1994 Ford Explorer Electrical System Problems

1994 FORD EXPLORER HAD SMOKE COMING OUT OF THE AIR-CONDITIONER VENTS INTO THE PASSENGER COMPARTMENT, SLIGHT AT FIRST, THEN SO HEAVY THAT FORWARD VISIBILITY WAS OBSCURED. AFTER STOPPING THE VEHICLE, A SMALL FIRE WAS SEEN BURNING THE PLASTIC EVAPORATOR COVER WHERE THE BLOWER MOTOR RESISTOR ASSEMBLY IS MOUNTED IN THE EVAPORATOR COVER. SOME SNOW THROWN ON THE FIRE PUT IT OUT. THE BLOWER MOTOR APPEARS TO BE SHORTED OR MAYBE JAMMED FROM ROTATING, CAUSING THE RESISTOR TO GET HOTTER THAN NORMAL, IGNITING THE PLASTIC COVER. MAYBE LEAVES OR OTHER FLAMMABLE DEBRIS CONTACTED THE RESISTOR, BUT I CAN'T TELL AS THE FLAMES BURNED UP ANYTHING IN THE AREA AROUND THE RESISTOR ASSEMBLY. FORTUNATELY, I WAS ABLE TO BRING THE VEHICLE TO A SAFE STOP, IN SPITE OF VERY LIMITED VISIBILITY IN THE HEAVY SMOKE. I WAS ON A SLOW SPEED, LOW TRAFFIC CITY STREET. THE RESULTS WOULD HAVE BEEN MUCH WORSE IF THE FIRE OCCURRED AT HIGHWAY SPEEDS. THE BLOWER MOTOR WILL BE AVAILABLE FOR INSPECTION WHEN I REMOVE AND REPLACE IT TO TRY AND GET THE AIR SYSTEM WORKING FOR HEAT AT LEAST. *TR

WHILE DRIVING, THE SUV CAUGHT FIRE FROM UNDER THE HOOD. THE VEHICLE WAS CONSUMED BY FLAMES IN LESS THAN 5 MINUTES. ALTHOUGH MANY MAKES AND MODELS OF FORDS HAVE BEEN RECALLED ( FAULTY CRUISE CONTROL - POTENTIAL FIRE HAZARD), THE 1994 FORD EXPLORER HAS NOT BEEN RECALLED. *TR

TL*THE CONTACT OWNS A 1994 FORD EXPLORER. WHILE DRIVING BETWEEN 25-30 MPH, WHITE SMOKE APPEARED FROM THE AIR CONDITIONING VENTS. THE CONTACT PULLED OVER AND EXITED THE VEHICLE. THE VEHICLE CONTINUED TO SMOKE AND THEN CAUGHT FIRE ON THE FRONT PASSENGER SIDE UNDERNEATH THE VEHICLE. THE VEHICLE WAS DESTROYED. A FIRE REPORT WAS FILED. THE CURRENT AND FAILURE MILEAGES WERE 150,000.

TL*THE CONTACT OWNS A 1994 FORD EXPLORER. WHILE DRIVING 2 MPH THE CONTACT ACTIVATED THE HEATER AND NOTICED SMOKE COMING FROM THE VENTS. SHE TURNED OFF THE ENGINE. SHE THEN RESTARTED THE VEHICLE AND ACTIVATED THE AIR CONDITIONER. THE CONTACT NOTICED FIRE ASCENDING FROM THE HOOD NEAR THE PASSENGER SIDE OF THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE MANUFACTURER STATED THAT THEY WOULD CONDUCT AN INVESTIGATION TO DETERMINE THE CAUSE OF THE FIRE. THE VEHICLE HAS NOT BEEN INSPECTED YET, AND THE INSURANCE COMPANY WAS UNABLE TO DETERMINE THE CAUSE OF THE FIRE. THE CURRENT AND FAILURE MILEAGES WERE 145,000.*AK

I BOUGHT THIS 1994 FORD EXPLORER EDDIE BAUER SUV FROM A DEALER. THE CAR HAD A PROBLEM WITH ALARM SO THE DEALER REMOVED IT. THE ABS LIGHT COMES ON AND OFF. A WEEK AFTER THE PURCHASE, WHILE DRIVING, THE ENGINE STOPS, CAR COMES TO A HALT IN THE MIDDLE OF THE ROAD, AND THE STEERING LOCKS. I ALMOST GOT HIT BY A TRUCK. IT STARTS BACK ON AFTER FEW MINUTES. IT DOES NOT START IF HAZARDS, HEADLIGHTS OR ANY ELECTRICAL COMPONENTS ARE ON. AFTER THAT THE SAME THING HAPPENED 5 TIMES IN 2 WEEKS ONCE AT NIGHT 12''O CLOCK. IT IS HIGHLY UNSAFE TO DRIVE THE CAR NOW. I'M NOT DRIVING IT ANYMORE. THE DEALER DOES NOT KNOW WHAT THE PROBLEM IS AND DOES NOT WANT TO TAKE THE CAR BACK. *JB

DT: 1994, FORD, EXPLORER LIMITED, CONSUMER WAS DRIVING ON HIGHWAY WHEN THE VEHCILE STARTED SMOKING. CONSUMER STARTED HAVING BREATHING PROBLEMS. THE SMOKE STARTED THICK, AND CONSUMER COULDN'T SEE, AND HE PULLED OVER. WHEN THE CONSUMER GOT OUT OF THE CAR HE EEN SPARKS, THEN THE CAR BLEW UP. OWNER HAD NO PHYSICAL INJURIES. THE FIRE WAS SO HOT THAT TIRES MELTED AND EVEN THE KEYS MELTED. *AK

VEHICLE WAS ON THE ROAD WHEN ALL OF A SUDDEN ENGINE CAUGHT ON FIRE TOOK VEHICLE TO DEALER FOR CHECKUP, BUT THE CAUSE WAS UNDETERMINED AT THIS TIME.*AK

1) SMELLED BURNING ELECTRICAL INSULATION WHILE DRIVING IN A RESIDENTIAL AREA OF IDAHO FALLS, ID. PREVIOUSLY THAT DAY, THE VEHICLE HAS BEEN DIFFICULT TO START ON ONE OCCASION. MULTIPLE VEHICLE STARTS AFTERWARDS HAD BEEN WITHOUT INCIDENT.*AK 2) PULLED OVER TO THE SIDE OF THE ROAD TO INVESTIGATE. FOUND THE ALTERNATOR OUTPUT WIRE GLOWING RED AND THE INSULATION BURNING. IMMEDIATELY STOPPED THE ENGINE, AND REMOVED THE BATTERY CABLES. ALTERNATOR WAS TOO HOT TO TOUCH (THEREFORE > 140F). 3) REPLACED THE ALTERNATOR. REMOVED SIX INCHES OF BURNED UP ALTERNATOR OUTPUT WIRE (#6 AWG) AND THE CONNECTION LUG (#6 AWG W/ 1/4" POST). RELUGGED THE OUTPUT WIRE AND INSULATED THE LUG WITH ELECTRICAL TAPE AND HEAT SHRINK TUBING. NOTED THAT THE CONNECTION LUG HAD SHORTED TO THE ALTERNATOR FRAME BY THE EVIDENCE OF MELTED ALUMINUM FROM THE ALTERNATOR ON THE LUG. THE FACTORY INSTALLED LUG WAS NOT INSULATED BETWEEN THE LUG SHAFT AND THE ALTERNATOR CASE. IT WAS PROTECTED ON ITS EXTERNAL SIDE BY A BOOT SLIDE ON BOOT. OLD PARTS AND PICTURES ARE AVAILABLE.

CAUGHT FIRE WHILE DRIVING UNDER DASH TOTAL LOSS TO VEHICLE. *AK

ON JULY 31, 2004, AT 5:00AM, I WAS AWAKEN BY POUNDING ON MY DOORS AND WINDOWS. AS I WAS COMING DOWN THE STAIRS I LOOKED OUT THE WINDOW CAUSE I SAW ALOT OF LIGHT. I OPENED THE DOOR TO FIND THE FIRE DEPARTMENT TELLING ME AND MY KIDS TO GET OUT OF THE HOUSE. HE STATED THAT MY CAR WAS ON FIRE. THIS HAD HAPPEN AFTER MY CAR HAD BEEN PARKED IN THE SAME SPOT SINCE 7:00PM THE PRIOR DAY. MY VEHICLE WAS A 1994 FORD EXPLORER XL, 4 DOOR. THANK GOD THAT SOMEONE HAD SAW IT BECAUSE WHERE MY VEHICLE WAS PARKED WAS RIGHT NEXT TO MY GAS METER ON THE HOUSE. THIS COULD OF KILLED ME AND MY CHILDREN. THE FIRE DEPARTMENT HAD TO PRY OPEN MY HOOD TO PUT THE FIRE OUT. THEY EVEN TRYED BREAKING OUT MY WINDOW TO GET TO IT. BY THEN THE WHOLE ENGINE COMPARTMENT WAS DESTROYED THE DASH BOARD, GLOVE BOX AND EVERYTHING IN THE FRONT END WAS DESTROYED. I ONLY HAD NO-FAULT INSURANCE SO THEY TOLD ME THERE WAS NOTHING TO BE DONE. I DIDN'T RECEIVE ANYTHING TO HELP ME FIX OR REPLACE IT. I HAD TO CALL A TOW TRUCK TO TAKE IT AWAY. I DIDN'T RECEIVE ANYTHING FROM THEM EITHER. I DID TAKE PICTURES OF THE VEHICLE AFTER THIS HAPPENED.

1994 FORD EXPLORER CAUGHT ON FIRE, JUST AFTER WIFE AND BABY GOT OUT OF VEHICLE. IT BURNED THE DRIVER SIDE DOOR, AND PART OF THE DASH. NHTSA CAMPAIGN #97V083000, I THINK IS RELEVANT, AND RESPONSIBLE FOR THIS ACCIDENT. I NOTIFED FORD OVER 3 WEEKS AGO, AND THEY KEEP TELLING ME CONSUMER AFFAIRS WILL CALL, BUT THEY NEVER HAVE YET. *LA

ON FOUR SEPARATE OCCASIONS, MY EXPLORER HAS STALLED AFTER DRIVING IT FOR AWHILE, IT WOULD RESTART AFTER ABOUT AN HOUR. THE ENGINE WOULD TURN OVER BUT NOT FIRE.S THERE A RECALL? THE CASE IS HOWARD VS. FORD 763785-2. *AK

TRUCK HAS BEEN DYING FOR THE LAST SEVERAL YEARS. EITHER WHEN IT GET TO HOT OUT SIDE OR IT JUST NEEDS TO TAKE A LITTLE BREAK. THEN WANT START UNTIL IT FEELS LIKE IT SHOULD. WHETHER ITS RUNNING OR WHEN I START IT UP. CHECKED THE FUEL PUMP, CHANGED THE SPARK PLUGS,WIRES, BATTERY CABLES, EVERYTHING BUT, IGNITION MODULE. WHICH I'M DOING TOMORROW. *NLM

WHILE VEHICLE WAS PARKED THE MIRROR SWITCH CAUGHT FIRE. *TT

ON 14 APRIL 2003 I PAID FOR SERVICE ON AN "INTERMITTENT START" PROBLEM; CHECKED THE BATTERY CHARGING SYSTEM, THE ALTERNATOR, AND TESTED THE BATTERY.PAID FOR LABOR $76.50 AND $79.95 FOR BATTERY ASSY. HERE IT IS 2004 AND THE PROBLEM WAS NOT FIXED BUT HAS GOTTEN WORSE. PURCHASED TWO NEW ALARM/ENTRY DEVICES (FOBS) ON 29 JUN 04 BECAUSE WE WERE TOLD BY ONE OF THE MECHANICS THAT THE NEW DEVICES SHOULD SOLVE THE PROBLEM. THIS BILL CAME TO $211.10. ALREADY PAID $70.65 ON OR ABOUT APRIL 28, 2004 FOR A DIAGNOSTIC TO FIND OUT WHAT THE PROBLEM WAS AND TOLD THE REPAIR PART NEEDED COST $210. I WAS UPSET AND ONLY PAID FOR THE DIAGNOSTIC. I'M GLAD WE DIDNT PAY FOR THAT PART, BECAUSE EACH SUCCESSIVE TIME, THE SOLUTION TO THE "PROBLEM" HAS BEEN DIFFERENT AND COST ADDITIONAL MONEY. NOTHING THE MECHANICS HAVE DONE HAS RESOLVED THE PROBLEM; ONLY MADE THINGS WORSE AND THE COST HAVE TOTALED $814.67 FOR THIS PROBLEM SO FAR. THE MECHANIC SAID THE VEHICLE NOT STARTING BACK UP AFTER IT HAS BEEN TURNED OFF IS TIED IN TO THE ALARM SYSTEM. THEY HAVE REPLACED THE ANTI THEFT CONTROL MODULE ON 26 JULY 2004, $368.82. NOW THE WIRING IS NOT PERFORMING, AS IT SHOULD!!! VEHICLE IS NOT STARTING AGAIN, THE INTERIOR LIGHTS WON'T GO OUT WHEN THE VEHICLE IS TURNED OFF AFTER IT WAS "FIXED", BRAKE LIGHTS COME ON, AND CHECK ENGINE LIGHT ALSO COMES ON; SEEMS TO HAVE A WIRING/ELECTRICAL PROBLEM NOW. MR. LEE HIGGS, RED TEAM SERVICE MANAGER, HAD THE FUSE TO THE INTERIOR LIGHTS TAKEN OUT SO THE LIGHTS WONT DRAIN THE BATTERY, AT LEAST UNTIL THEY CAN GET IT BACK IN TO BE FIXED "AGAIN". THE VEHICLE HAS BEEN IN AND OUT OF THE SERVICE DEPARTMENT AND THE PROBLEMS ARE INCREASING INSTEAD OF DECREASING. WE ARE STILL WAITING FOR AN OPENING IN THE SERVICE DEPARTMENT TO PUT THE VEHICLE BACK IN THE SHOP TO GET THIS RESOLVED AGAIN! *AK

THERE WAS NO WARNING. MY 1994 FORD EXPLORER CAUGHT ON FIRE AND WAS TOTALLY DAMAGED DUE TO A RECALL ON A MIRROR HARNESS SWITCH. FORD WAS NOTIFIED AND ADMITTED FAULT. THEY AGREED TO SEND ME A CHECK AND CLOSED THE ACCOUNT BEFORE ANYTHING WAS EVER SENT OUT TO ME. *AK

THE CONSUMER NOTICED THE DRIVER SIDE DOOR WAS ON FIRE. *TS *JB

THE VEHICLE THAT WAS PARKED AND UNOCCUPIED BEGAN SMOKING FROM THE DRIVER SIDE DOOR. THE VEHICLE HAD CAUGHT FIRE WITH POSSIBLE ELECTRICAL SHORT AND WAS A TOTAL LOSS. *YH

I HAD DRIVEN APPROXIMATELY 50 MILES ON THE FREEWAY DRIVING 65 TO70 MILES PER HOUR AND HAD GOTTEN OFF THE FREEWAY AND WAS TAKING A SIDE STREET DRIVING 50 MILES PER HOUR WHEN THE TOTAL ELECTRICAL SYSTEM WENT DEAD. THE CAR SEEMED TO BE WARM-IT WAS A HOT DAY AND I HAD BEEN USING MY AIR CONDITIONING TO THE MAXIMUM. I TRIED RESTARTING THE CAR BUT IT WOULD NOT START. AFTER 45 MINUTES THE CAR STARTED UP AGAIN. NOTE! WE HAD THIS SAME PROBLEM WITH THIS CAR ON JULY 9, 1999 AT APPROXIMATELY 96000 MILES ON THE CAR. IF THIS HAD OCCURRED WHILE I WAS DRIVING ON THE FREEWAY I COULD HAVE BEEN BADLY INJURED. I FEEL THAT THIS PROBLEM HAS TO DO WITH A FAULTY IGNITION SYSTEM WHICH HAS DESIGN PROBLEMS.*AK

WAS PROCEEDING INTO AN INTERSECTION FROM A STOP WHEN VEHICLE STALLED. NO WARNING & WAS IN THE MIDDLE OF HIGHWAY. BEEN TO DEALERSHIP & MECHANIC WHO INDICATED THAT CAUSE OF STALLING COULD NOT BE LOCATED. PRIVATE MECHANIC COULD NOT RESOLVE PROBLEM EITHER.*AK