IllustrationLETTER REGARDING RECALL 03S04 SEAT RECLINER BOLT..*MR (NAR) *CB THE CONSUMER STATED THE AIR BAG LIGHT ILLUMINATED. IT WAS DISCOVERED THAT A NEW WIRING HARNESS WAS NEEDED. *JB
1991 Ford Explorer
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 1991 Ford Explorer do not stand out strongly from the model-year median of 609.
About this comparison →How this year compares
Owner complaints by model year
Compare all Explorer years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 34 of 609 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Service Brakes, Hydraulic. Review the 118 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Tires. Review the 102 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
57 crash reports61 fire reports28 injury reports
Air Bags complaints
3 reportsWHILE DRIVING 60 MPH VEHICLE HIT A POLE ON DRIVER'S SIDE AND ROLLED OVER. DRIVER'S AIR BAG DID NOT DEPOLY. DEALER / MANUFACTURER WERE NOT NOTIFIED AT THIS TIME. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
WHIL ECONSUMER WAS DRIVING ANOTHER CAR HIT HER FROM BEHIND AND PUSHED HER INTO THE CURB, AND THEN INTO A TREE. NEITHER AIRBAG DEPLOYED. *AK
Official recalls
897V235001 · Structure:body:roof And Pillars
Dec 18, 1997
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.
Consequence & remedy
Consequence: 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.
96V024001 · Service Brakes, Hydraulic:power Assist:hydraulic
Feb 5, 1996
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.
Consequence & remedy
Consequence: 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.
92V113000 · Seat Belts:front:buckle Assembly
Aug 17, 1992
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.
Consequence & remedy
Consequence: 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.
91V189000 · Power Train:automatic Transmission
Nov 4, 1991
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Consequence & remedy
Consequence: 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.
91V026000 · Structure:body:bumpers
Feb 12, 1991
REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.
Consequence & remedy
Consequence: UNDER EXTREME CONDITIONS, BUMPER COULD SEPARATE FROM THEVEHICLE WHEN USING A BUMPER MOUNTED TRAILER HITCH BALL.
Remedy: INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.
91V024000 · Fuel System, Gasoline:storage:tank Assembly
Feb 11, 1991
THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.
Consequence & remedy
Consequence: 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.
91V025000 · Fuel System, Gasoline:storage:tank Assembly
Feb 11, 1991
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.
Consequence & remedy
Consequence: 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.
90V098000 · Visibility:sun/moon Roof Assembly
May 21, 1990
IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.
Consequence & remedy
Consequence: 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.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
17EA00012 · Spare Tire Winch Cable
Opened Apr 14, 2000 · Closed Oct 20, 2000
Status: closed (inferred from source dates) · Structure
There is no summary currently available
PE99072 · Spare Tire Winch Cable
Opened Nov 30, 1999 · Closed Apr 14, 2000
Status: closed (inferred from source dates) · Structure
FROM THE BEGINNING OF THE 1991 MODEL YEAR PRODUCTION UNTIL THE MIDDLE OF THE 1994 MODEL YEAR PRODUCTION, FORD USED A GALVANIZED STEEL CABLE TO LIFT AND HOLD IN STORED POSITION, THE EXPLORER SPARE TIRE.ON MAY 19, 1994, BASED ON THE RESULTS OF FORD DURABILITY TESTING , FORD CHANGED TO A 4.00MM STAINLESS STEEL CABLE.THERE HAVE BEEN OVER 100 INCIDENTS IN WHICH THE ORIGINAL GALVANIZED STEEL CABLE FAILED ALLOWING THE SPARE TIRE TO DROP FROM ITS REAR STORAGE WELL.ONE OF THESE INCIDENTS CAUSED A FOLLOWING VEHICLE TO BE INVOLVED IN A COLLISION AND ON SIX OTHER OCCASIONS THE WHEEL MADE CONTACT WITH FOLLOWING VEHICLES, RESULTING IN PROPERTY DAMAGE.
RQ99016 · Liftgate Support Bracket Failure
Opened Jul 29, 1999 · No close date supplied
Status: open (inferred from source dates) · Structure
SUMMARY:ON AUGUST 22, 1995, FORD CONDUCTED SAFETY RECALL, 95V-164, ON 1992 AND 1993 MODEL YEAR EXPLORER DUE TO LIFTGATE FAILURES.THE REAR LIFTGATE HYDRAULIC CYLINDER BRACKET CAN BECOME UNATTACHED ALLOWING THE LIFTGATE TO SUDDENLY DROP.THE RECALL REMEDY WAS TO INSTALL REINFORCEMENTS ON THE BRACKETS.FORD ALSO INITIATED A SAFETY IMPROVEMENT CAMPAIGN IN OCTOBER 1995, FOR 1991-1995 MODEL YEAR EXPLORER VEHICLES WHICH WERE NOT INCLUDED IN THE RECALL, TO INSTALL REINFORCEMENTS ON THOSE BRACKET THAT WERE FOUND TO BE LOOSE OR DETACHED.THIS CAMPAIGN ENDED IN OCTOBER 1996. SINCE NOVEMBER 1996, ODI HAS RECEIVED 51 CONSUMER COMPLAINTS ALLEGING LIFTGATE FAILURES CAUSED BY THE BRACKET SEPARATION, OF WHICH 19 REPORTED THE LIFTGATE STRUCK THE OCCUPANT CAUSING 12 INJURIES.ONE COMPLAINT WAS ON 1992 MODEL YEAR VEHICLE, THREE COMPLAINTS WERE ON 1993 MODEL YEAR VEHICLES, AND 47 COMPLAINTS WERE ON 1994 MODEL YEAR VEHICLES. THIS RQ IS TO DETERMINE THE EXTENT OF THE PROBLEM EXPERIENCE AND THE SCOPE OF SAFETY RECALL 95V-164.FORD AND MAZDA ARE CONDUCTING A SAFETY RECALL CAMPAIGN UNDER RECALL NUMBER 99V-310.001/.002.
Additional source detail variants (2)
Structure
SUMMARY:ON AUGUST 22, 1995, FORD CONDUCTED SAFETY RECALL, 95V-164, ON 1992 AND 1993 MODEL YEAR EXPLORER DUE TO LIFTGATE FAILURES.THE REAR LIFTGATE HYDRAULIC CYLINDER BRACKET CAN BECOME UNATTACHED ALLOWING THE LIFTGATE TO SUDDENLY DROP.THE RECALL REMEDY WAS TO INSTALL REINFORCEMENTS ON THE BRACKETS.FORD ALSO INITIATED A SAFETY IMPROVEMENT CAMPAIGN IN OCTOBER 1995, FOR 1991-1995 MODEL YEAR EXPLORER VEHICLES WHICH WERE NOT INCLUDED IN THE RECALL, TO INSTALL REINFORCEMENTS ON THOSE BRACKET THAT WERE FOUND TO BE LOOSE OR DETACHED.THIS CAMPAIGN ENDED IN OCTOBER 1996. SINCE NOVEMBER 1996, ODI HAS RECEIVED 51 CONSUMER COMPLAINTS ALLEGING LIFTGATE FAILURES CAUSED BY THE BRACKET SEPARATION, OF WHICH 19 REPORTED THE LIFTGATE STRUCK THE OCCUPANT CAUSING 12 INJURIES.ONE COMPLAINT WAS ON 1992 MODEL YEAR VEHICLE, THREE COMPLAINTS WERE ON 1993 MODEL YEAR VEHICLES, AND 47 COMPLAINTS WERE ON 1994 MODEL YEAR VEHICLES. THIS RQ IS TO DETERMINE THE EXTENT OF THE PROBLEM EXPERIENCE AND THE SCOPE OF SAFETY RECALL 95V-164.FORD AND MAZDA ARE CONDUCTING A SAFETY RECALL CAMPAIGN UNDER RECALL NUMBER 99V-310.001/.002.
Structure
SUMMARY:ON AUGUST 22, 1995, FORD CONDUCTED SAFETY RECALL, 95V-164, ON 1992 AND 1993 MODEL YEAR EXPLORER DUE TO LIFTGATE FAILURES.THE REAR LIFTGATE HYDRAULIC CYLINDER BRACKET CAN BECOME UNATTACHED ALLOWING THE LIFTGATE TO SUDDENLY DROP.THE RECALL REMEDY WAS TO INSTALL REINFORCEMENTS ON THE BRACKETS.FORD ALSO INITIATED A SAFETY IMPROVEMENT CAMPAIGN IN OCTOBER 1995, FOR 1991-1995 MODEL YEAR EXPLORER VEHICLES WHICH WERE NOT INCLUDED IN THE RECALL, TO INSTALL REINFORCEMENTS ON THOSE BRACKET THAT WERE FOUND TO BE LOOSE OR DETACHED.THIS CAMPAIGN ENDED IN OCTOBER 1996. SINCE NOVEMBER 1996, ODI HAS RECEIVED 51 CONSUMER COMPLAINTS ALLEGING LIFTGATE FAILURES CAUSED BY THE BRACKET SEPARATION, OF WHICH 19 REPORTED THE LIFTGATE STRUCK THE OCCUPANT CAUSING 12 INJURIES.ONE COMPLAINT WAS ON 1992 MODEL YEAR VEHICLE, THREE COMPLAINTS WERE ON 1993 MODEL YEAR VEHICLES, AND 47 COMPLAINTS WERE ON 1994 MODEL YEAR VEHICLES. THIS RQ IS TO DETERMINE THE EXTENT OF THE PROBLEM EXPERIENCE AND THE SCOPE OF SAFETY RECALL 95V-164.FORD AND MAZDA ARE CONDUCTING A SAFETY RECALL CAMPAIGN UNDER RECALL NUMBER 99V-310.001/.002.
DP98001 · Heavy Lateral Vibration
Opened Jan 6, 1998 · Closed Feb 4, 1998
Status: closed (inferred from source dates) · Structure
NHTSA WAS PETITIONED TO COMMENCE A DEFECT INVESTIGATION OF THE SUBJECT VEHICLES ON JANUARY 6, 1998.THE PETITION ALLEGES THAT EARLY MODEL FORD EXPLORER SPORT UTILITY VEHICLES DEVELOP HEAVY LATERAL VIBRATIONS AT SPEEDS ABOVE 55 MPH AND WHEN ENCOUNTERING BUMPS AT LOW SPEEDS.THE PETITION FURTHER ALLEGES THAT THESE VIBRATIONS COULD POSSIBLY CAUSE LOSS OF VEHICLE CONTROL.THE ANALYSIS OF THE PETITION IS PRESENTED IN THE ATTACHED NOTICE WHICH IS PUBLISHED IN THE FEDERAL REGISTER.
RQ97015 · Parking Pawl
Opened Oct 29, 1997 · Closed Apr 1, 1999
Status: closed (inferred from source dates) · Power Train:automatic Transmission
WHEN THE AUTOMATIC SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARKING PAWL DOES NOT ALWAYS ENGAGE THE PARK GEAR.THIS CAN LEAD TO THE VEHICLE JUMPING OUT OF GEAR UNINTENTIONALLY AND CAUSE THE VEHICLE TO START ROLLING INADVERTENTLY
EA97011 · Sunroof Shattering And Separation
Opened May 23, 1997 · Closed Jan 20, 1998
Status: closed (inferred from source dates) · Structure
There is no summary currently available
Additional source detail variants (2)
Structure
There is no summary currently available
Structure
There is no summary currently available
EA95018 · Separation Of Master Cylinder
Opened Jun 19, 1995 · Closed Apr 2, 1996
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY.LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS.IF EVIDENCE INDICATES THE SCOPE SHOULD BE EXPANDED, ODI WILL REOPEN THE INVESTIGATION AS WARRANTED.
Additional source detail variants (2)
Service Brakes, Hydraulic
FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY.LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS.IF EVIDENCE INDICATES THE SCOPE SHOULD BE EXPANDED, ODI WILL REOPEN THE INVESTIGATION AS WARRANTED.
Service Brakes, Hydraulic
FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY.LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS.IF EVIDENCE INDICATES THE SCOPE SHOULD BE EXPANDED, ODI WILL REOPEN THE INVESTIGATION AS WARRANTED.
PE95001 · Brake Master Cylinder/booster Separation
Opened Jan 3, 1995 · Closed Jun 19, 1995
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
PE94044 · Engine Cooling Fan Cracks
Opened Jun 10, 1994 · Closed Aug 31, 1994
Status: closed (inferred from source dates) · Engine And Engine Cooling
There is no summary currently available
EA93003 · Throttle Sticking
Opened Jan 15, 1993 · Closed Jan 6, 1994
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
PE92084 · Front Seat Track Failure
Opened Oct 23, 1992 · Closed Feb 26, 1993
Status: closed (inferred from source dates) · Seats
There is no summary currently available
PE92029 · Whl Separation/torque Loss
Opened Mar 16, 1992 · Closed Aug 31, 1992
Status: closed (inferred from source dates) · Suspension
There is no summary currently available
EA91040 · Vacuum Boostr Valve Fails
Opened Oct 3, 1991 · Closed Aug 17, 1992
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
PE91127 · Park Pawl Bending
Opened Sep 16, 1991 · Closed Nov 8, 1991
Status: closed (inferred from source dates) · Power Train:automatic Transmission
There is no summary currently available
Additional source detail variants (2)
Power Train:automatic Transmission
There is no summary currently available
Power Train:automatic Transmission
There is no summary currently available
EA91034 · Throttle Release Failure
Opened Jul 17, 1991 · Closed Apr 10, 1992
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
PE91084 · Vacuum Boostr Valve Fails
Opened Jun 10, 1991 · Closed Oct 3, 1991
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
PE91058 · Throttle Release Failure
Opened Mar 6, 1991 · Closed Jul 22, 1991
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available