1996 Ford Explorer Fuel system Problems
- Complaints
- 23about this part
- Share
- 2%of 1,450 total for the year
- Median mileage
- 175,500miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 23 complaints about the fuel system of the 1996 Ford Explorer, 2% of the 1,450 complaints for this model year. Where a mileage was given, the median is 175,500 miles. 1 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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. …”
NHTSA complaint #11046568, filed 2017-11, 5,000 miles“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.”
NHTSA complaint #10352174, filed 2010-08, 205,000 miles“I had this same problem with myh 1994 Explorer. When the temperature is over 85 degrees outside and the air conditioner is on, we get an extremely strong odor of raw gasoline inside the car. It makes us nauceous. This happens especially with in-town stop and go driving.”
NHTSA complaint #751129, filed 2001-08“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.”
NHTSA complaint #740037, filed 2001-01“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”
NHTSA complaint #10419805, filed 2011-08, 194,000 milesFuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 3 | 7% |
| 2025 | 3 | 3% |
| 2023 | 3 | 3% |
| 2022 | 37 | 14% |
| 2021 | 28 | 6% |
| 2020 | 42 | 3% |
| 2019 | 17 | 6% |
| 2018 | 23 | 3% |
| 2017 | 49 | 3% |
| 2016 | 112 | 5% |
| 2015 | 94 | 5% |
| 2014 | 72 | 4% |
| 2013 | 153 | 7% |
| 2012 | 34 | 4% |
| 2011 | 40 | 3% |
| 2010 | 9 | 8% |
| 2009 | 2 | 6% |
| 2008 | 2 | 1% |
| 2007 | 4 | 2% |
| 2006 | 27 | 4% |
| 2005 | 66 | 13% |
| 2004 | 33 | 3% |
| 2003 | 11 | 1% |
| 2002 | 72 | 2% |
| 2001 | 11 | 3% |
| 2000 | 19 | 2% |
| 1999 | 34 | 3% |
| 1998 | 63 | 3% |
| 1997 | 56 | 3% |
| 1996 | 23 | 2% |
| 1995 | 16 | 2% |
| 1994 | 33 | 3% |
| 1993 | 12 | 1% |
| 1992 | 18 | 3% |
| 1991 | 26 | 4% |
| 1990 | 2 | 17% |
Other parts of the 1996 Ford Explorer
570 complaintsVehicle speed control
148 complaintsBrakes
132 complaintsTransmission and drivetrain
120 complaintsSuspension
97 complaintsEngine cooling
81 complaintsSeat belts
78 complaintsBody and structure
63 complaintsElectrical system
47 complaintsSteering
47 complaintsVisibility (wipers, defrost, mirrors)
47 complaintsAir bags
41 complaints
← All problems reported for the 1996 Ford Explorer
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology