1991 Ford Explorer
This year had at least 30% fewer complaints than this model's typical year.
This verdict reflects complaint volume compared to this model's typical year. Recalls and safety issues below apply regardless of the verdict — always check them.
COMPLAINTS PER YEAR
View as data table
| Year | Complaints |
|---|---|
| 1984 | 1 |
| 1985 | 1 |
| 1986 | 3 |
| 1987 | 3 |
| 1988 | 4 |
| 1989 | 1 |
| 1990 | 12 |
| 1991 | 616 |
| 1992 | 640 |
| 1993 | 944 |
| 1994 | 1231 |
| 1995 | 843 |
| 1996 | 1450 |
| 1997 | 1731 |
| 1998 | 1959 |
| 1999 | 1348 |
| 2000 | 952 |
| 2001 | 375 |
| 2002 | 3294 |
| 2003 | 1131 |
| 2004 | 1304 |
| 2005 | 497 |
| 2006 | 630 |
| 2007 | 208 |
| 2008 | 148 |
| 2009 | 33 |
| 2010 | 115 |
| 2011 | 1196 |
| 2012 | 824 |
| 2013 | 2229 |
| 2014 | 1674 |
| 2015 | 1771 |
| 2016 | 2443 |
| 2017 | 1677 |
| 2018 | 720 |
| 2019 | 291 |
| 2020 | 1198 |
| 2021 | 412 |
| 2022 | 257 |
| 2023 | 106 |
| 2024 | 19 |
| 2025 | 95 |
| 2026 | 29 |
| 2027 | 0 |
KNOWN PROBLEM AREAS
Percentages can add to more than 100% -- a complaint can name more than one system.
24% of complaints: service brakes — 145 distinct reports on file, most commonly citing hydraulic and air.
CRASH INJURYShow complaint excerpts
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.
NHTSA ODI report, 20211220
17% of complaints: tires — 103 distinct reports on file, most commonly citing tread/belt and sidewall.
CRASH INJURY DEATH12% of complaints: power train — 76 distinct reports on file, most commonly citing automatic transmission and manual transmission.
CRASH FIRE INJURYShow complaint excerpts
DRIVING 55MPH CAR WAS IN DRI, PROCEEDED TO SHIFT INTO OVERDRIVE, TRANSMISSION LOCKED UP IN REVERSE, VEHICLE LOST CONTROL AND AS RESULT HAD ACCIDENT. TT
NHTSA ODI report, 19950417
10% of complaints: engine and engine cooling — 61 distinct reports on file, most commonly citing gasoline and engine.
FIRE INJURY9% of complaints: electrical system — 57 distinct reports on file, most commonly citing ignition and switch.
FIREShow complaint excerpts
AIR CONDITIONER CAUGHT FIRE UNDER THE HOOD. FIRE STARTED INSIDE THE AIR CONDITIONER PROBABLY THE FAN SPEED RESISTORS. MELTED THE LEFT SIDE OF THE HOUSING WHERE THE RESISTORS AND FAN ARE HOUSED LETTING SMOKE AND FUMES IN THE CAR.
NHTSA ODI report, 20030429
CONSUMER STATED THAT THERE WAS A FIRE IN THE VEHICLE IN THE INSTRUMENT PANEL AREA. THIS HAPPENED AFTER THE CONSUMER HAD PARKED THE VEHICLE FOR THE NIGHT. CONTACTED DEALER AND THE DEALER IS NOT WILLING TO DO ANYTHING. *NLM PHOTOS ATTACHED. *TT
NHTSA ODI report, 20021002
VEHICLE FIRE CAUSED BY FAULTY WIRING. *AK
NHTSA ODI report, 19941003
SAFETY TIMELINE
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.
Campaign 90V098000 — check if this car was fixed
THROTTLE RELEASE FAILURE
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.
Campaign 91V024000 — check if this car was fixed
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.
Campaign 91V025000 — check if this car was fixed
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.
Campaign 91V026000 — check if this car was fixed
VACUUM BOOSTR VALVE FAILS
THROTTLE RELEASE FAILURE
PARK PAWL BENDING
VACUUM BOOSTR VALVE FAILS
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.
Campaign 91V189000 — check if this car was fixed
WHL SEPARATION/TORQUE LOSS
FRONT SEAT TRACK FAILURE
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 TH
Remedy: FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.
Campaign 92V113000 — check if this car was fixed
THROTTLE STICKING
ENGINE COOLING FAN CRACKS
BRAKE MASTER CYLINDER/BOOSTER SEPARATION
SEPARATION OF MASTER CYLINDER
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
Remedy: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.
Campaign 95I007000 — check if this car was fixed
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 CA
Remedy: DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.
Campaign 96V024001 — check if this car was fixed
SUNROOF SHATTERING AND SEPARATION
PARKING PAWL
HEAVY LATERAL VIBRATION
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 ENGAGE
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 W
Campaign 97V235001 — check if this car was fixed
LIFTGATE SUPPORT BRACKET FAILURE
SPARE TIRE WINCH CABLE
SPARE TIRE WINCH CABLE
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 TIR
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.
Campaign 00T005000 — check if this car was fixed
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 WILDERN
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.
Campaign 01X001000 — check if this car was fixed
BUY-SMART CHECKLIST
1991 Ford Explorer — pre-purchase inspection
- Test/inspect for service brakes issues (145 reports on file for this year).
- Test/inspect for tires issues (103 reports on file for this year).
- Test/inspect for power train issues (76 reports on file for this year).
- Verify recall 90V098000 (visibility) has been completed.
- Verify recall 91V024000 (fuel system, gasoline) has been completed.
- Verify recall 91V025000 (fuel system, gasoline) has been completed.
- Verify recall 91V026000 (structure) has been completed.
- Verify recall 91V189000 (power train) has been completed.
- Verify recall 92V113000 (seat belts) has been completed.
- Verify recall 95I007000 (structure) has been completed.
- Verify recall 96V024001 (service brakes, hydraulic) has been completed.
- Verify recall 97V235001 (structure) has been completed.
- Verify recall 00T005000 (tires) has been completed.
- Verify recall 01X001000 (tires) has been completed.
OTHER YEARS OF THIS MODEL
BEST YEARS
WORST YEARS
FAQ
Is the 1991 Ford Explorer reliable?
Based on NHTSA complaint volume compared to this model's typical year, the 1991 Ford Explorer is rated "better than typical".
What are the most common problems with the 1991 Ford Explorer?
The most-reported component is service brakes, accounting for 24% of complaints on file.
How many recalls does the 1991 Ford Explorer have?
11 recalls on file for this model year.
Data updated 2026-09-01 · Complaints are unverified owner reports filed with NHTSA, not independently verified defects. Methodology.