1991 Ford Explorer Recalls, Complaints & Specs
8 safety recalls list the 1991 Ford Explorer, and owners have filed 609 complaints with NHTSA. Check your own VIN below.
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8 safety recalls for the 1991 Ford Explorer
Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.
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Roof and pillars (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 engagement. This was caused by improper sunroof installation of the glass panel.
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…
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Hydraulic (service brakes)
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.
Remedy: Dealers will replace the power brake vacuum booster assembly.
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Buckle assembly (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 the buckle ejector finger and the buckle tongue window. The second defect is the safety belt buckle may not latch. The third possible defect…
Remedy: Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.
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Automatic transmission (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.
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Bumpers (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.
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Tank assembly (fuel system)
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.
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Tank assembly (fuel system)
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.
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Sun/moon roof assembly (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.
609 owner complaints filed with NHTSA
Owners of the 1991 Ford Explorer have filed 609 complaints with NHTSA; 57 describe a crash and 63 describe a fire. Reports cite 44 injuries and 4 deaths. The average mileage at failure in those reports is 121,056 miles. Complaints peaked in 1995 with 124 filed that year.
Most-reported components
What owners are reporting
“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 a”
Owner complaint to NHTSA, December 20, 2021 · Service brakes
“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 inj”
Owner complaint to NHTSA, May 7, 2015 · Seat belts
Fuel economy and specs
EPA ratings for the 1991 Ford Explorer (Explorer 2WD, Explorer 4WD). Ranges cover every tested configuration.
| Combined | 16–18 mpg |
|---|---|
| City / Highway | 14–16 / 19–21 |
| Fuel | Regular |
| EPA class | Special Purpose Vehicle 2WD, Special Purpose Vehicles |
| Engine | 6 cyl, 4 L |
| Transmission | Automatic 4-spd; Manual 5-spd |
Compare Ford Explorer model years
Recall and complaint counts for every Ford Explorer model year in NHTSA's database.
Checking a specific 1991 Ford Explorer
How do I know if my 1991 Ford Explorer has an open recall?
Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 8 campaigns currently list the 1991 Ford Explorer; your car may already have been repaired under some of them.
Is the recall repair free?
Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised Ford dealer with your VIN and the NHTSA campaign number (for example 90V098000).
What is the difference between a recall and a complaint?
A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.
Other Ford models
- F-15037,961 complaints
- Escape27,430 complaints
- Fusion22,405 complaints
- Focus22,096 complaints
- Taurus18,159 complaints
- Windstar14,158 complaints
- Edge14,065 complaints
- Expedition9,359 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.