FordExplorer1996Overview/ford/explorer/1996/base/

1996 Ford Explorer

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1996 Explorer.

Body SUV

The 1996 Ford Explorer is an SUV equipped with a 5.0‑quart oil capacity and 5W‑20 API oil specifications. It recorded 1,640 total owner complaints, with tire problems topping the complaint list and 11 recall actions issued, placing its complaint volume near the lower end of the 1990‑2025 span that ranges from a low of 12 complaints in 1990 to a high of 3,620 in 2002. This relative position places the 1996 model year nearer the lower‑complaint end of the recorded range, though tire‑related concerns remained a notable focus.

Model year202620252024202320212020201920181996

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 · 650 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 · 650 CCAOEM · verified
Tire sizeP225-70R15SLOEM · verified
Wheel / rim6.5-,7-JJ inOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length178.7 in
Overall width70.1 in
Overall height67.7 in
Wheelbase101.6 in
Curb weight3309 lb
Track (front / rear)58.7 / 58.7 in

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Explorer of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

8.8–9.5 sec0–60 mph (tested)quickest 8.80 sec — 1996 XLT V8
YearTrim / engine0–60¼ mileHPDrivetrain
1996XLT V8 5.0L V88.80 sec16.90 sec210 hpRWD
1996XLT V8 5.0L V88.90 sec16.80 sec210 hp4x4
1996XLT V8 5.0L V89.50 sec17.30 sec210 hp4x4
1995XLT 4.0L V610.70 sec17.90 sec160 hp4x4
1995Eddie Bauer 4.0L V610.90 sec17.90 sec160 hp4x4
1995XLT 4.0L V611.60 sec18.20 sec160 hp4x4
1997XLT 4.0L V68.50 sec16.50 sec160 hp4x4
1999XLT 4.0L V68.40 sec16.60 sec210 hp4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-20 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs. The firing order is 1-3-7-2-6-5-4-8.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear OilSYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity5.5 Pints (rear)
Engine Oil5W-20 · API
Engine Oil Capacity5.0 qt
Power Steering FluidATF
Transfer Case FluidATF
Transfer Case Fluid Capacity3 PINTS

Engine torques

Connecting Rod (Large End) Bearings18-24 ft-lbs
Connecting Rod (Large End) Bearings19-24 ft-lbs
Engine Flywheel Bolts59 ft-lbs
Engine Flywheel Bolts79-85 ft-lbs
Intake Manifold to Engine BoltsUpper: 15-
Exhaust Manifold to Cylinder Head Bolts20 ft-lbs
Intake Manifold to Engine BoltsLower: 23-; Upper: 12-
Exhaust Manifold to Cylinder Head Bolts18-24 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)88.0-108.0 ft-lbs
Leaf Spring to Chassis Bracket74.0-115.0 ft-lbs
Leaf Spring to Rear Shackle74.0-115.0 ft-lbs
Leaf Spring Rear Shackle to Chassis Bracket74.0-115.0 ft-lbs
Lug Nuts100 ft-lbs
Transfer Case Fill Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Transfer Case Drain Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Front Wheel Hub195 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Cylinder Firing Order1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)750 rpm
Curb Idle Speed Variance (No Load)25 rpm
Curb Idle Speed (No Load)825 rpm
Curb Idle Speed Variance (No Load)25 rpm
Curb Idle Speed (No Load)700 rpm
Curb Idle Speed Variance (No Load)50 rpm

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.63-1.65 lbs
Oil GroupPAG
Oil Capacity7.00-11.00 oz
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca

Service checks

Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature183-190 °F
Key ON Engine OFF (KOEO)35-45
RPM30-45 @ Idle rpm
Engine Oil Pressure40-60 psi
Engine Oil Pressure RPM2000 rpm
Intake Valve LashHydraulic in

Brakes

Torque Caliper to Bracket38-48 ft-lbs
Torque to Knuckle125-170 ft-lbs
Torque Caliper to Bracket38-48 ft-lbs
Torque to Knuckle125-170 ft-lbs
Torque Caliper to Bracket20 ft-lbs
Torque to Knuckle40 ft-lbs
Minimum Pad ThicknessFront: 0.060; Rear: 0.030 in
Rotor Runout Limit0.003 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 2 stages
135-40 ft. lbs.35–40 ft. lbs
256-60
Cylinder Head — tightening sequence 3 stages
122-26 ft. lbs.22–26 ft. lbs
252-56 ft. lbs.52–56 ft. lbs
390
Cylinder Head — tightening sequence 3 stages
125-35 ft. lbs.25–35 ft. lbs
245-55 ft. lbs.45–55 ft. lbs
385-95

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 5,000 miClutch Master Cylinder (inspect fluid level) · Driveshaft Slip Yoke (lubricate) · Driveshaft U-Joint (lubricate) · Exhaust System (Complete) (inspect) · Shift Linkage (lubricate) · Steering Linkage (inspect)
Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace)
Every 10,000 miClutch Master Cylinder (inspect fluid level) · Driveshaft Slip Yoke (lubricate) · Driveshaft U-Joint (lubricate) · Exhaust System (Complete) (inspect) · Shift Linkage (lubricate) · Steering Linkage (inspect)
Every 12,000 miBattery (inspect)
Every 15,000 miBrake Line (inspect) · Brake System (inspect) · Disc Brake Caliper Guide Pin (lubricate) · Engine Coolant System (leak inspection) · Engine Coolant System Hoses (inspect)
Every 30,000 miAccessory Drive Belt (inspect) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Fuel Filter (replace) · Parking Brake System (inspect) · Throttle Body Lever Stud (lubricate)
At 50,000 miEngine Coolant System (drain, flush & refill)
At 60,000 miAccessory Drive Belt (inspect)
Every 60,000 miAir Injection System (inspect) · PCV Valve (replace) · Transfer Case Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 1996 Ford Explorer sits at the peak of the complaint trajectory for its generation, with 1,640 complaints—higher than any year from 1990 to 1995 and only surpassed by 1997’s 1,981. Recall activity remains relatively flat, with 11 recalls in 1996 versus 12 in 1995 and 12 in 1997, indicating that the high complaint volume was not driven by widespread safety recalls. Investigations dropped sharply to 3 in 1996 from 6 in 1995 and 6 in 1997, suggesting that many complaints were not tied to regulatory investigations. The top complaint categories—Tires (629), Vehicle Speed Control (119), Power Train (104), and Service Brakes, Hydraulic (86)—highlight specific areas that may require closer inspection when evaluating a used vehicle. With 204 crash complaints and 39 fire complaints, the 1996 model does not show an extraordinary safety signal relative to its peers. Overall, while the high complaint count warrants diligence, the absence of a corresponding spike in recalls or investigations means a 1996 Explorer can still be a reasonable purchase if those specific components are thoroughly inspected.

11
Open recalls
NHTSA campaigns
267
Service bulletins
Manufacturer communications
3
ODI investigations
Office of Defects Investigation
1,640
Owner complaints
204 involved a crash · 39 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★

Owner complaints filed with NHTSA, by component

All 1,640 complaints on record, top 8 components.

Tires629
Vehicle Speed Control119
Power Train104
Service Brakes, Hydraulic86
Suspension81
Engine & Engine Cooling78
Seat Belts72
Structure46

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 11 campaigns on record for this vehicle.

09E025000Exterior Lighting:HeadlightsReported 11/05/2009

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE… Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT…

09V399000Vehicle Speed ControlReported 13/10/2009

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY… Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE…

Technical service bulletins NHTSA · verified

Showing 5 of 267 bulletins on record with NHTSA.

BulletinDateComponentSummary
0305082005-04-01Power TrainFRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD. *TT
021382003-11-10Power TrainLOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT), SLIPPING SHIFTS AND / OR DELAYED…
031812003-09-15Electrical SystemREMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT
031482003-07-21Power TrainNEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES…
167352003-04-01SuspensionVARIOUS NOISE ISSUES FROM THE REAR LEAF SPRINGS WHILE DRIVING. *TT

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Explorer. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 1996 Explorer take?

5.0 qt of 5W-20 API, per the factory manual.

Does the 1996 Explorer have open recalls?

NHTSA lists 11 recall campaign(s) for this model year. Check your specific vehicle by VIN.