Problems owners report
Complaints filed with NHTSA about the 1991 Ford Explorer, by the system named in each complaint. One complaint can name several.
- Service brakes, hydraulic118
- Tires102
- Power train69
- Engine and engine cooling52
- Electrical system52
- Suspension33
- Visibility32
- Structure31
- Vehicle speed control30
- Equipment29
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 44 injuries and 4 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 5 1991 Explorer vehicles were involved in crashes on US public roads in which someone died; 3 people died inside them, and 2 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 1991 Ford Explorer failed the safety check 0.00% of the time — 100% less often than the average 1991 passenger car (1.13%). Median odometer at inspection: 73,025 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls in Canada
9 Transport Canada recalls for the 1991 Ford Explorer.
| 2001193 16 Jul 2001 | Other Certain vehicles, from Ontario to Newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicl… |
| 1998016 28 Jan 1998 | Structure NOTE: VEHICLES EQUIPPED WITH FACTORY INSTALLED SUNROOFS WITH REMOVABLE GLASS PANELS. IF MISINSTALLED BY THE OPERATOR, THE SUNROOF'S REMOVABLE GLASS PANEL MAY S… |
| 1992120 29 Sept 1992 | Seats And Restraints SEAT BELT BUCKLES ON THESE VEHICLES MAY EXPERIENCE CONDITIONS WHEREBY THE BUCKLE MAY NOT UNLATCH WHEN THE RELEASE BUTTON IS DEPRESSED OR MAY NOT LATCH, OR IN S… |
| 1992077 30 Jun 1992 | Lights And Instruments NOTE: ALSO INCLUDES SOME MEDIUM AND HEAVY TRUCKS. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 108 - LIGHTING. DAYTIME RUNNING LIGHT MODULE MAY MALFUNCTION … |
| 1991149 6 Nov 1991 | Powertrain THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHI… |
| 1991029 25 Feb 1991 | Structure THE REAR BUMPER REINFORCEMENT MAY BE SUSCEPTIBLE TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL. THIS… |
| 1991028 25 Feb 1991 | Fuel System THE CORNER OF THE FRONT HEAT SHIELD MAY CONTACT THE UPPER FRONT CORNER OF THE PLASTIC FUEL TANK. THIS COULD DAMAGE THE TANK AND ALLOW FUEL OR FUEL VAPOUR TO… |
| 1991030 25 Feb 1991 | Fuel System THE HOT PLATE WELD WHICH ATTACHES THE VAPOUR VENT VALVE TO THE TOP OF THE PLASTIC FUEL TANK MAY PARTIALLY FRACTURE, ALLOWING VAPOUR OR FUEL TO ESCAPE FROM T… |
| 1990078 30 May 1990 | Structure ON FOUR DOOR VEHICLES SO EQUIPPED, IF THE SUNROOF GLASS IS REMOVED AND REINSTALLED BY THE VEHICLE OPERATOR, THERE IS A RISK THAT THE HINGED ASSEMBLIES ON TH… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
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.
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.
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.
THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.
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.
IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 1991 Ford Explorer: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 635982 | SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT |
| 628153 | OWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF WILDERNESS AT TIRES. *TT |
| 627752 | SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT |
| 623988 | INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC |
| 623944 | SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC |
| 618532 | SUBJECT PERTAINING TO SUPPLEMENTAL TIRE INFLATION LABEL. *JB |
| 616531 | ON SOME VEHICLES, THE ACCELERATOR PEDAL BRACKET MAY BECOME LOOSE OR SEPARATED FROM THE DASH PANEL. THIS MAY BE CAUSED BY REPEATED EXCESSIVE FORCE ON THE ACCELERATOR PEDAL, RESULTING IN CRACKING OF THE DASH PANEL SHEET METAL AT THE ACCELERATOR PEDAL BRACKET. *TT |
| 613292 | INFORMATION ON SETTING THE TIRE INFLATION PRESSURE FOR 1991 THROUGH 1999 MODEL YEAR VEHICLES IN THE PRE-DELIVERY PROCESS AND DURING MAINTENANCE INTERVALS. *TT |
| 613105 | INFORMATION REGARDING THE TIRE INFLATION PRESSURE FOR ALL MODELS DURING PREDELIVERY PROCESS AND DURING MAINTENANCE INTERVALS. *MJS |
| 612203 | INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS |
| 610793 | SOME VEHICLES EQUIPPED WITH MANUAL TRANSMISSION MAY EXHIBIT NEUTRAL GEAR ROLLOVER NOISE (A LIGHT METALLIC RATTLING SOUND FROM THE TRANSMISSION) WHICH OCCURS AT IDLE WITH TRANSMISSION IN NEUTRAL CLUTCH ENGAGED (CLUTCH PEDAL UP). *TT |
| 610704 | SOME VEHICLES MAY EXHIBIT AN AUDIBLE PINGING OR CREAKING NOISE THAT MAY BE HEARD FROM THE DRIVELINE WHEN ENGINE TORQUE IS INITIALLY APPLIED TO THE DRIVELINE. *TT |
| 6091931 | SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT |
| 6090087 | INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT |
| 6089681 | SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT |
| 6089649 | CONCERNS WITH BURNING ODOR OR SMOKE, AND / OR RUSTLING NOISE WHILE BLOWER MOTOR IS ON. *TT |
| 608921 | SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT |
| 608435 | SOME VEHICLES MAY EXHIBIT A BURNING ODOR OR SMOKE, AND / OR RUSTLING NOISE OCCURING WHEN THE BLOWER MOTOR IS RUNNING IF LEAVES OR FOREIGN MATERIAL ENTERS THE BLOWER CASE. *TT |
| 608431 | INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT |
| 607369 | CONCERNS WITH AXLE WIND-UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS. *TT |
| 606945 | INFORMATION ON MAINTAINING TIRE PRESSURE. *TT |
| 606937 | SOME VEHICLES MAY EXPERIENCE AXLE WIND UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS ON VEHICLES EQUIPPED WITH A FOUR WHEEL DRIVE HI OR LOW RANGE MODE. *TT |
| 606460 | EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP. *TT |
| 606420 | FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT |
| 605803 | CUSTOMER COMPLAINT OF ENGINE MISS UNDER LOAD WHILE GOING UP STEEP HILLS. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARE TIRE WINCH CABLE
SPARE TIRE WINCH CABLE
LIFTGATE SUPPORT BRACKET FAILURE
HEAVY LATERAL VIBRATION
PARKING PAWL
SUNROOF SHATTERING AND SEPARATION
SEPARATION OF MASTER CYLINDER
BRAKE MASTER CYLINDER/BOOSTER SEPARATION
ENGINE COOLING FAN CRACKS
THROTTLE STICKING
FRONT SEAT TRACK FAILURE
WHL SEPARATION/TORQUE LOSS
VACUUM BOOSTR VALVE FAILS
PARK PAWL BENDING
THROTTLE RELEASE FAILURE
VACUUM BOOSTR VALVE FAILS
THROTTLE RELEASE FAILURE
NHTSA Office of Defects Investigation