Recall Register

1991 Ford Explorer: recalls and complaints

NHTSA lists 8 recall campaigns for the 1991 Ford Explorer. The newest campaign is 97V235001. NHTSA received the report on 18 Dec 1997. The NHTSA record gives the component Structure / Body / Roof and Pillars. NHTSA has 605 complaints on file for this model year. 17 NHTSA investigations name this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 97V235001, in the NHTSA record

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.
NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.

NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on . Complaint file through . Recall file through .

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

8 campaigns, newest first. 1,915,500 units in total.

  • 97V235001Structure / Body / Roof and Pillars
  • 96V024001Service Brakes, Hydraulic / Power Assist / Hydraulic
  • 92V113000Seat Belts / Front / Buckle Assembly
  • 91V189000Power Train / Automatic Transmission
  • 91V026000Structure / Body / Bumpers
  • 91V025000Fuel System, Gasoline / Storage / Tank Assembly
  • 91V024000Fuel System, Gasoline / Storage / Tank Assembly
  • 90V098000Visibility / Sun/Moon Roof Assembly

  1. 97V235001Received . 185,000 units.

    Structure / Body / Roof and Pillars

    Defect, in the NHTSA record
    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, in the NHTSA record
    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, in the NHTSA record
    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.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  2. 96V024001Received . 108,000 units.

    Service Brakes, Hydraulic / Power Assist / Hydraulic

    Defect, in the NHTSA record
    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, in the NHTSA record
    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, in the NHTSA record
    Dealers will replace the power brake vacuum booster assembly.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  3. 92V113000Received . 565,000 units.

    Seat Belts / Front / Buckle Assembly

    Defect, in the NHTSA record
    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, in the NHTSA record
    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, in the NHTSA record
    Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  4. 91V189000Received . 792,000 units.

    Power Train / Automatic Transmission

    Defect, in the NHTSA record
    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, in the NHTSA record
    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, in the NHTSA record
    Repair the transmission with a new park pawl.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  5. 91V026000Received . 220,000 units.

    Structure / Body / Bumpers

    Defect, in the NHTSA record
    Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
    Consequence, in the NHTSA record
    Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
    Remedy, in the NHTSA record
    Install two brackets to reinforce the bumper.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  6. 91V025000Received . 18,000 units.

    Fuel System, Gasoline / Storage / Tank Assembly

    Defect, in the NHTSA record
    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, in the NHTSA record
    The escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.
    Remedy, in the NHTSA record
    Fuel tank will be removed and inspected for weld integrity. Fuel tanks with inadequate welds will be replaced.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  7. 91V024000Received . 25,000 units.

    Fuel System, Gasoline / Storage / Tank Assembly

    Defect, in the NHTSA record
    The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
    Consequence, in the NHTSA record
    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, in the NHTSA record
    Relocate the heat shield; inspect and replace damaged fuel fuel tanks.

    Report filed by FORD MOTOR COMPANY. Owner notification date in the NHTSA record: .

  8. 90V098000Received . 2,500 units.

    Visibility / Sun/Moon Roof Assembly

    Defect, in the NHTSA record
    If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
    Consequence, in the NHTSA record
    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, in the NHTSA record
    Install revised sunroof hinges that will adequately retain sunroof assembly.

    Report filed by FORD MOTOR COMPANY.

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

605 complaints, 760 component mentions.

A complaint can name more than one component. Each component that a complaint names is one component mention. The figure per 1,000 component mentions shows how many of each 1,000 mentions name the component.

  • 1991 Ford Explorer
  • All 1991 vehicles
1991 Ford Explorer: complaints by component, per 1,000 component mentions
Component1991 ExplorerAll 1991 vehiclesExplorer, all yearsMentions
Service Brakes, Hydraulic189.5185.276.9144
Tires147.428.8199.9112
Power Train98.7105.7153.575
Engine and Engine Cooling86.8101.673.366
Electrical System81.69244.362
Suspension47.428.865.236
Structure46.156.77835
Visibility43.434.35033
Vehicle Speed Control40.836.866.331
Equipment38.223.617.729

The table shows the 10 components with the most mentions, of 23.

Complaints that report a crash
56
Complaints that report a fire
62
Injuries in the complaints
44
Deaths in the complaints
4
Date of the newest complaint
25 Oct 2009

These figures are the entries of the persons who sent the complaints.

Complaint: A report about a possible safety problem that a person sends to NHTSA. This site shows the number of complaints and not their text.

Complaints about the 1991 Ford Explorer, by the year NHTSA received them. The largest year is 1995, with 124 complaints.

Investigations

NHTSA investigations that name the 1991 Ford Explorer
NumberTypeSubjectComponentOpenedClosedCampaign
EA00012Engineering analysisSPARE TIRE WINCH CABLEStructure14 Apr 200020 Oct 2000
PE99072Preliminary evaluationSPARE TIRE WINCH CABLEStructure30 Nov 199914 Apr 2000
RQ99016Recall queryLIFTGATE SUPPORT BRACKET FAILUREStructure29 Jul 1999Open99V310001
DP98001Defect petitionHEAVY LATERAL VIBRATIONStructure6 Jan 19984 Feb 1998
RQ97015Recall queryPARKING PAWLPower Train / Automatic Transmission29 Oct 19971 Apr 199991V189000
EA97011Engineering analysisSUNROOF SHATTERING AND SEPARATIONStructure23 May 199720 Jan 199897V235001
EA95018Engineering analysisSEPARATION OF MASTER CYLINDERService Brakes, Hydraulic19 Jun 19952 Apr 199696V024001
PE95001Preliminary evaluationBRAKE MASTER CYLINDER/BOOSTER SEPARATIONService Brakes, Hydraulic3 Jan 199519 Jun 1995
PE94044Preliminary evaluationENGINE COOLING FAN CRACKSEngine and Engine Cooling10 Jun 199431 Aug 1994
EA93003Engineering analysisTHROTTLE STICKINGVehicle Speed Control / Linkages15 Jan 19936 Jan 1994
PE92084Preliminary evaluationFRONT SEAT TRACK FAILURESeats23 Oct 199226 Feb 1993
PE92029Preliminary evaluationWHL SEPARATION/TORQUE LOSSSuspension16 Mar 199231 Aug 1992
EA91040Engineering analysisVACUUM BOOSTR VALVE FAILSService Brakes, Hydraulic3 Oct 199117 Aug 1992
PE91127Preliminary evaluationPARK PAWL BENDINGPower Train / Automatic Transmission16 Sep 19918 Nov 199191V189000
EA91034Engineering analysisTHROTTLE RELEASE FAILUREVehicle Speed Control / Linkages17 Jul 199110 Apr 1992
PE91084Preliminary evaluationVACUUM BOOSTR VALVE FAILSService Brakes, Hydraulic10 Jun 19913 Oct 1991
PE91058Preliminary evaluationTHROTTLE RELEASE FAILUREVehicle Speed Control / Linkages6 Mar 199122 Jul 1991

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

  1. 19770
  2. 19840
  3. 19850
  4. 19860
  5. 19870
  6. 19880
  7. 19890
  8. 19900
  9. 19918
  10. 19924
  11. 19936
  12. 19944
  13. 19955
  14. 19966
  15. 19977
  16. 19989
  17. 19999
  18. 20009
  19. 20016
  20. 20024
  21. 20032
  22. 20040
  23. 20050
  24. 20061
  25. 20071
  26. 20081
  27. 20090
  28. 20101
  29. 20116
  30. 20125
  31. 201311
  32. 20146
  33. 20158
  34. 201614
  35. 201713
  36. 20187
  37. 20196
  38. 202033
  39. 202126
  40. 202224
  41. 202315
  42. 202410
  43. 202520
  44. 202614
  45. 20271

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

Official channels

Cite this page

Recall Register. 1991 Ford Explorer: recalls and complaints. https://recallregister.com/vehicle/ford/explorer/1991/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through .

Sources

Source
NHTSA Office of Defects Investigation
Licence
US government work, public domain
Recall file through
29 Sep 2026
Complaint file through
29 Mar 2018
First complaint in the file
1 Jan 1995
Manufacturer in the recall file
FORD MOTOR COMPANY

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 1991 Ford Explorer?
1,915,500 units in 8 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the Ford Explorer have for all model years?
NHTSA lists 142 recall campaigns for the Ford Explorer, model years 1977 to 2027. 8 of them name the 1991 model year.
Which component do the complaints about the 1991 Ford Explorer name most often?
Service Brakes, Hydraulic: 144 of 760 component mentions, or 189.5 per 1,000. For all 1991 vehicles the figure is 185.2 per 1,000.
Is an NHTSA investigation of the 1991 Ford Explorer open?
1 investigation has no closing date in the NHTSA file, of 17 that name this model year.