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 housing, near the firewall. This unobstructed opening facilitated the rodents' entry to the heating system. It is of my opinion this is unsafe, and had the foreign material not been flame resistant, I'm convinced my vehicle would have burned. I entered my VIN number into Ford's official web site, and was returned zero results for recalls of any sort. I did not find any recalls related to heater blowers for similar models either. I have repaired the heating system but am at a loss for how to prevent this in the future, as this opening still exists and I'm unaware of any sanctioned remedies.

- Orwell, OH, USA

1996 Ford Explorer vehicle caught on fire while traveling. (Ohio traffic crash report # 10-0629-91)8jb updated 04/22/11

- Newton Falls, OH, USA

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.

- Omaha, NE, USA

I have researched and found numerous complaints about blown or leaking head gaskets on the 1996 Ford Explorer, and that is my complaint is.I have a 1996 Ford Explorer XLT with 66,000 miles is gararged year round and is maintained regularly and is only driven by my wife localy back and forth to work approximatly 10-20 miles a day I feel that there is no way I should have both head gaskets leaking coolant with realitivly low mileage for the year.there is definatly a problem here and feel that this needs to be investigated further by Ford, I was also speaking with a gentleman at a local auto parts store (where I work part time ) and he is having the same problem with his 1998 Ford Explorer XLT, both engies involved are the 4.0 V6. I hope Ford will do what is nesesary to rectify this problem not only for myself but for others that will ultimatly hit them quite hard in the pocketbook for work done at a sevice center.I do not want to drive the vehicle untill I find out what can be done by Ford but have to in order to get my wife back and forth to work, I do not know if anything can be done to seal the problem without taking the heads off and replacing the gaskets.I have checked into what the cost would be and have been told anywhere from $1,200-$1,500 dollars, a bill I cannot afford.it is a shame because we love the vehicle and have had a number of Ford products but are seriously considering trading it in on another brand of vehicle.

- Eastfalmouth, MA, USA

Repair shop stated that the Explorer by Ford has a weak spot that he has had to repair on numerous occasions. It is the L cylinder #4 that cracked.

- Highlands Ranch, CO, USA

Was driving and engine check light came on & stayed. Been to dealer. Had sensors replaced, but problem came back. Temperature gauge had failed to register. Fuel guage was not working, and stablizer bar had broken and was replaced. Also, power locks failed to release. The sensors were being replaced over and over again.

- York, ME, USA

Temperature gauge showed hot. Drove to dealer 5 miles away. Dignosis: Blown head gasket.

- Sherman Oaks, CA, USA

Gas gauge does not move when filled with gas or while driving. Cause unkown. Dealer cannot correct problem. The temperature gauge is erratic, dealer replaced a wiring harness, however this did not work, dealer can not remedy the erratic temperature gauge or the inaccurate gas gauge.

- Tucson, AZ, USA