1991 Ford Explorer: problems, recalls and reliability
11 recalls and 609 owner complaints on record; the weakest area is service brakes, hydraulic (17% of complaints).
Data updated weekly · latest recall May 2001
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 609 owner complaints filed with NHTSA for this exact model year.
“The component that malfunctioned was the abs sensor. It is not available for inspection. I was driving going around 45 in traffic and the drivers side rear brake locked up and spun me out of control and caused me to collide with another vehicle. I only lightly pressed the brakes and it happened suddenly and unexpectedly. It was not inspected before it was towed after the accident. There were no warning lamps.”Owner report · Service Brakes · Dec 2021
“Tl* the contact owns a 1991 ford explorer. While driving 15 mph with another passenger, the seat belts disengaged and caused the passenger seat to overturn between the seats. The passenger was not injured. The vehicle was not taken to a dealer or independent mechanic. The vehicle was not repaired. The approximate failure mileage was 91,000.”Owner report · Seat Belts · May 2015
“On june 4th my daughter and I were driving east bound on 62nd and over-hill in los angeles ca. Shortly after 12:00pm. When suddenly the ford explorer was engulfed in flames. My daughter and I were ordered to exit the vehicle. I was never notified of a recall. Due to investigation on my own I have received a recall number. It is 96s35. I have attempted to resolve this matter with ford however I just received a letter from them refusing to assist me. My daughter and I could have been burned alive. I would like to know if you could assist me. The vehicle has since been destroyed. I only have in my possession the picture, and a fire report. *tr”Owner report · Fuel/Propulsion System · Jun 2010
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“Tl*the contact owns a 1991 ford explorer. While driving 5 mph on a driveway incline, the engine idled excessively high and the vehicle stalled unexpectedly. The engine restarted and resumed normal operation. The contact detected smoke inside and outside of the vehicle and immediately turned off the engine. The vehicle was inspected underneath the hood and massive flames erupted from the engine compartment. The fire department was called to the scene. The vehicle was completely destroyed and has not been towed away from the scene. The contact sustained minor injuries to her hands. The insurance company was notified of the failure. The failure and current mileages were unavailable.”Owner report · Engine And Engine Cooling · Apr 2009
“Tl*the contact owned a 1991 ford explorer. While driving 40 mph, the contact noticed smoke coming from the instrument panel. The vehicle failed to restart. She managed to maneuver the vehicle to the shoulder and left to call for help. Upon returning to the vehicle, it was consumed in flames. The vehicle was destroyed and a police report was filed. The failure and current mileages were over 100,000.”Owner report · Electrical System · Sep 2008
“Tl*the contact owns a 1991 ford explorer. The contact experienced automatic transmission failure. He took the vehicle to a mechanic and they claimed to repair it, but actually did not. The vehicle failed and was towed to a ford dealer and they replaced the cruise control switch. The automatic transmission was not repaired. The vehicle is currently in the possession of another mechanic. The current and failure mileages were greater than 100,000. Updated 03/11/08. *lj”Owner report · Power Train · Aug 2007
“Tl*the contact owns a 1991 ford explorer. After receiving the recall notice for the vehicle speed control: cruise control, the contact called the dealer. The dealer stated that they did not have the part for the repair; however, the recall stated that they were available. They did not know when the parts would arrive. There had been no failure to date. The recall number was unknown. The failure and current mileages were 81,000.”Owner report · Vehicle Speed Control · Aug 2007
“I have just purchased a vehicle not too long ago that has the wilderness ht tires on it that look very unsafe. I looked them up on your website and they were recalled. Is there anyway I could get a recall info sheet to replace the tires on the vehicle...there are hardly any miles on the tires and I have not been able to drive it because they are so unsafe. They are model # p22570r15. I have 2 little girls that I would like to keep safe!”Owner report · Tires · Sep 2006
“Dt*: the contact stated 4 out of the 5 safety belts in the vehicle would not latch properly. If they were shaken, or if there was any force applied to them they became unlatched. The vehicle was not taken in for service. The manufacturer was notified. There was a NHTSA recall # 92v113000, pertaining to the front buckle assembly. The vehicle was not included in the recall due to the VIN. Updated 10/04/06. *jb”Owner report · Seat Belts · May 2006
“I have contacted the local dealership ie.. Hansel ford and curtis ford. The service department stated that since my vehicle (1991) ford explorer was over 10 years. Old they no longer had any information on recalled parts or recalled paint ect. Please mail or e-mail me a completet list of all recalls 1991 ford exlporer. *jb”Owner report · Unknown Or Other · Jan 2006
When filing, owners marked a crash in 57 of these complaints and injuries in 44 - self-reported to NHTSA, not verified accident statistics.
Recalls - 11 campaigns
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.
IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.
Remedy: INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. THE CAMPAIGN WILL REINFORCE THE BRACKET ATTACHMENTS OF THE REAR LIFTGATE GAS ASSIST CYLINDERS WHICH COULD PULL AWAY FROM THE INSIDE OF THE LIFTGATE.
Remedy: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.
THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION.
Remedy: DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.
REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.
Remedy: INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.
THE HOT PLATE WELD WHICH ATTACHES THE VAPOR VENT VALVE CARRIER TO THE TOP OF THE PLASTIC FUEL TANK MAY PARTIALLY FRACTURE, ALLOWING VAPOR OF FUEL TO ESCAPE FROM THE TOP OF THE TANK.
Remedy: FUEL TANK WILL BE REMOVED AND INSPECTED FOR WELD INTEGRITY. FUEL TANKS WITH INADEQUATE WELDS WILL BE REPLACED.
THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.
Remedy: RELOCATE THE HEAT SHIELD; INSPECT AND REPLACE DAMAGED FUEL FUEL TANKS.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH FACTORY INSTALLED SUNROOF. THE SUNROOF GLASS PANEL ASSEMBLY CAN SEPARATE WHILE THE VEHICLE IS MOVING DUE TO INCORRECT HINGE ENGAGEMENT. THIS WAS CAUSED BY IMPROPER SUNROOF INSTALLATION OF THE GLASS PANEL.
Remedy: OWNERS WILL BE PROVIDED WITH AN INSTRUCTION BOOKLET WHICH THOROUGHLY OUTLINES, WITH ILLUSTRATIONS, THE PROPER PROCEDURES FOR THE REMOVAL, STORAGE, AND REINSTALLATION OF THE SUNROOF'S GLASS PANEL. A WARNING LABEL FOR ATTACHMENT TO THE SUNROOF'S LATCH KNOB WILL ALSO BE PROVIDED TO THE OWNERS.
TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE TIRE TREAD.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE ASSISTANCE.
THE RIGID MOUNTED SAFETY BELT BUCKLES ARE DEFECTIVE IN THREE WAYS. FIRST, A FASTENED SAFETY BELT BUCKLE WILL NOT UNLATCH WHEN THE RELEASE BUTTON IS DEPRESSED. THIS RESULTS FROM INTERFERENCE BETWEEN THE BUCKLE EJECTOR FINGER AND THE BUCKLE TONGUE WINDOW. THE SECOND DEFECT IS THE SAFETY BELT BUCKLE MAY NOT LATCH. THE THIRD POSSIBLE DEFECT IS THAT THE TONGUE MAY BE RETAINED BY THE BUCKLE, BUT IT MAY NOT BE LATCHED SUFFICIENTLY TO PROVIDE OCCUPANT PROTECTION.
Remedy: FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.
Specifications
Factory options offered for the 1991 model year, decoded from the NHTSA vPIC database. Individual vehicles have one of each.
How other years compare
Check your exact Explorer by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 1991 Ford Explorer reliable?
NHTSA has 609 owner complaints and 11 recall campaigns on record for the 1991 Ford Explorer. The most complained-about area is service brakes, hydraulic (17% of complaints).
At what mileage do 1991 Ford Explorer problems usually appear?
Half of the complaints that mention mileage were filed at 121,902 miles or less.
Does the 1991 Ford Explorer have open recalls?
11 recall campaigns have been issued, the latest concerning power train:automatic transmission. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.