1996 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
1996 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Ford Explorer has 7 documented known issues, with 5 rated critical. The most serious are 4.0L OHV cracked cylinder heads and blown head gaskets from overheating ($1,000-$2,800 repair), Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) ($0-$900 repair), Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) ($600-$1,000 repair), Frame, rear subframe, and rocker/body-mount rust ($200-$3,000 repair) and Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 repair). Across all issues with published estimates, repair costs range from $25 to $3,500. DIY maintenance guides at au7o.io.
SEATS:FRONT ASSEMBLY:RECLINER
FORD IS RECALLING CERTAIN MODEL YEAR 2010 FUSION, EXPLORER, EXPLORER SPORT TRAC, AND MERCURY MILAN AND MOUNTAINEER VEHICLES MANUFACTURED BETWEEN DECEMBER 15, 2009 THROUGH FEBRUARY 3, 2010 EQUIPPED WITH FRONT SEAT MANUAL RECLINERS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 202, "HEAD RESTRAINT." THE RECLINER GEAR PLATE TEETH MAY BE OUT OF DIMENSION SPECIFICATION WHICH COULD RESULT IN LIMITED PAWL TO GEAR PLATE TOOTH ENGAGEMENT.
EQUIPMENT
MARATHON IS RECALLING CERTAIN SEAT COVERS, BRAND SUPERHIDES WITH PART NUMBERS 593, 594, 578, 960, 228, 228-09, 267-08, 333, 625, AND 630, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE SEAT COVERS ARE MADE OF HEAVIER THREAD AND ARE NOT COMPATIBLE WITH SEATS CONTAINING SIDE AIRBAGS. THE HEAVIER SEAT COVER COULD INTERFERE WITH FULL DEPLOYMENT OF THE AIRBAG IN THE EVENT OF A CRASH.
VISIBILITY:GLASS, SIDE/REAR
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
STEERING
ON CERTAIN SPORT UTILITY VEHICLES, THE TWO BOLTS THAT ATTACH THE STEERING GEAR ASSEMBLY TO THE FRAME MAY HAVE BEEN OVER-TIGHTENED. THIS CONDITION COULD RESULT IN ONE OR BOTH OF THE BOLTS FRACTURING, CAUSING THE STEERING GEAR TO BECOME LOOSE.
POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH THE 4.6L ENGINE AND 6R TRANSMISSION, THE BOLT SECURING THE TRANSMISSION OIL COOLER LINE FITTINGS AT THE TRANSMISSION MAY NOT HAVE BEEN SUFFICIENTLY TORQUED DURING VEHICLE ASSEMBLY. AS A RESULT, THE BOLT MAY LOOSEN AND THE TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION, CAUSING A TRANSMISSION FLUID LEAK.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Ford Explorer has 7 documented issues. The most frequently reported are: 4.0L OHV cracked cylinder heads and blown head gaskets from overheating, Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023), Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023). Of these, 5 are rated critical and should be addressed promptly.
The 1996 Ford Explorer has 7 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: 4.0L OHV cracked cylinder heads and blown head gaskets from overheating and Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023) and Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Automatic transmission overdrive failure (A4LD / 4R55E). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Explorer issues range from $0 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4.0L OHV cracked cylinder heads and blown head gaskets from overheating, typically costs $1,000-$2,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The pushrod 4.0L OHV V6 (Cologne) is otherwise regarded as a durable 'tank,' but the cast heads are intolerant of overheating and are prone to cracking and gasket failure, typically appearing around 100k miles or after any single serious overheat event. The root cause is usually… Repairs typically run $1,000-$2,800. Severity: high.
The 1995-2001 Explorer was factory-fitted with P235/75R15 Firestone Radial ATX, ATX II and Wilderness AT tires that suffered tread-belt separation, especially in hot climates and when underinflated to Ford's low placard pressure. A rear tread separation at highway speed frequentl… Repairs typically run $0-$900. Severity: high.
The defining safety issue of the 1990s Explorer: original-equipment and replacement Firestone ATX, ATX II, and Wilderness AT P235/75R15 tires (notably from the Decatur, IL plant) suffered tread/belt separation at highway speed. Combined with the Explorer's relatively high center… Repairs typically run $600-$1,000. Severity: high.
In salt-belt climates, 1991-1999 Explorers rot in predictable structural areas: the inner rocker panels, the tops of the front leaf-spring hangers (dirt packs between the hanger and inner rocker, which the factory welded only at the bottom), rear spring hangers/shackles, and the… Repairs typically run $200-$3,000. Severity: high.
The 4-speed automatics behind the 4.0L - the early A4LD and the later electronically controlled 4R44E/4R55E - are a known weak point, commonly failing in the 120k-mile range, most often losing 4th gear (overdrive). The overdrive planetary is fragile (early units used a weaker pin… Repairs typically run $25-$3,500. Severity: high.
The 4.0L (both OHV and SOHC) drives the camshaft position sensor off a gear-driven 'synchronizer' assembly in place of a conventional distributor. The synchronizer's shaft/bushing wears or gums up with varnish, developing play and producing a distinctive squeak/chirp that is ofte… Repairs typically run $150-$500. Severity: medium.
The cable-drive window regulators on the Explorer/Mountaineer/Sport Trac fail as their plastic cable guides crack and the steel lift cable frays or jumps off the drum. The window then binds, drops crooked, or falls down inside the door — the motor often still runs. The front door… Repairs typically run $120-$400. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
