RecallRepo

1991 Ford Explorer Recalls

Recalls on record Updated July 2026

The 1991 Ford Explorer has 8 NHTSA recall campaigns affecting an estimated 1,915,500 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 764 complaints with NHTSA, most often about the tires. Last updated July 5, 2026.

Recall campaigns

STRUCTURE 97V235001 1997-12-18 185,000 affected
Defect

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

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.

SERVICE BRAKES, HYDRAULIC 96V024001 1996-02-05 108,000 affected
Defect

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

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.

SEAT BELTS 92V113000 1992-08-17 565,000 affected
Defect

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…

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.

POWER TRAIN 91V189000 1991-11-04 792,000 affected
Defect

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

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.

STRUCTURE 91V026000 1991-02-12 220,000 affected
Defect

REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.

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.

FUEL SYSTEM, GASOLINE 91V025000 1991-02-11 18,000 affected
Defect

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

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.

FUEL SYSTEM, GASOLINE 91V024000 1991-02-11 25,000 affected
Defect

THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.

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.

VISIBILITY 90V098000 1990-05-21 2,500 affected
Defect

IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.

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.

Complaints by component

TIRES:TREAD/BELT
54
9crashes15injuries3deaths
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
52
14crashes5injuries
TIRES
52
8crashes4injuries
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
25
14fires3injuries
POWER TRAIN:AUTOMATIC TRANSMISSION
22
2crashes1fires
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
20
1crashes
VEHICLE SPEED CONTROL
20
7crashes2injuries
ENGINE AND ENGINE COOLING:ENGINE
18
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
17
1crashes
ELECTRICAL SYSTEM:IGNITION:SWITCH
16
12fires
Total complaints764

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“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…”

SERVICE BRAKES · reported 2021-12-16

“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.…”

SEAT BELTS · reported 2015-05-07

“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 · reported 2011-09-15

“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…”

FUEL/PROPULSION SYSTEM · reported 2010-06-04

“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…”

TIRES · reported 2009-10-25

“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…”

ENGINE AND ENGINE COOLING · reported 2009-04-28

“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…”

ELECTRICAL SYSTEM · reported 2008-09-03

“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…”

VEHICLE SPEED CONTROL:CRUISE CONTROL · reported 2007-08-16

Defect investigations

Investigation DP98001 Opened 1998-01-06 · closed 1998-02-04

HEAVY LATERAL VIBRATION

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…

Investigation EA00012 Opened 2000-04-14 · closed 2000-10-20

SPARE TIRE WINCH CABLE

There is no summary currently available

Investigation EA91034 Opened 1991-07-17 · closed 1992-04-10

THROTTLE RELEASE FAILURE

There is no summary currently available

Investigation EA91040 Opened 1991-10-03 · closed 1992-08-17

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

Investigation EA93003 Opened 1993-01-15 · closed 1994-01-06

THROTTLE STICKING

There is no summary currently available

Investigation EA95018 Opened 1995-06-19 · closed 1996-04-02

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…

Investigation EA95018 Opened 1995-06-19 · closed 1996-04-02

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…

Investigation EA97011 Opened 1997-05-23 · closed 1998-01-20

SUNROOF SHATTERING AND SEPARATION

There is no summary currently available

Investigation EA97011 Opened 1997-05-23 · closed 1998-01-20

SUNROOF SHATTERING AND SEPARATION

There is no summary currently available

Investigation PE91058 Opened 1991-03-06 · closed 1991-07-22

THROTTLE RELEASE FAILURE

There is no summary currently available

Investigation PE91084 Opened 1991-06-10 · closed 1991-10-03

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

Investigation PE91127 Opened 1991-09-16 · closed 1991-11-08

PARK PAWL BENDING

There is no summary currently available

Investigation PE91127 Opened 1991-09-16 · closed 1991-11-08

PARK PAWL BENDING

There is no summary currently available

Investigation PE92029 Opened 1992-03-16 · closed 1992-08-31

WHL SEPARATION/TORQUE LOSS

There is no summary currently available

Investigation PE92084 Opened 1992-10-23 · closed 1993-02-26

FRONT SEAT TRACK FAILURE

There is no summary currently available

Investigation PE94044 Opened 1994-06-10 · closed 1994-08-31

ENGINE COOLING FAN CRACKS

There is no summary currently available

Investigation PE95001 Opened 1995-01-03 · closed 1995-06-19

BRAKE MASTER CYLINDER/BOOSTER SEPARATION

There is no summary currently available

Investigation PE99072 Opened 1999-11-30 · closed 2000-04-14

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…

Investigation RQ97015 Opened 1997-10-29 · closed 1999-04-01

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

Investigation RQ99016 Opened 1999-07-29 · open

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…

Investigation RQ99016 Opened 1999-07-29 · open

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…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Ford Explorer as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.