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. I only lightly pressed the brakes and it happened suddenly and unexpectedly. It was not inspected before it was towed after the accident. There were no warning lamps.
The worst 1991 Ford Explorer problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes123
- Tires102
- Transmission70
- Electrical52
- Engine52
- Suspension33
- Visibility32
- Acceleration30
- Body30
- Fuel system26
- Seat belts26
- Seats16
- Wheels13
- Locks12
- Steering10
- Lights6
- Airbags3
Specific symptoms reported on the 1991 Ford Explorer
Tire blowout 45Fire or smoke 44ABS 28Brake failure 20Seat belt 14Transmission failure 12Overheating 9Stalling 9Sudden acceleration 9Door locks 7Grinding brakes 6Fuel pump 6Adaptive cruise 5Fuel leak 5Sunroof shattered 5
Recalls 8
Structure: body: roof and pillars
- What is wrong
- 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.
- Risk
- 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.
Recall number 97V235001 · Recall details
Service brakes, hydraulic: power assist: hydraulic
- What is wrong
- 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.
- Risk
- 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.
Recall number 96V024001 · Recall details
Seat belts: front: buckle assembly
- What is wrong
- 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.
- Risk
- 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.
Recall number 92V113000 · Recall details
Power train: automatic transmission
- What is wrong
- When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
- Risk
- 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.
Recall number 91V189000 · Recall details
Structure: body: bumpers
- What is wrong
- Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
- Risk
- Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
- Remedy
- Install two brackets to reinforce the bumper.
Recall number 91V026000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
- Risk
- 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.
Recall number 91V024000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- 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.
- Risk
- 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.
Recall number 91V025000 · Recall details
Visibility: sun/moon roof assembly
- What is wrong
- If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
- Risk
- 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.
Recall number 90V098000 · Recall details
See all 8 recalls for the 1991 Ford Explorer
Defect investigations
Spare tire winch cable
There is no summary currently available
EA00012
Spare tire winch cable
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.
PE99072
Liftgate support bracket failure
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.
RQ99016
Heavy lateral vibration
The federal safety agency 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.
DP98001
Parking pawl
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
RQ97015
Sunroof shattering and separation
There is no summary currently available
EA97011
Separation of master cylinder
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.
EA95018
Brake master cylinder/booster separation
There is no summary currently available
PE95001
Engine cooling fan cracks
There is no summary currently available
PE94044
Throttle sticking
There is no summary currently available
EA93003
Front seat track failure
There is no summary currently available
PE92084
Whl separation/torque loss
There is no summary currently available
PE92029
Vacuum boostr valve fails
There is no summary currently available
EA91040
Park pawl bending
There is no summary currently available
PE91127
Throttle release failure
There is no summary currently available
EA91034
Vacuum boostr valve fails
There is no summary currently available
PE91084
Throttle release failure
There is no summary currently available
PE91058
Technical service bulletins for the 1991 Ford Explorer 63
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Various noise issues from the rear leaf springs while driving. tt
- Some vehicles equipped with an automatic transmission and a 4.0L ohv engine may exhibit a noise /...
- Some vehicles equipped with the 4.0L ohv engine may exhibit an engine noise which may be perceived by the...
- Owner notification program supplement 7 revised information - regarding replacement of wilderness at tires. tt
- Some vehicles may exhibit heater core leaks. slc
- Information regarding transmission fluid usage charts. slc
- On some vehicles, the accelerator pedal bracket may become loose or separated from the dash panel. this...
- Subject pertaining to supplemental tire inflation label. jb
- Information regarding the new transmission cooler flusher- service tip. mjs
- Some vehicles equipped with manual transmission may exhibit neutral gear rollover noise (a light metallic...
1991 Ford Explorer fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 4.0L 6‑cyl | RWD | 15-16 | 20-21 | 16-18 |
| 4.0L 6‑cyl | 4WD | 14-15 | 19 | 16 |
What 1991 Ford Explorer owners say
Most recent owner complaints, unedited.
Tl* the contact owns a 1991 ford explorer. While driving 15 MPH with another passenger, the seat belts disengaged and caused the passenger seat to overturn between the seats. The passenger was not injured. The vehicle was not taken to a dealer or independent mechanic. The vehicle was not repaired. The approximate failure mileage was 91,000.
On june 4th my daughter and I were driving east bound on 62nd and over-hill in los angeles ca. Shortly after 12:00pm. When suddenly the ford explorer was engulfed in flames. My daughter and I were ordered to exit the vehicle. I was never notified of a recall. Due to investigation on my own I have received a recall number. It is 96s35. I have attempted to resolve this matter with ford however I just received a letter from them refusing to assist me. My daughter and I could have been burned alive. I would like to know if you could assist me. The vehicle has since been destroyed. I only have in my possession the picture, and a fire report.
I purchased two michelin ltx ms2 235/75r15 tires from tire rack.com, e732381. They were delivered september 15, 2011 with an incorrectly completed omb control no. 2127-0050 tire registration card. The card listed the brand as bf goodrich and the tire identification numbers as betjmx912711. The tires I received are michelin b3dddvox2511 according to the tire sidewalls. I contacted tire rack's customer service department. They advised that there system showed that I was sent michelin b3dddvox2511 tires and that it was not their responsibility to correctly complete the tire registration card. Does this comply with dot regulations regarding tire retailer's conduct regarding tire recall registration?
Uniroyal tire side wall cracks lt 235 75r15 - no failure - just crack. All 4 of my tires had a side wall crack the entire diameter of the tire about 3 inches down on the side wall . I noticed the crack on the inside as well so it appears the tires had some issue. I had never applied tire foam cleaner(armor all tirefoam prior ) but one time this last week I did apply some and found the crack. Looking under the 1991 ford explorer 4x4 I did see the same issue on the inside of a front tire as well...I never applied any armor all type cleaner on the inside either. Uniroyal factory phone support blamed me of applying tire cleaner which ruins tires and so did the walmart tire store staff . I never applied anything as this is an older vehicle which and no pr or show appeal. Walmart replaced all 4 tires on 10-25-09 but the tire pressure was not 35 psi its was around 43 according to my gage..the tires are rated for 50psi. Walmart charged the problem to my warranty and then wanted to charge again for a new warranty. This was a tire factory problem as both side of the tires had a crack not a field road hazard issue. Kingman az has temp ranges from 110 in july to 9 degrees in winter...this may be factor.
Tl*the contact owns a 1991 ford explorer. While driving 5 MPH on a driveway incline, the engine idled excessively high and the vehicle stalled unexpectedly. The engine restarted and resumed normal operation. The contact detected smoke inside and outside of the vehicle and immediately turned off the engine. The vehicle was inspected underneath the hood and massive flames erupted from the engine compartment. The fire department was called to the scene. The vehicle was completely destroyed and has not been towed away from the scene. The contact sustained minor injuries to her hands. The insurance company was notified of the failure. The failure and current mileages were unavailable.
Tl*the contact owned a 1991 ford explorer. While driving 40 MPH, the contact noticed smoke coming from the instrument panel. The vehicle failed to restart. She managed to maneuver the vehicle to the shoulder and left to call for help. Upon returning to the vehicle, it was consumed in flames. The vehicle was destroyed and a police report was filed. The failure and current mileages were over 100,000.
Tl*the contact owns a 1991 ford explorer. After receiving the recall notice for the vehicle speed control: cruise control, the contact called the dealer. The dealer stated that they did not have the part for the repair; however, the recall stated that they were available. They did not know when the parts would arrive. There had been no failure to date. The recall number was unknown. The failure and current mileages were 81,000.
Tl*the contact owns a 1991 ford explorer. The contact experienced automatic transmission failure. He took the vehicle to a mechanic and they claimed to repair it, but actually did not. The vehicle failed and was towed to a ford dealer and they replaced the cruise control switch. The automatic transmission was not repaired. The vehicle is currently in the possession of another mechanic. The current and failure mileages were greater than 100,000. Updated 03/11/08.
Copy of letter to fmc: I own a 1991 ford explorer 4wd xlt [xxx]. I purchased this vehicle on 11/9/96, from crown dodge, ventura, california. The selling dealer assured me at the time that no recalls were outstanding on this vehicle. On november 11/22/06, as I closed the hatch on this vehicle, the bracket that attaches the right-side liftgate gas assist cylinder to the hatch tore away from the hatch. I have just learned that a safety improvement campaign (number 95i007000) was issued in october 1995 to reinforce this bracket. The campaign stated that "if a bracket and gas assist cylinder were to detach completely from the liftgate and no longer bear against the liftgate as intended, the remaining cylinder would not hold the liftgate in an open position. Personal injury could occur." the corrective action was for ford dealers to reinforce the bracket attachments. My local ford dealer service representative stated today they could not honor this safety improvement campaign. Rebecca (#6048) at the ford customer service call center told me the campaign had expired, and couldn't offer assistance. Your company's response to date is not acceptable. The bracket was attached to the hatch by only two small spot welds, as is the left-side bracket. The failure still has the potential for causing serious injury, especially if the left-side bracket were to fail. The vehicle was apparently not repaired under this safety improvement campaign. I was not notified of the campaign nor offered an opportunity to have this defect repaired. Since the safety hazard that this safety improvement campaign sought to resolve still exists on my vehicle, I request that the broken bracket be repaired and the remaining bracket reinforced at no charge to me, per the intent of the safety improvement campaign. Thank you for your assistance. [xxx] *nm updated 07/12/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)
Compare the 1991 Ford Explorer
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Other model years
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Questions about the 1991 Ford Explorer
Is the 1991 Ford Explorer reliable?
Owners have filed 608 complaints about the 1991 Ford Explorer, fewer than a typical Explorer model year.
What is the most common problem with the 1991 Ford Explorer?
Brakes, with 123 complaints. Next is tires (102).
How many recalls does the 1991 Ford Explorer have?
8 recalls, covering structure, service brakes, hydraulic and seat belts.
Was there a recall on the 1991 Ford Explorer brakes?
Yes, 1 recall: 96V024001. Check your VIN to see if your car still needs the free repair.
What year does the Ford Explorer have bad brakes?
The Ford Explorer model years with the most brakes complaints are 1994 (261 complaints), 1993 (244 complaints) and 1996 (132 complaints).
What gas mileage does the 1991 Ford Explorer get?
Official estimates for the 1991 Ford Explorer range from 16 to 18 mpg combined. The most efficient version (4.0L 6-cyl, RWD) gets 15-16 city and 20-21 highway.
VIN decoder
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