The 1996 Ford Explorer has 6 recalls, the most serious being a throttle that can stick open in extreme cold, leaving the engine at high idle even after the driver lifts off the accelerator pedal.
In very cold conditions, ice can form around the throttle plate after extended highway driving, causing the engine to hold a high idle or fail to return to normal when the accelerator is released. A related recall, limited to 5.0L engines in certain northern states, addresses the same type of runaway throttle concern; while the vehicle can be brought under control by braking or shifting to neutral, stopping distances may increase. On the suspension side, a front sway bar link can fracture, which affects how the vehicle handles through corners and reduces stability. There are also two structural recalls covering the same problem: a bracket holding the liftgate's gas cylinder strut has welds that may not hold, causing the strut to lose its support and the rear liftgate to drop unexpectedly on anyone nearby. A final compliance recall affects 4.0L-equipped models, where an incorrect fuel vapor valve was installed that allows evaporative emissions to exceed the legal standard.
At a glance
What can fail
Under certain conditions, the front sway bar link on your vehicle can crack or break. This connects the sway bar to the suspension and helps control vehicle stability during turning.
What the fix does
The dealer will replace both the left and right front sway bar links with new ones.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The welds connecting the liftgate assist gas cylinder bracket to the right side panel may be undersized, potentially causing the bracket to separate and the gas cylinder to fail supporting the liftgate.
What the fix does
The bracket attachment will be reinforced with two pop rivets to strengthen the connection.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The bracket holding the liftgate assist gas cylinder on the right side was incorrectly welded and may not securely hold the cylinder.
What the fix does
Dealers will reinforce the bracket attachment by installing two pop rivets to secure it properly.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
In cold climates below -20°F, ice can build up in the throttle body during extended highway driving, preventing the engine from returning to idle speed.
What the fix does
Dealers will install a revised PCV system with a heated water vacuum source to prevent ice buildup.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
In cold temperatures below -29°C during extended highway driving, ice can form around the throttle plate, causing higher than normal idle speeds and preventing the throttle from returning when you release the accelerator pedal.
What the fix does
Install a revised PCV system with an engine coolant heated vacuum source to prevent ice formation.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
Vehicles with 4.0-liter engines have an incorrect fuel vapor management valve installed, allowing engine emissions to exceed federal standards.
What the fix does
The fuel vapor management valve will be replaced with the correct part to bring emissions into compliance.
Summarized — see the official notice for exact wording, dates, and contacts.
