1991 Ford Explorer Problems, Recalls & Reliability
764 owner complaints sit in the federal file for the 1991 Ford Explorer, alongside 11 recall campaigns and 17 defect investigations. It scores 24/100 on the trouble index — a middle-of-the-pack year for this model. Brakes & stability leads the reports.
Typical
Where 1991 sits among all Explorer years
What owners report
“Consumer is having problem with the brake master cylinder, causing rear brake failure. Tt”— owner report to NHTSA, 1991 Explorer
“The right rear tire separated while driving on an unobstructed interstate highway, causing damage to the vehicle. Consumer wants to be rembursed (firestone tire size p235-75-r15,dot w2hl 1mo 270).”— owner report to NHTSA, 1991 Explorer
“While driving the transmission failed, causing the vehicle to go out of gear. The dealer is repairing the vehicle.”— owner report to NHTSA, 1991 Explorer
“Started vehicle smelt smoke turned off vehicle and vehicle caught on fire. Fire started in ignition switch. Tt”— owner report to NHTSA, 1991 Explorer
“The 3rd and 4th heads are cracked on the engine and cracked at 55,000 miles. Please edescribe. Tt”— owner report to NHTSA, 1991 Explorer
“The spare tire retaining cable broke at some unknown time, dropping the spare tire on the road.”— owner report to NHTSA, 1991 Explorer
Mileage when trouble shows up
Among the 37 reports that include an odometer reading, problems most often appear around 113,804 miles. Half of those reports fall between 79,284 and 160,300 miles — a useful range to weigh against the mileage of the exact car you're looking at.
Recalls (11)
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…
Fix: 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.
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…
Fix: 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.
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…
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…
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.
Fix: DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER 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…
Fix: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.
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…
Fix: FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.
Fix: 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.
Fix: 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.
Fix: RELOCATE THE HEAT SHIELD; INSPECT AND REPLACE DAMAGED FUEL FUEL TANKS.
IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.
Fix: INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.
Federal defect investigations
Led to recall campaign 99V310001.
Led to recall campaign 91V189000.
Led to recall campaign 97V235001.
Led to recall campaign 96V024001.
Led to recall campaign 91V189000.
Complaint history for this model year
When owners filed their reports — a long tail means problems kept surfacing for years.
Questions buyers ask
Is the 1991 Ford Explorer reliable?
The 1991 Ford Explorer drew 764 complaints in federal safety records — a middle-of-the-pack year for this model. Its trouble index is 24/100, scored against the model's worst year (2002).
What are the most common 1991 Ford Explorer problems?
The top reported problems for the 1991 Ford Explorer are brakes & stability (151 complaints), wheels & tires (126), and transmission & drivetrain (75).
At what mileage do 1991 Ford Explorer problems show up?
Owners most often report 1991 Ford Explorer problems around 113,804 miles. Half of all reports that include an odometer reading fall between 79,284 and 160,300 miles.
Does the 1991 Ford Explorer have recalls?
11 recall campaigns apply to the 1991 Ford Explorer. Recall repairs are free at any franchised dealer.
Every number on this page is a count of records in the federal complaint, recall, and investigation files published by NHTSA's Office of Defects Investigation. Check any specific vehicle's open recalls by VIN at nhtsa.gov/recalls.