Car Record Book

1991 Ford Explorer recalls & problems

The 1991 Ford Explorer has 8 safety recalls and 609 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (144 complaints).

Recalls8safety recalls
Complaints609filed by owners
Crashes · fires57 · 63reported in complaints
Injuries · deaths44 · 4reported in complaints

Safety recalls

Structure › Body › Roof and pillars

NHTSA recall 97V235001 · Dec 18, 1997 · 185,000 vehicles · opened after NHTSA action (ODI)

Problem: 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.

Risk: UNEXPECTED SEPARATION OF THE SUNROOF GLASS PANEL COULD POSSIBLY DISTRACT THE DRIVER INCREASING THE RISK OF A VEHICLE CRASH OR LOSS OF VEHICLE CONTROL.

Fix: 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.

Service brakes, hydraulic › Power assist › Hydraulic

NHTSA recall 96V024001 · Feb 5, 1996 · 108,000 vehicles · opened after NHTSA action (ODI)

Problem: 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.

Risk: IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER COULD THEN SEPARATE FROM THE VACUUM BOOSTER, WHEN THE BRAKES ARE APPLIED, PREVENTING THE SERVICE BRAKES FROM ACTIVATING INCREASING THE RISK OF A VEHICLE ACCIDENT.

Fix: DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

Seat belts › Front › Buckle assembly

NHTSA recall 92V113000 · Aug 17, 1992 · 565,000 vehicles · opened after NHTSA action (ODI)

Problem: 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.

Risk: AN INSUFFICIENTLY LATCHED OR UNLATCHED SAFETY BELTINCREASES THE RISK OF INJURY TO SEAT OCCUPANTS IN THE EVENT OF A SUDDEN STOP ORACCIDENT. IF THE SAFETY BELT BUCKLE WILL NOT UNLATCH, IT WILL NOT ALLOW THEOCCUPANT TO GET OUT OF THE VEHICLE IN AN EMERGENCY SITUATION.

Fix: FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.

Power train › Automatic transmission

NHTSA recall 91V189000 · Nov 4, 1991 · 792,000 vehicles · opened after NHTSA action (ODI)

Problem: WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Risk: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VEHICLE ACCIDENT.

Fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

Structure › Body › Bumpers

NHTSA recall 91V026000 · Feb 12, 1991 · 220,000 vehicles

Problem: REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.

Risk: UNDER EXTREME CONDITIONS, BUMPER COULD SEPARATE FROM THEVEHICLE WHEN USING A BUMPER MOUNTED TRAILER HITCH BALL.

Fix: INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.

Fuel system, gasoline › Storage › Tank assembly

NHTSA recall 91V024000 · Feb 11, 1991 · 25,000 vehicles

Problem: THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.

Risk: THIS PENETRATION OF THE FUEL TANK CAUSES VAPORS TO ESCAPEAND POSSIBLY FUEL TO SPILL, WHICH COULD CATCH FIRE IN THE PRESENCE OF ANIGNITION SOURCE.

Fix: RELOCATE THE HEAT SHIELD; INSPECT AND REPLACE DAMAGED FUEL FUEL TANKS.

Fuel system, gasoline › Storage › Tank assembly

NHTSA recall 91V025000 · Feb 11, 1991 · 18,000 vehicles

Problem: 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.

Risk: THE ESCAPED VAPOR OR LEAKED FUEL COULD CAUSE A FIRE INTHE PRESENCE OF A SOURCE OF IGNITION.

Fix: FUEL TANK WILL BE REMOVED AND INSPECTED FOR WELD INTEGRITY. FUEL TANKS WITH INADEQUATE WELDS WILL BE REPLACED.

Visibility › Sun/moon roof assembly

NHTSA recall 90V098000 · May 21, 1990 · 2,500 vehicles

Problem: IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.

Risk: SUNROOF COULD DETACH FROM THE VEHICLE WHILE BEING DRIVEN,CREATING A RISK TO FOLLOWING VEHICLES OR PEOPLE IN THE VICINITY, OR TO VEHICLEOCCUPANTS IF THE GLASS SHOULD FALL INTO THE CABIN.

Fix: INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

1991 Ford Explorer 4-DR. 4x4

OverallNot Rated
Frontal crashNot Rated
Side crashNot Rated
RolloverNot Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Explorer 2WD

18mpg combined
City / highway16 / 21 mpg
FuelRegular Gasoline

4 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $3,700/year to fuel

Explorer 2WD

16mpg combined
City / highway15 / 20 mpg
FuelRegular Gasoline

4 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,200/year to fuel

Explorer 4WD

16mpg combined
City / highway14 / 19 mpg
FuelRegular Gasoline

4 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel

Explorer 4WD

16mpg combined
City / highway15 / 19 mpg
FuelRegular Gasoline

4 L · 6 cyl · Manual 5-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem areaComplaintsCrashesFiresInjuriesTypical mileage*
Service brakes, hydraulic
Antilock/traction control/electronic limited slip; Foundation components › Master cylinder
1441805—
Tires
Tread/belt; Sidewall
11317019—
Power train
Automatic transmission; Manual transmission
75623100,000 mi
Engine and engine cooling
Engine › Gasoline; Engine
66017474,096 mi
Electrical system
Ignition › Switch; Ignition
620380135,651 mi
Suspension
Front; Front › Wheel bearing
36204—
Structure
Body › Door; Frame and members
35317161,000 mi
Visibility
Sun/moon roof assembly; Defroster/defogger/hvac system
33030—
Vehicle speed control
Cruise control; Accelerator pedal
31913100,000 mi
Equipment
Mechanical › Carrier/rack; Appliance › Air conditioner
29222—
Seat belts
Front › Buckle assembly; Front › Anchorage
28404147,402 mi
Fuel system, gasoline
Storage › Tank assembly; Delivery › Hoses, lines/piping, and fittings
25043130,000 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations