1996 Ford EXPLORER Workshop OEM Service DIY Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Explorer Year: 1996 Codes Vin Prefix Decoder: 1FMEU (North America) 👋 Introduction Market Position Vehicle Segment: Mid-size Sport Utility Vehicle (SUV) Original Purpose: Versatile family vehicle offering off-road capability and towing capacity, competing with Jeep Cherokee, Chevrolet Blazer, and Toyota 4Runner. Competitive Analysis Key Competitors 1996: Jeep Grand Cherokee, Chevrolet Blazer/S-10 Blazer, Toyota 4Runner, Nissan Pathfinder, Dodge Durango (introduced later) Key Features Platform: Ford Ranger pickup truck chassis (body-on-frame construction) Drivetrain Options: Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD) with Electronic Shift-On-Demand (ESO) or Control Trac (full-time AWD capability) 📋 Manual Details Coverage Areas Primary Coverage: 1996 Ford Explorer Engine Options: 4.0L V6, 5.0L V8 Transmission Options: 4-speed Automatic (4R55E, 4R70W), 5-speed Manual (M5OD-R1) Page Count Estimated Pages: 1500-2000 (typical for OEM workshop manuals of this era) Manual Type Type: OEM Workshop Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (4.0L Cologne V6, 5.0L Windsor V8), Fuel system, Ignition system, Exhaust system, Automatic Transmission (4R55E, 4R70W), Manual Transmission (M5OD-R1), Driveline (2WD, 4WD, AWD transfer case operation) Chassis: Suspension (Independent Front Suspension - Twin I-Beam, Rear Solid Axle), Steering (Power Steering), Brakes (Front Disc, Rear Drum/Disc, ABS operation), Wheels and Tires Electrical: Body Electrical, Lighting, Instrumentation, Power Accessories (windows, locks, mirrors), Charging System, Starting System, Audio System, Climate Control Electrical Components, Powertrain Control Module (PCM) related diagnostics Body: Interior and Exterior Trim, Doors, Windows, Seats, Body Panels, Glass, Bumpers, Wipers, Sunroof (if equipped), Convertible Top (if equipped - less common for '96) Procedures Included Maintenance: Oil change, Filter replacements (oil, air, fuel), Fluid checks and changes (coolant, brake, transmission, power steering, differential), Spark plug replacement, Belt inspection and replacement, Battery maintenance Repair: Engine component replacement (heads, gaskets, pistons, bearings), Transmission rebuild/overhaul, Brake system service (pads, rotors, calipers, lines), Suspension component replacement (ball joints, tie rods, shocks, struts), Steering system repair, Electrical component diagnosis and replacement, Body panel repair and alignment, HVAC system service Troubleshooting: Diagnostic Trouble Codes (DTCs), Wiring diagrams, Component testing procedures, Symptom-based troubleshooting guides, Fuel injection system diagnostics, Ignition system diagnostics Technical Depth Depth: Comprehensive (from basic fluid changes to full engine/transmission rebuilds and complex electrical diagnostics) Diagnostics: Includes detailed diagnostic procedures, wiring diagrams, connector pinouts, and step-by-step troubleshooting trees for various systems. Special Tools: Lists required special tools for specific procedures. 📊 Manual Specifications File Format Digital Format: Searchable PDF (typically) Print Quality Readability: High resolution, clear text and diagrams suitable for printing. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 4.0 Liters (245 cu in) Engine 1 Type: Overhead Valve (OHV) V6 (Cologne design) Engine 1 Horsepower: 160 hp @ 4200 RPM Engine 1 Torque: 220 lb-ft @ 2400 RPM Optional Engine Engine 2 Displacement: 5.0 Liters (302 cu in) Engine 2 Type: Overhead Valve (OHV) V8 (Windsor design) Engine 2 Horsepower: 205 hp @ 4000 RPM Engine 2 Torque: 285 lb-ft @ 2400 RPM Fuel System Fuel Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Fuel Pump Pressure 4.0L: 30-40 PSI Fuel Pump Pressure 5.0L: 30-40 PSI Lubrication Oil Type 4.0L: API SG or SH, SAE 5W-30 (check owner's manual for specific temperature ranges) Oil Capacity 4.0L: 5.0 US quarts (with filter) Oil Type 5.0L: API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific temperature ranges) Oil Capacity 5.0L: 5.0 US quarts (with filter) Cooling System Coolant Type: Permanent, ethylene glycol-based antifreeze (typically green) Coolant Capacity: Approx. 11.7 US quarts (4.0L V6), 12.0 US quarts (5.0L V8) 🔧 Transmission Standard Type: 4-speed Automatic (4R55E) Optional Automatic Type: 4-speed Automatic (4R70W - often with 5.0L V8) Optional Manual Type: 5-speed Manual (M5OD-R1) Fluid Type Automatic Fluid Specification: Mercon (MERCON V is backward compatible) Fluid Capacity Automatic Capacity: Approx. 11.5 US quarts (total capacity, refill typically 4-5 quarts) Fluid Type Manual Fluid Specification: Mercon V or equivalent manual transmission fluid (e.g., Synchromesh) Fluid Capacity Manual Capacity: Approx. 2.5 US quarts 📐 Dimensions Exterior Wheelbase: 104.7 inches (2659 mm) Length: 178.9 inches (4544 mm) Width: 70.5 inches (1791 mm) Height: 63.3 inches (1608 mm) (approx. varies with 2WD/4WD) Weights Curb Weight Approx 2Wd: 3,900 - 4,100 lbs (1769 - 1860 kg) Curb Weight Approx 4Wd: 4,100 - 4,300 lbs (1860 - 1950 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5,500 - 5,800 lbs (2495 - 2630 kg) Cargo Cargo Volume Behind Rear Seat: Approx. 40.5 cu ft (1147 L) Cargo Volume With Rear Seat Folded: Approx. 81.5 cu ft (2308 L) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: N/A specific rating for '96 model, but generally higher risk for SUVs of this era compared to sedans. Manual provides rollover mitigation advice. Active Features ABS: Available Anti-lock Braking System (ABS) on rear...

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Type: Car

Verkoper:

Sku: 584787

Collecties: ALL Ford

Beschikbaarheid: Op voorraad

Labels: 1996 Car Cars EXPLORER Ford

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Description

🏷️ Basic Information

Identification

Make:

Model:

Explorer

Year:

Codes

Vin Prefix Decoder:

1FMEU (North America)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size Sport Utility Vehicle (SUV)

Original Purpose:

Versatile family vehicle offering off-road capability and towing capacity, competing with Jeep Cherokee, Chevrolet Blazer, and Toyota 4Runner.

Competitive Analysis

Key Competitors 1996:

Jeep Grand Cherokee, Chevrolet Blazer/S-10 Blazer, Toyota 4Runner, Nissan Pathfinder, Dodge Durango (introduced later)

Key Features

Platform:

Ford Ranger pickup truck chassis (body-on-frame construction)

Drivetrain Options:

Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD) with Electronic Shift-On-Demand (ESO) or Control Trac (full-time AWD capability)

📋 Manual Details

Coverage Areas

Primary Coverage:

1996 Ford Explorer

Engine Options:

4.0L V6, 5.0L V8

Transmission Options:

4-speed Automatic (4R55E, 4R70W), 5-speed Manual (M5OD-R1)

Page Count

Estimated Pages:

1500-2000 (typical for OEM workshop manuals of this era)

Manual Type

Type:

OEM Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (4.0L Cologne V6, 5.0L Windsor V8), Fuel system, Ignition system, Exhaust system, Automatic Transmission (4R55E, 4R70W), Manual Transmission (M5OD-R1), Driveline (2WD, 4WD, AWD transfer case operation)

Chassis:

Suspension (Independent Front Suspension - Twin I-Beam, Rear Solid Axle), Steering (Power Steering), Brakes (Front Disc, Rear Drum/Disc, ABS operation), Wheels and Tires

Electrical:

Body Electrical, Lighting, Instrumentation, Power Accessories (windows, locks, mirrors), Charging System, Starting System, Audio System, Climate Control Electrical Components, Powertrain Control Module (PCM) related diagnostics

Body:

Interior and Exterior Trim, Doors, Windows, Seats, Body Panels, Glass, Bumpers, Wipers, Sunroof (if equipped), Convertible Top (if equipped - less common for '96)

Procedures Included

Maintenance:

Oil change, Filter replacements (oil, air, fuel), Fluid checks and changes (coolant, brake, transmission, power steering, differential), Spark plug replacement, Belt inspection and replacement, Battery maintenance

Repair:

Engine component replacement (heads, gaskets, pistons, bearings), Transmission rebuild/overhaul, Brake system service (pads, rotors, calipers, lines), Suspension component replacement (ball joints, tie rods, shocks, struts), Steering system repair, Electrical component diagnosis and replacement, Body panel repair and alignment, HVAC system service

Troubleshooting:

Diagnostic Trouble Codes (DTCs), Wiring diagrams, Component testing procedures, Symptom-based troubleshooting guides, Fuel injection system diagnostics, Ignition system diagnostics

Technical Depth

Depth:

Comprehensive (from basic fluid changes to full engine/transmission rebuilds and complex electrical diagnostics)

Diagnostics:

Includes detailed diagnostic procedures, wiring diagrams, connector pinouts, and step-by-step troubleshooting trees for various systems.

Special Tools:

Lists required special tools for specific procedures.

📊 Manual Specifications

File Format

Digital Format:

Searchable PDF (typically)

Print Quality

Readability:

High resolution, clear text and diagrams suitable for printing.

Binding Type

Physical Binding:

N/A (Digital Format)

Paper Type

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

4.0 Liters (245 cu in)

Engine 1 Type:

Overhead Valve (OHV) V6 (Cologne design)

Engine 1 Horsepower:

160 hp @ 4200 RPM

Engine 1 Torque:

220 lb-ft @ 2400 RPM

Optional Engine

Engine 2 Displacement:

5.0 Liters (302 cu in)

Engine 2 Type:

Overhead Valve (OHV) V8 (Windsor design)

Engine 2 Horsepower:

205 hp @ 4000 RPM

Engine 2 Torque:

285 lb-ft @ 2400 RPM

Fuel System

Fuel Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Fuel Pump Pressure 4.0L:

30-40 PSI

Fuel Pump Pressure 5.0L:

30-40 PSI

Lubrication

Oil Type 4.0L:

API SG or SH, SAE 5W-30 (check owner's manual for specific temperature ranges)

Oil Capacity 4.0L:

5.0 US quarts (with filter)

Oil Type 5.0L:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific temperature ranges)

Oil Capacity 5.0L:

5.0 US quarts (with filter)

Cooling System

Coolant Type:

Permanent, ethylene glycol-based antifreeze (typically green)

Coolant Capacity:

Approx. 11.7 US quarts (4.0L V6), 12.0 US quarts (5.0L V8)

🔧 Transmission

Standard

Type:

4-speed Automatic (4R55E)

Optional Automatic

Type:

4-speed Automatic (4R70W - often with 5.0L V8)

Optional Manual

Type:

5-speed Manual (M5OD-R1)

Fluid Type Automatic

Fluid Specification:

Mercon (MERCON V is backward compatible)

Fluid Capacity Automatic

Capacity:

Approx. 11.5 US quarts (total capacity, refill typically 4-5 quarts)

Fluid Type Manual

Fluid Specification:

Mercon V or equivalent manual transmission fluid (e.g., Synchromesh)

Fluid Capacity Manual

Capacity:

Approx. 2.5 US quarts

📐 Dimensions

Exterior

Wheelbase:

104.7 inches (2659 mm)

Length:

178.9 inches (4544 mm)

Width:

70.5 inches (1791 mm)

Height:

63.3 inches (1608 mm) (approx. varies with 2WD/4WD)

Weights

Curb Weight Approx 2Wd:

3,900 - 4,100 lbs (1769 - 1860 kg)

Curb Weight Approx 4Wd:

4,100 - 4,300 lbs (1860 - 1950 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,500 - 5,800 lbs (2495 - 2630 kg)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 40.5 cu ft (1147 L)

Cargo Volume With Rear Seat Folded:

Approx. 81.5 cu ft (2308 L)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

N/A specific rating for '96 model, but generally higher risk for SUVs of this era compared to sedans. Manual provides rollover mitigation advice.

Active Features

Available Anti-lock Braking System (ABS) on rear wheels, or all four wheels depending on trim and options.

Passive Features

Airbags:

Driver-side airbag standard.

Seatbelts:

3-point seat belts in front, 2-point lap belts in rear (later models may have 3-point rear belts). Child seat anchor points (LATCH not standard).

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player standard, optional CD player. Basic speaker configurations.

Driver Assistance

Cruise Control:

Available

Anti Lock Brakes:

Optional (ABS)

Connectivity

Auxiliary Inputs:

N/A (no factory standard AUX or USB)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (or 6 months), depending on driving conditions and oil used. Consult manual for specific recommendations.

Tire Rotation Interval:

Every 5,000-7,500 miles

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, depending on towing or severe use. Manual transmission fluid typically every 60,000-100,000 miles.

Coolant Flush Interval:

Every 30,000-60,000 miles or 2-4 years.

Fluid Specifications

Power Steering Fluid:

Mercon or Mercon V (check manual)

Brake Fluid:

DOT 3

Differential Fluid Rear Std:

API GL-5, SAE 80W-90 (or 75W-140 for towing)

Differential Fluid Rear Lsd:

API GL-5, SAE 80W-90 with friction modifier (if limited slip differential)

Transfer Case Fluid:

Mercon or Mercon V

Known Issues

Common Wear Items:

Ball joints, tie rod ends, wheel bearings, brake components, U-joints, catalytic converter.

Engine 4.0L Common Problems:

Head gasket leaks (especially early 4.0L), valve cover gasket leaks, oil pan gasket leaks, intake manifold gasket leaks.

Engine 5.0L Common Problems:

Less prone to major gasket failures than the early 4.0L, but still susceptible to valve cover and oil pan leaks.

Transmission Common Problems:

4R55E/4R70W solenoids failing, torque converter issues, valve body issues, overheating.

4Wd System Common Problems:

Transfer case actuator issues (if electronic shift), vacuum leaks for hub operation (if applicable).

📚 Vehicle History

Brand Heritage

Ford SUV Legacy:

Ford's SUV lineage includes the Bronco, which paved the way for more family-oriented models.

Model Evolution

First Generation:

The 1991-2001 generation introduced the Explorer, quickly becoming a best-seller and defining the modern mid-size SUV market for Ford.

Second Generation Transition:

While this is a first-generation model, the 1995 redesign brought significant updates including more aerodynamic styling and a new independent front suspension option, which the '96 model continues.

Production

Manufacturing Plants:

Louisville, Kentucky; St. Louis, Missouri

Production Years First Gen:

1990 (as 1991 model) - 2001

🏆 Awards & Recognition

Recognitions

Initial Reception:

The first-generation Explorer was an immediate sales success and widely praised for its car-like ride and versatility compared to older truck-based SUVs.