What is the 1991-1999 Ford Explorer Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023)?

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.

What is the 1991-1999 Ford Explorer Frame, rear subframe, and rocker/body-mount rust?

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.

What is the 1991-1999 Ford Explorer Camshaft synchronizer / CMP sensor bushing failure?

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.

What is the 1995-2010 Ford Explorer Power Window Regulator Cable/Clip Failure Causing Window to Fall Into the Door?

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.

Ford · Known Issues

1996 Ford Explorer Problems: 7 Known Issues

1996 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated August 2026

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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), Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 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) and Frame, rear subframe, and rocker/body-mount rust ($200-$3,000 repair). Across all issues with published estimates, repair costs range from $25 to $3,500. DIY maintenance guides at au7o.io.

All 7 Known Issues

Frequently Asked Questions

What are the most common Ford Explorer problems?

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, Automatic transmission overdrive failure (A4LD / 4R55E), Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023). Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Explorer reliable?

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 Automatic transmission overdrive failure (A4LD / 4R55E) 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. 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.

How much does it cost to fix common Ford Explorer 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.

What is the 1991-1999 Ford Explorer 4.0L OHV cracked cylinder heads and blown head gaskets from overheating?

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.

All 7 Known Issues

1995-2001 Ford Explorer: Firestone/Wilderness AT Tire Tread Separation Causing Blowouts and Rollovers (Recall EA00-023)#

1991-1999 Ford Explorer: Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023)#

1991-1999 Ford Explorer: 4.0L OHV cracked cylinder heads and blown head gaskets from overheating#

1991-1999 Ford Explorer: Automatic transmission overdrive failure (A4LD / 4R55E)#

1991-1999 Ford Explorer: Frame, rear subframe, and rocker/body-mount rust#

1991-1999 Ford Explorer: Camshaft synchronizer / CMP sensor bushing failure#

1995-2010 Ford Explorer: Power Window Regulator Cable/Clip Failure Causing Window to Fall Into the Door#

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