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. Now I see there is a problem with the newer Explorer and I feel that this has been a manufacturing problem for many, many years, but just now has caught up with Ford because it was investigated by news media, where I had no recourse back in the day for the correction on my vehicle.

- Templeton, CA, USA

15 minutes after parking the vehicle and getting off the vehicle caught onfire under the hood in the drivers side. The fire expanded quickly caught drivers side front tire and moved on to the entire motor before the firefighters came and stopped the fire.

- Brownsville, TX, USA