THE VEHICLE WAS TAKEN TO A SERVICE DEALER, THE REPAIR WERE MADE FOR A FEE. ALSO EVERY 25000 MILES, THE OIL PAN GASKET NEEDED TO BE CHANGED DUE A SMALL LEAK. THE MECHANIC WAS UNABLE TO DETERMINE THE CAUSE OF THE PROBLEM. THIRD, THE EXHAUST AND INTAKE MANIFOLDS WERE LEAKING CAUSING A NOXIOUS SMELL INSIDE THE VEHICLE. THE VEHICLE WAS THEN TAKEN TO THE SAME SERVICE DEALER. THE DEALER REPLACED BOTH MANIFOLDS, AND DETERMINED THAT THERE WAS AN OIL LEAK DRIPPING ONTO THE EXHAUST SYSTEM.”

“ON SUNDAY DECEMBER 11, 2005 WHILE TRAVELING ON THE HIGHWAY I EXPIRED A SUDDEN SPIKE IN TEMPERATURE ON MY 1996 FORD CROWN VICTORIA. AFTER TAKING MY CAR TO A FORD DEALERSHIP I WAS INFORMED THAT MY "PLASTIC" INTAKE MANIFOLD HAD CRACKED. I HAVE RESEARCHED THE CURRENT INVESTIGATION AND HAD NEVER RECEIVED ANY SORT OF CUSTOMER NOTIFICATION FROM FORD. I HEARD ABOUT THE MANIFOLD ISSUE FROM A FELLOW EMPLOYEE. THE TOTAL COST OF REPAIRS FOR THIS FAULTY MANIFOLD WAS $978.00. I FEEL IF THEY KNEW THEY NEEDED TO UPDATE IT WITH AN ALUMINUM MANIFOLD THAN THEY KNEW THE PLASTIC ONES WERE FAULTY.*JB”