yo!
We have a 96, bought it new in May 96 and basically, we "over-maintain" it...meaning 3k mile oil/filter changes & ***** all filters changed, etc.. using Ford's severe duty schedule.
One of the most reliable daily drivers and beach run/light off road vehicles we've have ever had (incl the ex 78).
Still, we had minor problems that we addressed quickly.
Besides the usual visual, driveability and leak checks, look for:
- oil pan rust - our's formed spots @ 62k miles - sand it down and prime/paint it w/Rust Bullet® Automotive) & high temp. paint - too time-consuming replacement for such a basic thing as not having better gauge and undercoat/paint by Ford
- radiator plastic side seam leaks, esp. during engine cool-down period/overnight - our's leaked @ 50k miles & again just recently - look for leaks after engine has cooled down, esp overnight
- auto tranny - E4OD had a lot of improvements made by 96 so look for good shifts and see the maintenance records; fluids/filter should have been changed every 15k miles and less if used for towing ("...For 1995, Ford Motor Company has reduced the mileage interval of automatic transmission fluid changes to 30,000 miles. This applies to all transmissions except the E40D transmission used in Ford trucks. The E40D change interval is 15,000 miles. Ford engineers stated that the intervals were reduced due to fluid degradation especially in humid climates. As you all know, the above-mentioned service intervals are for "normal driving" conditions, severe duty conditions (fleet, city driving, short trips, dusty conditions, hilly areas, towing, snowplowing) require more frequent service. Always change the transmission filter when you change the fluid...")
- rust in inner rear fender lips, bottom of B pillars and bottom of tailgate (fender lips are rusting due to Ford's flawed spot weld process on the inner (tub) and 1/4 panel that lets moisture & debris in the seam) ...
check tg drains for clogs/rust..check weather seals, esp the outer ws on glass
- radius arm bushing deterioration (I coated em w/pure silicone, from day 1) but replaced at 80k miles w/Daystar polyurethane bushings
- ball joints.. costly if not DIY
- Programmable Speedometer Odometer Module (PSOM), make sure it works; look for a waver in the needle at highway speeds; most get yard units for DIY
- look for some maint records or contact a dealer to see what maint was done to it a Ford dealership in the past (need VIN)
or on-line dealer service record summaries (Ford is adding entries now), etc. at Ford myford.fordvehicles.com (need VIN) & must register if you haven't already for your other Fords.
Car Fax is ok, but they did NOT list over $5k in single accident damages on 3 of our past vehicles; & our ex-92 Van had less mileage listed than when we sold it according to a CarFax report 2 years later... they did nothing after we contacted them.
- cracked exhaust manifold/Y, etc.
- roof/gutter area cracks (mostly appl. to earlier years)
- emissions air check valve & cat. converter (AIR) tubes tend to rust early; as does the AIR tube; buy locally or from pciinc.com
- radiator core supports, lower, it rusts mainly on passenger side, PIA to replace
For a 96 get it checked for codes free at Parts Stores if you don't diy; For pre 96 do a SELF TEST by my friend here, BroncoJoe19; do the KOEO = Key On Engine Off portion first & Remember to have engine @ Normal Operating Temperature before doing the KEY ON ENGINE RUNNING (KOER) portion
- transfer case operation - electric push button motor/connector is a prob. area; usually usually a broken travel stop or the motor connector is fouled, etc.
GL!