Model year record

1991 Ford Explorer

8 recall campaigns on file for this model year. 764 owner complaints on file.

Recalls

Recall campaignNHTSA 97V235001

Structure: body: roof and pillars

Component
Structure: body: roof and pillars
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
185,000
Reported to NHTSA
1997-12-18
Owners notified
1998-03-02

Defect description

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.

Safety 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.

Manufacturer 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 campaignNHTSA 96V024001

Service brakes, hydraulic: power assist: hydraulic

Component
Service brakes, hydraulic: power assist: hydraulic
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
108,000
Reported to NHTSA
1996-02-05
Owners notified
1996-03-22

Defect description

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.

Safety 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.

Manufacturer remedy

DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

Recall campaignNHTSA 92V113000

Seat belts: front: buckle assembly

Component
Seat belts: front: buckle assembly
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
565,000
Reported to NHTSA
1992-08-17
Owners notified
1992-10-30

Defect description

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.

Safety 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.

Manufacturer remedy

FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.

Recall campaignNHTSA 91V189000

Power train: automatic transmission

Component
Power train: automatic transmission
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
792,000
Reported to NHTSA
1991-11-04
Owners notified
1992-03-02

Defect description

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Safety 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.

Manufacturer remedy

REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

Recall campaignNHTSA 91V026000

Structure: body: bumpers

Component
Structure: body: bumpers
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
220,000
Reported to NHTSA
1991-02-12
Owners notified
1991-03-26

Defect description

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

Safety risk

UNDER EXTREME CONDITIONS, BUMPER COULD SEPARATE FROM THEVEHICLE WHEN USING A BUMPER MOUNTED TRAILER HITCH BALL.

Manufacturer remedy

INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.

Recall campaignNHTSA 91V024000

Fuel system, gasoline: storage: tank assembly

Component
Fuel system, gasoline: storage: tank assembly
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
25,000
Reported to NHTSA
1991-02-11
Owners notified
1991-03-26

Defect description

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

Safety 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.

Manufacturer remedy

RELOCATE THE HEAT SHIELD; INSPECT AND REPLACE DAMAGED FUEL FUEL TANKS.

Recall campaignNHTSA 91V025000

Fuel system, gasoline: storage: tank assembly

Component
Fuel system, gasoline: storage: tank assembly
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
18,000
Reported to NHTSA
1991-02-11
Owners notified
1991-03-26

Defect description

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.

Safety risk

THE ESCAPED VAPOR OR LEAKED FUEL COULD CAUSE A FIRE INTHE PRESENCE OF A SOURCE OF IGNITION.

Manufacturer remedy

FUEL TANK WILL BE REMOVED AND INSPECTED FOR WELD INTEGRITY. FUEL TANKS WITH INADEQUATE WELDS WILL BE REPLACED.

Recall campaignNHTSA 90V098000

Visibility: sun/moon roof assembly

Component
Visibility: sun/moon roof assembly
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
2,500
Reported to NHTSA
1990-05-21
Owners notified
1990-05-09

Defect description

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

Safety 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.

Manufacturer remedy

INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.

Owner complaints

A complaint is one person's report to a federal agency. It is not a finding.

ComponentComplaintsMedian mileage
Tires: tread/belt54
Service brakes, hydraulic: antilock/traction control/electronic limited slip52130,000 mi
Tires522,000 mi
Engine and engine cooling: engine: gasoline25
Power train: automatic transmission22100,000 mi
Service brakes, hydraulic: foundation components: master cylinder20
Vehicle speed control20
Engine and engine cooling: engine1874,096 mi
Service brakes, hydraulic: foundation components17160,300 mi
Electrical system: ignition: switch16
Visibility: sun/moon roof assembly16
Unknown or other15
Electrical system: ignition13
Equipment: mechanical: carrier/rack13
Equipment: appliance: air conditioner12
Power train: manual transmission11
Seat belts: front: buckle assembly11113,804 mi
Suspension11
Engine and engine cooling: cooling system: fan10
Service brakes, hydraulic: foundation components: disc: rotor10
Structure: body: door10
Suspension: front10
Visibility: defroster/defogger/hvac system10
Seats9
Fuel system, gasoline: storage: tank assembly879,300 mi
Power train: axle hubs875,200 mi
Seat belts: front: anchorage8
Service brakes, hydraulic: foundation components: disc8
Service brakes, hydraulic: foundation components: disc: caliper8
Electrical system: wiring: interior/under dash7159,000 mi
Seats: front assembly: recliner7
Service brakes, hydraulic: foundation components: disc: pads7
Service brakes, hydraulic: power assist: vacuum7
Structure: frame and members7
Power train: automatic transmission: lever and linkage: column shift6
Vehicle speed control: cruise control6100,000 mi
Wheels6100,000 mi
Wheels: lugs/nuts/bolts/studs674,096 mi
Electrical system5100,000 mi
Electrical system: wiring5133,302 mi
Power train: transfer case (4-wheel drive)512,000 mi
Seat belts591,000 mi
Structure: body5
Structure: body: hatchback/liftgate: support device/strut5161,000 mi
Electrical system: wiring: front underhood4100,000 mi
Engine and engine cooling: cooling system4
Engine and engine cooling: cooling system: radiator assembly4
Latches/locks/linkages: doors: latch4
Power train: axle assembly: axle shaft4158,000 mi
Service brakes, hydraulic: foundation components: drum4
Suspension: front: wheel bearing4
Tires: sidewall4
Vehicle speed control: accelerator pedal4
Electrical system: alternator/generator/regulator3
Electrical system: starter assembly3
Fuel system, gasoline: delivery: fuel pump3
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings3130,000 mi
Latches/locks/linkages: hatchback/liftgate: lock3
Latches/locks/linkages: hood: latch3237,150 mi
Parking brake: conventional3
Power train: automatic transmission: torque converter3
Power train: clutch assembly3
Steering: hydraulic power assist: hose, piping, and connections3
Air bags: frontal2
Child seat2
Electrical system: 12V/24V/48V battery2
Electrical system: wiring: fuses and circuit breakers2
Engine and engine cooling260,000 mi
Exterior lighting: headlights2229,000 mi
Fuel system, gasoline2
Fuel system, gasoline: delivery2
Fuel system, gasoline: storage2
Latches/locks/linkages2
Power train: automatic transmission: cooling unit and lines2
Power train: automatic transmission: gear position indication (PRNDL)2
Seat belts: front2181,000 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip: ABS warning light2
Service brakes, hydraulic: antilock/traction control/electronic limited slip: control unit/module2
Service brakes, hydraulic: foundation components: differential proportional valve2
Service brakes, hydraulic: power assist: vacuum: hoses, lines/piping, and fittings2
Steering: hydraulic power assist system2
Steering: hydraulic power assist: pump2
Steering: linkages: knuckle: spindle: arm2
Structure2
Structure: body: bumpers2
Suspension: front: springs: torsion bar2
Suspension: rear: shock absorber2
Tires: temporary/emergency spare tire2
Visibility: defroster/defogger/hvac system: fan/motor2
Visibility: rearview mirrors/devices2
Air bags1
Electrical system: 12V/24V/48V battery: cables1
Electrical system: ignition: module1
Engine and engine cooling: exhaust system1
Engine and engine cooling: exhaust system: emission control1
Engine and engine cooling: exhaust system: manifold/header/muffler/tail pipe1
Equipment1
Equipment: electrical: radio/tape deck/CD etc.1
Equipment: mechanical: winch1
Equipment: other: owners/service/other manual1
Exterior lighting: brake lights1
Exterior lighting: headlights: switch1
Exterior lighting: tail lights: switch1
Exterior lighting: turn signal1
Exterior lighting: turn signal: flasher unit1
Fuel system, gasoline: carburetor system1
Fuel system, gasoline: fuel injection system1
Fuel system, gasoline: storage: auxillary tank1
Fuel system, gasoline: storage: tank assembly: filler pipe and cap1
Fuel system, gasoline: storage: tank assembly: mounting1
Fuel system, other1
Fuel/propulsion system115,000 mi
Parking brake: conventional: mechanical: linkage and cable1
Power train1
Power train: automatic transmission: park/neutral start interlock switch1
Power train: axle assembly1
Power train: axle assembly: axle shaft: seal1
Power train: clutch assembly: pedal/hand lever(motorcycle)1
Power train: driveline: differential unit1
Power train: driveline: driveshaft1
Power train: manual transmission: lubricant1
Power train: manual transmission: shift pattern indicator1
Seat belts: front: retractor1
Seat belts: rear/other1197,000 mi
Service brakes1
Service brakes, air: disc: caliper1
Service brakes, air: disc: rotor1
Service brakes, hydraulic: foundation components: drum: drum1
Service brakes, hydraulic: foundation components: hoses, lines/piping, and fittings1
Service brakes, hydraulic: pedals and linkages1
Steering: gear box (other than rack and pinion)1
Structure: body: door: hinge and attachments1
Structure: body: hatchback/liftgate1
Structure: body: hatchback/liftgate: hinge and attachments115,000 mi
Structure: body: hood1
Suspension: front: control arm1
Suspension: front: control arm: upper ball joint1
Suspension: front: hub1
Suspension: front: stabilizer bar1
Suspension: multiple axle1
Suspension: rear1
Suspension: rear: springs: leaf spring assembly1
Tires: bead1
Vehicle speed control: linkages1
Visibility: defroster/defogger/hvac system: heater core1
Visibility: power window devices and controls1
Visibility: windshield wiper/washer1
Wheels: hub1

The 1990 model has 64 times as many complaints as this one. The 1992 model has roughly the same number of complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Open investigations

An investigation is not a recall. It indicates that NHTSA is currently evaluating an alleged defect but has not reached a final determination.

RQ99016LIFTGATE SUPPORT BRACKET FAILURE

Structure

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.