1991 Ford Explorer

▲ Better than typical
1991 Ford Explorer
BUILT 2026-09-02

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.

How is this computed?

COMPLAINTS PER YEAR

Complaints per year, Ford Explorer Bar chart of distinct NHTSA complaints filed per model year, 1991 highlighted. 1984: 1 complaints 1984 1985: 1 complaints 1986: 3 complaints 1987: 3 complaints 1988: 4 complaints 1989: 1 complaints 1990: 12 complaints 1990 1991: 616 complaints 1991 1992: 640 complaints 1993: 944 complaints 1994: 1231 complaints 1995: 843 complaints 1996: 1450 complaints 1996 1997: 1731 complaints 1998: 1959 complaints 1999: 1348 complaints 2000: 952 complaints 2001: 375 complaints 2002: 3294 complaints 2002 2003: 1131 complaints 2004: 1304 complaints 2005: 497 complaints 2006: 630 complaints 2007: 208 complaints 2008: 148 complaints 2008 2009: 33 complaints 2010: 115 complaints 2011: 1196 complaints 2012: 824 complaints 2013: 2229 complaints 2014: 1674 complaints 2014 2015: 1771 complaints 2016: 2443 complaints 2017: 1677 complaints 2018: 720 complaints 2019: 291 complaints 2020: 1198 complaints 2020 2021: 412 complaints 2022: 257 complaints 2023: 106 complaints 2024: 19 complaints 2025: 95 complaints 2026: 29 complaints 2026 2027: 0 complaints 2027
1991: 616 complaints
View as data table
YearComplaints
19841
19851
19863
19873
19884
19891
199012
1991616
1992640
1993944
19941231
1995843
19961450
19971731
19981959
19991348
2000952
2001375
20023294
20031131
20041304
2005497
2006630
2007208
2008148
200933
2010115
20111196
2012824
20132229
20141674
20151771
20162443
20171677
2018720
2019291
20201198
2021412
2022257
2023106
202419
202595
202629
20270

KNOWN PROBLEM AREAS

Percentages can add to more than 100% -- a complaint can name more than one system.

SERVICE BRAKES 24%

24% of complaints: service brakes — 145 distinct reports on file, most commonly citing hydraulic and air.

CRASH INJURY
Show 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

TIRES 17%

17% of complaints: tires — 103 distinct reports on file, most commonly citing tread/belt and sidewall.

CRASH INJURY DEATH
POWER TRAIN 12%

12% of complaints: power train — 76 distinct reports on file, most commonly citing automatic transmission and manual transmission.

CRASH FIRE INJURY
Show 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

ENGINE AND ENGINE COOLING 10%

10% of complaints: engine and engine cooling — 61 distinct reports on file, most commonly citing gasoline and engine.

FIRE INJURY
ELECTRICAL SYSTEM 9%

9% of complaints: electrical system — 57 distinct reports on file, most commonly citing ignition and switch.

FIRE
Show 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

R 19900509 — visibility

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

I 19910306 — PE (closed 19910722)

THROTTLE RELEASE FAILURE

R 19910326 — fuel system, gasoline

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

R 19910326 — fuel system, gasoline

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

R 19910326 — structure

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

I 19910610 — PE (closed 19911003)

VACUUM BOOSTR VALVE FAILS

I 19910717 — EA (closed 19920410)

THROTTLE RELEASE FAILURE

I 19910916 — PE (closed 19911108)

PARK PAWL BENDING

I 19911003 — EA (closed 19920817)

VACUUM BOOSTR VALVE FAILS

R 19920302 — power train

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

I 19920316 — PE (closed 19920831)

WHL SEPARATION/TORQUE LOSS

I 19921023 — PE (closed 19930226)

FRONT SEAT TRACK FAILURE

R 19921030 — seat belts

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

I 19930115 — EA (closed 19940106)

THROTTLE STICKING

I 19940610 — PE (closed 19940831)

ENGINE COOLING FAN CRACKS

I 19950103 — PE (closed 19950619)

BRAKE MASTER CYLINDER/BOOSTER SEPARATION

I 19950619 — EA (closed 19960402)

SEPARATION OF MASTER CYLINDER

R 19951025 — structure

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

R 19960322 — service brakes, 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 CA

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

Campaign 96V024001 — check if this car was fixed

I 19970523 — EA (closed 19980120)

SUNROOF SHATTERING AND SEPARATION

I 19971029 — RQ (closed 19990401)

PARKING PAWL

I 19980106 — DP (closed 19980204)

HEAVY LATERAL VIBRATION

R 19980302 — structure

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

I 19990729 — RQ (open)

LIFTGATE SUPPORT BRACKET FAILURE

I 19991130 — PE (closed 20000414)

SPARE TIRE WINCH CABLE

I 20000414 — EA (closed 20001020)

SPARE TIRE WINCH CABLE

R 20000826 — tires

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

R 20010604 — tires

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

▲ 2009 ▲ 2025 ▲ 2023

WORST YEARS

■ 2002 ■ 2016 ■ 2013

See all years ranked →

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.