Service Brakes, Hydraulic. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 34 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

10 crash reports17 fire reports5 injury reports

Engine And Engine Cooling complaints

34 reports

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Mileage unknown · Jan 9, 2001

Engine And Engine Cooling

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THE "Y" PIPE HAS FAILED TWICE, ALLOWING EXHAUST TO ENTER THE ENGINE COMPARTMENT. FIRST TOOK IT TO AN OUT OF TOWN DEALER WHO SAID HE DID NOT HAVE PARTS TO FIX BUT WARNED ME TO KEEP FRESH AIR COMING INTO THE CAB.. THE LOCAL DEALER REPLACED ONCE AND THE SECOND TIME SAID IT WAS NO LONGER COVERED AND BESIDES DID NOT KNOW HOW TO FIX THE PROBLEM. SUGGESTED I TAKE IT TO A PRIVATE MUFFLER SHOP WHO TOLD ME THAT FORD WAS WELL AWARE OF THE PROBLEM, THAT IT WAS DANGEROUS BECAUSE IT WOULD LEAK CARBON MONOXITE INTO THE CAB AND SUGGESTED I TAKE IT BACK TO THE DEALER AND PUSH FOR A REPLACEMENT. DEALER GAVE ME A FORM TO FILL OUT BUT HAVE NEVER HEARD BACK. I TOOK VEHICLE TO ANOTHER DEALER, AND THEY TOLD ME A SIMILAR STORY AND SAID IF IT WAS A CALIFORNIA VEHICLE FORD WOULD STAND BY IT, BUT BECAUSE IT WAS NOT, I WOULD HAVE TO TAKE IT TO A MUFFLER SHOP AND HAVE A CUSTOM ONE BUILT. THEY ALSO WARNED ME TO BE CAREFUL TO KEEP AIR COMING IN THRU THE HEATER/AC SO I WOULD NOT GET CARBON MONOXIDE POISONING AND/OR FALL ASLEEP.

NHTSA ODI #739104

Mileage unknown · Nov 18, 2000

Engine And Engine Cooling

CRACKED MANIFOLD ON EACH SIDE IN THREE PLACES. *AK

NHTSA ODI #736502

Mileage unknown · Nov 15, 2000

Engine And Engine CoolingPower TrainService Brakes, Hydraulic

VEHICLE WAS AT A STANDSTILL/ IDLING, AND SUDDENLY EXHAUST SOUNDED LIKE MARBLES, AND TURBO QUIT. ALSO, HAD TO GET REAR MAIN SEAL REPLACED TWICE. BRAKE ROTORS WERE WARPED, AND TRANSMISSION DID NOT SHIFT PROPERLY. PLEASE ADD ANY ADDITIONAL INFORMATION. *AK

NHTSA ODI #875015

Mileage unknown · Sep 8, 2000

Engine And Engine Cooling

ON FAILURE OF COMPONENT AT ANY SPEED COMPLETE LOSS OF POWER,STEERING,BRAKING AFTER ONE APPLICATION. DIESEL ENGINE USES BELT DRIVEN VACUUM PUMP TO SUPPLY BRAKING BOOST ALSO POWER STEERING PUMP POWER IS LOST.

NHTSA ODI #730769

Mileage unknown · Aug 11, 2000

Engine And Engine Cooling

OVER THE COURSE OF 400 MILES THE TRUCK LOST 4 QUARTS OF OIL. *AK

NHTSA ODI #727561

Mileage unknown · May 21, 2000

Engine And Engine CoolingFire

ENGINE DEVELOPED FIRE ON RIGHT REAR SECTION OF THE ENGINE NEAR THE TURBO. DOES THIS TRUCK HAVE A HISTORY OF ENGINE FIRES? CAUSE OF FIRE IS UNKNOWN. *AK

NHTSA ODI #722969

Mileage unknown · May 19, 2000

Engine And Engine Cooling

THE VEHICLE IS NOT PROVIDED WITH EXHAUST MANIFOLD GASKETS WHICH CAUSES FASTENER FAILURES CAUSING EXHAUST LEAKAGE DIRECTLY FROM THE CYLINDERS. THE EXHAUST THEN ENTERS THE CAB OF THE TRUCK. *AK

NHTSA ODI #722891

Mileage unknown · Mar 21, 2000

Engine And Engine CoolingService Brakes, Hydraulic

BOTH BRAKE ROTORS CRACKED ON TWO SEPARATE ACCASIONS . FORD REPLACED THE FIRST BAD SET UNDER WARRANTY, BUT WONT ADMIT THERE'S SOMETHING WRONG & WONT REPLACE THEM AGAIN.I'VE ALSO GOT AN EXHAUST LEAK THAT THEY TEMPERARILY FIXED UNDER WARANTY.

NHTSA ODI #720413

Mileage unknown · Oct 22, 1999

Engine And Engine Cooling

THE DEALER HAS REPLACED LEFT AND RIGHT MANIFOLS. THIS OCCURED IN 1997, 1998, AND NOW IN 1999. I WAS TOLD BY OTHER OWNNERS THIS MAY HAPPEN ON MY VEHICLE BEFORE IT HAPPENED. THIS IS THIRD TIME, ONCE JUST THE GASKET, ONE SIDE WAS COVERED BY DEALERSHIP, THE OTHER SIDE I HAD TO PAY OUT OF MY POCKET @ $449.

NHTSA ODI #713690

Mileage unknown · May 14, 1999

Engine And Engine CoolingPower Train

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THE VEHICLE HAS HAD TRANSMISSION/AND OR ELECTRICAL PROBLEMS SINCE IT WAS PURCHASED. EVERY FEW WEEKS THE ENGINE COMPUTER PICKS UP A TROUBLED CODE. THE CODE IS TCC/OR TORQUE CONVERTER CLUTCH FAILURE.THE VEHICLE THEN GOES INTO SAFE MODE,AND RUNS ON PREDETERMINED VALUES SET BY THE ENGINE COMPUTER.THE TRANSMISSION SHIFTS EXTREMELY HARD DURING THIS CONDITION.(AUTOMATIC E40D). THE DEALER HAS BEEN NOTIFIED, AND HAS FAILED TO CORRECT THE PROBLEM. I HAVE TAKEN THE VEHICLE TO 2 TRANSMISSION SHOPS, AND THEY CANT FIND ANYTHING WRONG WITH THE TRANSMISSION. SINCE THIS HAS BEEN AN ONGOING PROBLEM, MY NEXT COURSE OF ACTION IS TO SEEK RELIEF UNDER THE USED VEHICLE LEMON LAW. *AK

NHTSA ODI #706499

Official recalls

06V286000 · Vehicle Speed Control

Aug 1, 2006

ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.

Consequence & remedy

Consequence: OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.

Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE: ALSO SEE RECALLS 05V017 AND 05V388)

05V388000 · Vehicle Speed Control

Sep 7, 2005

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence & remedy

Consequence: A FIRE AT THE SWITCH COULD OCCUR.

Remedy: BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)

96V064000 · Seats

Apr 16, 1996

THE WIRE HARNESS FOR THE POWER LUMBAR FEATURE ON THE SEAT IS UNDERNEATH THE FRONT SEAT CUSHION SUPPORT WIRES. THE SUPPORT WIRES ON THE DRIVER SEAT CAN CONTACT AND DAMAGE THE INSULATION HARNESS RESULTING IN A HIGH RESISTANCE ELECTRICAL SHORT THROUGH THE SUPPORT WIRES.

Consequence & remedy

Consequence: CONSEQUENCE OF DEFECT: OVER HEATING OF THE SUPPORT WIRES COULD RESULT, AND MELTING, SMOKE, OR POSSIBLE IGNTION OF THE SURROUNDING MATERIALS COULD OCCUR.

Remedy: DEALERS WILL INSPECT THE SEATS ON THE AFFECTED VEHICLES. IF NO DAMAGE IS FOUND, THE DRIVER SEAT WIRE HARNESS WILL BE COVERED WITH A PROTECTIVE CONVOLUTE TUBING, WRAPPED WITH ELECTRICAL TAPE AND THE HARNESS WILL BE REROUTED. IF DAMAGE IS FOUND, THE WIRE HARNESS WILL BE REPLACED.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

EA05005 · Engine Compartment Fires

Opened Mar 22, 2005 · Closed Aug 2, 2006

Status: closed (inferred from source dates) · Electrical System; Electrical System:wiring:front Underhood; Vehicle Speed Control:cruise Control

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

Additional source detail variants (21)

Electrical System

Electrical System:wiring:front Underhood

Vehicle Speed Control:cruise Control

PE96052 · Separated Front Suspension

Opened Aug 23, 1996 · Closed Jan 27, 1997

Status: closed (inferred from source dates) · Suspension

CONSUMER COMPLAINTS REPORT THAT BOLTS WHICH RETAIN THE AXLE PIVOT BRACKET TO THE FRAME CROSS MEMBER CAN LOOSEN OR FAIL, CAUSING THE INBOARD END OR THE AXLE TO BECOME DETACHED FROM THE VEHICLE.OWNERS ALLEGE THAT THIS COULD RESULT IN LOSS OF STEERING CONTROL, HOWEVER THE COMPLAINT DATA SHOWS ONLY ONE INCIDENT WHERE THE VEHICLE LEFT THE ROADWAY FOLLOWING AXLE SEPARATION, WITH NO DAMAGE TO THE VEHICLE.IN ADDITION TO THE 225 CONSUMER COMPLAINTS, THERE WERE 4,315 WARRANTY CLAIMS RELATED TO THE FRONT SUSPENSION AND MEMBERS, AND 22 VEHICLES WERE REPLACED FOR GOODWILL.DOCUMENTS SUBMITTED BY FORD, UNDER REQUEST FOR CONFIDENTIAL TREATMENT INDICATE THAT THE BOLTS WERE INADEQUATE FOR THE DURABILITY REQUIREMENTS OF THE VEHICLE.ALSO, BOLTS WERE FOUND TO HAVE BEEN INADEQUATELY TORQUED AT ONE OR MORE ASSEMBLY PLANTS.OTHER FACTORS, SUCH AS WAX TREATMENT OF THE FRAME, CONTRIBUTED TO THE PROBLEM.INCREASED BOLT DIAMETER AND INCREASED TORQUE APPARENTLY CORRECTED THE PROBLEM.A SERVICE BULLETIN, 96-20-13, WAS ISSUED TO ADVISE DEALERS OF THIS CORRECTIVE ACTION.IN THESE DOCUMENTS, FORD ALSO REPORTED THAT A VEHICLE, EQUIPPED FOR SIMULTANEOUS CATASTROPHIC FAILURE OF ALL PIVOT BRACKET FASTENERS, WAS EVALUATED RESULTING IN A SLIGHT VEHICLE PULL TO ONE SIDE WITH NO LOSS OF VEHICLE CONTROL.ODI HAS NOT REPLICATED FORD'S VEHICLE TESTING, HOWEVER ANALYSIS OF THE DESIGN OF THE FRONT SUSPENSION INDICATES THAT EVEN IF THE INBOARD END OF THEAXLE BECAME DISCONNECTED FROM THE FRAME, THE OUTBOARD END WOULD REMAIN FIRMLY ATTACHED TO THE LEAF SPRING WITH TWO U-BOLTS.THIS WOULD RETAIN THE WHEEL IN ITS APPROXIMATE POSITION, ALTHOUGH THE WHEEL ALIGNMENT WOULD BE GREATLY IN ERROR.THEREFORE IT IS UNLIKELY THAT CONTROL OF THE VEHICLE WOULD BE LOST.OWNERS REPROT MANY SIGNIFICANT NOISES IN THE SUSPENSION, SUCH AS CREAKING, GROANING, CLUNKING, AND SQUEAKING, PRIOR TO NOTICING ANY SEPARATION OF THE AXLE.THIS PROVIDES WARNING OF THE LOOSENING OF THE BOLTS TO THE DRIVER, AND SHOULD NOT BE IGNORED.FORD HAS STATED THAT REPAIRS WILL BE COVERED UNDER THE VEHICLE'S BUMPER WARRANTY.COMPLAINTS ABOUT WARRANTY COVERAGE BY A FORD DEALER SHOULD BE ADDRESSED TO FORD, OR TO APPROPRIATE STATE AND LOCAL AGENCIES.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.