1991 Ford Explorer: Recalls, Problems & MPG
Here are the deets on the 1991 Ford Explorer: 8 recalls, 609 owner complaints and up to 18 mpg combined.
Recalls
8 vehicle recalls from the manufacturer, plus 3 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Visibility (wipers, glass) Vehicle recall #90V098000 · 1990 · 2,500 vehicles
What's wrong: If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
Why it matters: 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.
The fix: Install revised sunroof hinges that will adequately retain sunroof assembly.
Fuel system Vehicle recall #91V024000 · 1991 · 25,000 vehicles
What's wrong: The front heat shield May contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
Why it matters: This penetration of the fuel tank causes vapors to escapeand possibly fuel to spill, which could catch fire in the presence of anignition source.
The fix: Relocate the heat shield; inspect and replace damaged fuel fuel tanks.
Fuel system Vehicle recall #91V025000 · 1991 · 18,000 vehicles
What's wrong: 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.
Why it matters: The escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.
The fix: Fuel tank will be removed and inspected for weld integrity. Fuel tanks with inadequate welds will be replaced.
Body & structure Vehicle recall #91V026000 · 1991 · 220,000 vehicles
What's wrong: Rear bumper reinforcement May be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
Why it matters: Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
The fix: Install two brackets to reinforce the bumper.
Transmission & drivetrain Vehicle recall #91V189000 · 1991 · 792,000 vehicles
What's wrong: When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Why it matters: 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…
The fix: Repair the transmission with a new park pawl.
Seat belts Vehicle recall #92V113000 · 1992 · 565,000 vehicles
What's wrong: 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…
Why it matters: 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.
The fix: Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.
Brakes (hydraulic) Vehicle recall #96V024001 · 1996 · 108,000 vehicles
What's wrong: 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.
Why it matters: 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.
The fix: Dealers will replace the power brake vacuum booster assembly.
Body & structure Vehicle recall #97V235001 · 1997 · 185,000 vehicles
What's wrong: 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.
Why it matters: Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
The fix: 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.
3 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Body & structure Recall #95I007000 · 1996 · 1,029,380 vehicles
What's wrong: This is not a safety recall in accordance with federal regulation 573. However, it is deemed a safety improvement campaign by the agency. The campaign will reinforce the bracket attachments of the rear liftgate gas assist cylinders which could pull away from the inside of the liftgate.
Why it matters: 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 assist cylinder would not hold the liftgate in an open position. Personal injury could occur.
The fix: Ford dealers will reinforce the bracket attachments.
Tires Tire recall #00T005000 · 2000 · 14,400,000 vehicles
What's wrong: Tire description: firestone wilderness at, size p235/75r15, produced at the decatur, illinois tire plant and all firestone radial atx and radial atx II tires, size p235/75r15. Operation of these tires at low inflation pressures, high speed, and in hot weather, can contribute to separation of the tire tread.
Why it matters: If the tread separates from the tire, the driver can lose control of the vehicle, possibly resulting in a crash causing injury or death.
The fix: The replacement/reimbursement program for this campaign expired on August 29, 2001. However, customers should contact firestone customer service at 1-800-465-1904 for possible assistance.
Tires Recall #01X001000 · 2001 · 13,000,000 vehicles
What's wrong: This is not a safety recall in accordance with the safety act. However, it is deemed a safety improvement campaign by the agency. Equipment description: Ford is replacing all firestone wilderness at 15, 16, and 17 inch tires mounted on Ford trucks and suvs. Ford reports tread separation can occur due to a combination of the sensitivity of the tire design to stress, aging, and manufacturing differences between…
Why it matters: Should the tread separate at highway speeds, a vehicle crash could occur, possibly resulting in personal injury or death.
The fix: The replacement/reimbursement program for this campaign expired on March 31, 2002. However, customers can contact Ford at 1-877-917-3673 or go on-line to www.Ford.com for possible assistance.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 63 mention a fire, 44 injuries and 4 deaths were reported.
What owners describe
- Brakes (hydraulic) (118): the most common themes are brake failure / soft pedal (30), noise or vibration (10).
- Tires (102): the most common themes are tire tread / blowout (102).
- Transmission & drivetrain (69): the most common themes are hard / delayed shifting (12), noise or vibration (6).
- Engine & cooling (52): the most common themes are fire / smoke (14), leaks (8), stalls / loses power (6).
The 1991 Ford Explorer has 609 owner complaints, ranking #23 of 38 Explorer model years for complaints (about average; the typical year has 909). Complaints peaked in 1995 (118 filed that year). The typical problem showed up when the car was about 6 years old, at a median of 121,902 miles. Neighboring years: 1990 (12 complaints, 0 recalls), 1992 (633 complaints, 4 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 4.0 L 6-cyl | Manual 5-spd | Rear-Wheel Drive | 16 | 21 | 18 | Regular |
| 4.0 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 15 | 20 | 16 | Regular |
| 4.0 L 6-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | Regular |
| 4.0 L 6-cyl | Manual 5-spd | 4-Wheel or All-Wheel Drive | 15 | 19 | 16 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 1991 Ford Explorer.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
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FAQ
Does the 1991 Ford Explorer have any recalls?
Yes. NHTSA lists 8 vehicle recalls for the 1991 Ford Explorer, plus 3 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 1991 Ford Explorer problems?
Owners have filed 609 complaints with NHTSA. The most-reported areas are brakes (hydraulic) (118), tires (102), transmission & drivetrain (69).
What gas mileage does the 1991 Ford Explorer get?
EPA ratings run up to 18 mpg combined (4.0 L, Manual 5-spd), across 4 engine and transmission combos.
Where can I get a 1991 Ford Explorer repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.