FORD EXPLORER · model year

1991 FORD EXPLORER

764 NHTSA complaints, 70 crash reports for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 1991FORDEXPLORER carries 764 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 70 crashes, 73 fires, 60 injuries, and 4 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1991 EXPLORER is tires:tread/belt with 54 filings, followed by service brakes, hydraulic:antilock/traction control/electronic limited slip (52) and tires (52). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.

NHTSA currently has 13 investigation files overlapping the 1991 EXPLORER, and 1 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

764
Complaints
70
Crashes
73
Fires
60
Injuries
4
Deaths

Total Complaints

764 filings

Crashes Reported

70 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

Above median complaint volume — review patterns below.

Complaints by Component

ComponentCount
TIRES:TREAD/BELT54
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP52
TIRES52
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE25
POWER TRAIN:AUTOMATIC TRANSMISSION22
VEHICLE SPEED CONTROL20
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER20
ENGINE AND ENGINE COOLING:ENGINE18
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS17
VISIBILITY:SUN/MOON ROOF ASSEMBLY16
ELECTRICAL SYSTEM:IGNITION:SWITCH16
UNKNOWN OR OTHER15
EQUIPMENT:MECHANICAL:CARRIER/RACK13
ELECTRICAL SYSTEM:IGNITION13
EQUIPMENT:APPLIANCE:AIR CONDITIONER12

Recent Complaints

20211220CrashSERVICE BRAKES

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.

20150507SEAT BELTS

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.

Mileage: 91,000

20130705FireFUEL/PROPULSION SYSTEM

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. *TR

Mileage: 15,000

20111021TIRES

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? *TR

20091025TIRES

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 CH

Mileage: 2,000

20090430FireENGINE AND ENGINE COOLING

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.

20080908FireELECTRICAL SYSTEM

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.

Mileage: 100,000

20080327VEHICLE SPEED CONTROL:CRUISE CONTROL

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.

20080226VEHICLE SPEED CONTROL:CRUISE CONTROL

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. *LJ

Mileage: 100,000

20080226POWER TRAIN:AUTOMATIC TRANSMISSION

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. *LJ

Mileage: 100,000

20061127STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

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 CAMPA

Mileage: 161,000

20060925TIRES:TREAD/BELT

I HAVE JUST PURCHASED A VEHICLE NOT TOO LONG AGO THAT HAS THE WILDERNESS HT TIRES ON IT THAT LOOK VERY UNSAFE. I LOOKED THEM UP ON YOUR WEBSITE AND THEY WERE RECALLED. IS THERE ANYWAY I COULD GET A RECALL INFO SHEET TO REPLACE THE TIRES ON THE VEHICLE...THERE ARE HARDLY ANY MILES ON THE TIRES AND I HAVE NOT BEEN ABLE TO DRIVE IT BECAUSE THEY ARE SO UNSAFE. THEY ARE MODEL # P22570R15. I HAVE 2 LITTLE GIRLS THAT I WOULD LIKE TO KEEP SAFE!

20060831SEAT BELTS:FRONT:BUCKLE ASSEMBLY

DT*: THE CONTACT STATED 4 OUT OF THE 5 SAFETY BELTS IN THE VEHICLE WOULD NOT LATCH PROPERLY. IF THEY WERE SHAKEN, OR IF THERE WAS ANY FORCE APPLIED TO THEM THEY BECAME UNLATCHED. THE VEHICLE WAS NOT TAKEN IN FOR SERVICE. THE MANUFACTURER WAS NOTIFIED. THERE WAS A NHTSA RECALL # 92V113000, PERTAINING TO THE FRONT BUCKLE ASSEMBLY. THE VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO THE VIN. UPDATED 10/04/06. *JB

Mileage: 113,804

20060812UNKNOWN OR OTHER

I HAVE CONTACTED THE LOCAL DEALERSHIP IE.. HANSEL FORD AND CURTIS FORD. THE SERVICE DEPARTMENT STATED THAT SINCE MY VEHICLE (1991) FORD EXPLORER WAS OVER 10 YEARS. OLD THEY NO LONGER HAD ANY INFORMATION ON RECALLED PARTS OR RECALLED PAINT ECT. PLEASE MAIL OR E-MAIL ME A COMPLETET LIST OF ALL RECALLS 1991 FORD EXLPORER. *JB

20050719FireELECTRICAL SYSTEM

VEHICLE CAUGHT FIRE AND WAS A TOTAL LOSS

Mileage: 43,000

20050711FireELECTRICAL SYSTEM

DT: THE CONSUMER SMELL SMOKE, AND THEN SOME SMOKE STARTED COMING OUT OF THE LEFT SIDE OF THE HOOD. ALL OF THE GAUGES LOOKED OKAY AND THE CONSUMER THOUGHT IT WAS OVERHEATING. THEN THE CAR CAUGHT ON FIRE FAST WITH SMOKE ON THE LEFT AND FIRE ON THE RIGHT OF THE HOOD AND BURNED ALL THE WAY TO THE BACK OF MY CAR, AND THE TWO CARS ON EITHER SIDE. THIS HAPPENED IN A DENNY'S PARKING LOT IN FAIRBANKS ON 6/30/05. FIRE DEPARTMENT CASE NUMBER: 051947. TOWED VEHICLE TO THE MECHANIC. *NM *NM

Mileage: 138,000

20050412TIRES:TEMPORARY/EMERGENCY SPARE TIRE

SPARE TIRE WINCH CABLE ON 1991 FORD EXPLORER FAILED AT INTERSECTION FOLLOWING BUMP ON REAR FROM ANOTHER MOTORIST. NO DAMAGE TO REAR BUT CORRODED CABLE BROKE AND TIRE FELL TO GROUND.*AK

20050411SEAT BELTS

I FOUND SEVERAL RECALLS FOR MY VEHICLE. IT IS AN OLD VEHICLE, BUT I ONLY BOUGHT IT IN 2003. I KNOW SOME OF THEM EXPIRED, AND IT SAYS TO CONTACT FOD. I DID VIA WEB SITE. THEY DO NOT SHOW ANY RECALLS. BUT, YOU SHOWED ME OVER 5 RECALLS? CAN I STILL GET THEM FIXED? MY TIRES I GUESS, HAVE BEEN REPLACED BUT THEY DID NIT REPLACE THE SPARE TIRE. I STILL HAVE THE RECALLED SPARE TIRE?? WHAT DO I DO NOW? CAN I DO ANYTHING? BUT, I STILL HAVE BAD TIRES, THE 2001 TIRE RECALL DOES NOT SAY WHAT BRAND? I HAVE ATX AND APT FIRESTONE TIRES. CAMPAIN #92V113000,91V189000,00T005000 AND ANOTHER TIRE RECALL, I DID NOT GET THE #, BUT IT WAS IN 2001. THANK YOU. *AK

20050411TIRES

I FOUND SEVERAL RECALLS FOR MY VEHICLE. IT IS AN OLD VEHICLE, BUT I ONLY BOUGHT IT IN 2003. I KNOW SOME OF THEM EXPIRED, AND IT SAYS TO CONTACT FOD. I DID VIA WEB SITE. THEY DO NOT SHOW ANY RECALLS. BUT, YOU SHOWED ME OVER 5 RECALLS? CAN I STILL GET THEM FIXED? MY TIRES I GUESS, HAVE BEEN REPLACED BUT THEY DID NIT REPLACE THE SPARE TIRE. I STILL HAVE THE RECALLED SPARE TIRE?? WHAT DO I DO NOW? CAN I DO ANYTHING? BUT, I STILL HAVE BAD TIRES, THE 2001 TIRE RECALL DOES NOT SAY WHAT BRAND? I HAVE ATX AND APT FIRESTONE TIRES. CAMPAIN #92V113000,91V189000,00T005000 AND ANOTHER TIRE RECALL, I DID NOT GET THE #, BUT IT WAS IN 2001. THANK YOU. *AK

20050411POWER TRAIN:AUTOMATIC TRANSMISSION

I FOUND SEVERAL RECALLS FOR MY VEHICLE. IT IS AN OLD VEHICLE, BUT I ONLY BOUGHT IT IN 2003. I KNOW SOME OF THEM EXPIRED, AND IT SAYS TO CONTACT FOD. I DID VIA WEB SITE. THEY DO NOT SHOW ANY RECALLS. BUT, YOU SHOWED ME OVER 5 RECALLS? CAN I STILL GET THEM FIXED? MY TIRES I GUESS, HAVE BEEN REPLACED BUT THEY DID NIT REPLACE THE SPARE TIRE. I STILL HAVE THE RECALLED SPARE TIRE?? WHAT DO I DO NOW? CAN I DO ANYTHING? BUT, I STILL HAVE BAD TIRES, THE 2001 TIRE RECALL DOES NOT SAY WHAT BRAND? I HAVE ATX AND APT FIRESTONE TIRES. CAMPAIN #92V113000,91V189000,00T005000 AND ANOTHER TIRE RECALL, I DID NOT GET THE #, BUT IT WAS IN 2001. THANK YOU. *AK

Compare 1991FORDEXPLORER to Similar Vehicles

NHTSA Investigations 1 Open

View all investigations

Frequently Asked Questions

How many complaints does the 1991 FORD EXPLORER have?
The 1991 FORD EXPLORER has 764 NHTSA complaints, 70 crashes, 73 fires, 60 injuries, and 4 deaths reported.
What are the most common problems with the 1991 FORD EXPLORER?
The most-complained component for the 1991 FORD EXPLORER is TIRES:TREAD/BELT with 54 complaints. Other frequently reported areas include SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP and TIRES.
Is the 1991 FORD EXPLORER safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.