1991 Ford Explorer

Complaint history

When NHTSA received these reports. Changes in reporting alone do not establish a change in failure rates.

Problems owners report

Listed groups have at least 3 complaints. The page includes the 20 largest groups plus any additional flagged groups; some complaints are not assigned to a group.

AI groups complaints by meaning; the groups are approximate. Share ratio compares the problem’s share of this vehicle’s complaints with its share on other vehicles over the last 24 months (shown from 3 recent complaints). A 2× ratio means twice the complaint share, not twice the failure risk. Flags mark unusual shares or recent surges after an AI review of the complaint content. “First signal” does not mean the pattern has persisted continuously.How recall estimates are calculated.

Recalls

• NHTSA recall #97V235001December 18, 1997185,000 vehicles affected

  structure: body: roof and pillars

  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.

  Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.

  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.

• NHTSA recall #96V024001February 5, 1996108,000 vehicles affected

  service brakes, hydraulic: power assist: hydraulic

  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.

  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.

  Remedy

  Dealers will replace the power brake vacuum booster assembly.

• NHTSA recall #92V113000August 17, 1992565,000 vehicles affected

  seat belts: front: buckle assembly

  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.

  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.

  Remedy

  Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.

• NHTSA recall #91V189000November 4, 1991792,000 vehicles affected

  power train: automatic transmission

  When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.

  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.

  Remedy

  Repair the transmission with a new park pawl.

• NHTSA recall #91V026000February 12, 1991220,000 vehicles affected

  structure: body: bumpers

  Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.

  Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.

  Remedy

  Install two brackets to reinforce the bumper.

• NHTSA recall #91V024000February 11, 199125,000 vehicles affected

  fuel system, gasoline: storage: tank assembly

  The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.

  This penetration of the fuel tank causes vapors to escapeand possibly fuel to spill, which could catch fire in the presence of anignition source.

  Remedy

  Relocate the heat shield; inspect and replace damaged fuel fuel tanks.

• NHTSA recall #91V025000February 11, 199118,000 vehicles affected

  fuel system, gasoline: storage: tank assembly

  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.

  The escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.

  Remedy

  Fuel tank will be removed and inspected for weld integrity. Fuel tanks with inadequate welds will be replaced.

• NHTSA recall #90V098000May 21, 19902,500 vehicles affected

  visibility: sun/moon roof assembly

  If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies Can be accidentally improperly mated.

  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.

  Remedy

  Install revised sunroof hinges that will adequately retain sunroof assembly.

Other model years

• 1991
• 1992 633
• 1993 939
• 1994 1,207
• 1995 843
• 1996 1,450
• 1997 1,731
• 1998 1,959
• 1999 1,348
• 2000 952
• 2001 375
• 2002 3,295
• 2003 1,131
• 2004 1,304
• 2005 497
• 2006 630
• 2007 208
• 2008 148
• 2009 33
• 2010 115
• 2011 1,197
• 2012 830
• 2013 2,237
• 2014 1,684
• 2015 1,813
• 2016 2,465
• 2017 1,704
• 2018 734
• 2019 300
• 2020 1,249
• 2021 451
• 2022 271
• 2023 113
• 2025 107
• 2026 42