NHTSA Owner Complaint Log
This page lists owner-reported complaints filed with NHTSA for the 1991 Ford Explorer. Complaints are unverified consumer reports submitted to NHTSA and do not by themselves prove a defect or defect rate.
WHILE DRIVING FRONT PAD CAME OFF, AND FELL UNDER THE TRUCK, CAUSING MAJOR DAMGE TO VEHICLE.*AK
WHILE DRIVING FRONT REAR LEFT WHEEL FELL OFF, CAUSING MAJOR DAMAGE TO VEHICLE.*AK
WHILE AT A COMPLETE STOP THE CONSUMER WAS ADJUSTING SEAT, AND WHEN THE CONSUMER ATTEMPTED TO ACCELERATE, THE SEAT BROKE. *AK *TT *JB
WHILE DRIVING AT 55 MPH CONSUMER SMELLED SMOKE. CONSUMER PULLED OVER, AND SAW TRANSMISSION FLUID ALL OVER THE GROUND, AND BOTTOM OF VEHICLE WAS ON FIRE. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK
A FIRE HAS STARTED IN ENGINE COMPARTMENT WHILE DRIVING AT HIGHAY SPEED OF 60 MPH. DEALER AND MANUFACTURER WERE NOT NOTIFIED AT THIS TIME. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
VEHICLE EXPERIENCED A FIRE IN THE ENGINE AREA/RUNNING GEAR/WHEEL AREA.*JG (FIRE INCIDENT REPORT)
WHILE CONSUMER WAS PAYING A TOLL AT THE TOLL BOOTH, VEHICLE CAUGHT ON FIRE IN THE ENGINE COMPARTMENT, THERE WAS DAMAGE TO THE TOLL BOOTH AND THE VEHICLE WAS COMPLETELY CONSUMED BY THE FIRE, OHIO TRAFFIC CRASH REPORT. *SLC
TRUCK LEAKING ANTIFREEZE AND REQUIRED REPLACEMENT OF HEAD GASKET AND MANIFOLD GASKET. *NLM
WHILE DRIVING ABOUT ANY MPH WOULD STEP ON BRAKE PEDAL TO STOP OR TO REDUCE VEHICLE SPEED, BUT VEHICLE WOULD NOT STOP ON TIME, RESULTING IN EXTENDED STOPPING DISTANCE. ALSO, ROTORS HAD BEEN REPLACED A COUPLE OF TIMES. PLEASE PROVIDE MORE INFORMATION.*AK
WHILE CONSUMER'S DAUGTHER WAS DRIVING ABOUT 25 MPH ENGINE SUDDENLY STALLED. THEN, DRIVER RESTARTED ENGINE WHEN SHE SAW FIRE COMING FROM DRIVER'S SIDE. JUMPED OUT, AND VEHICLE BURNED DOWN. FIRE DEPARTMENT COULD NOT DETERMINE WHERE FIRE HAD STARTED. PLEASE PROVIDE MORE INFORMATION. *AK
WHILE TRAVELING 55MPH ON HIGHWAY AND WITHOUT PRIOR WARNING LEFT REAR WHEEL BEARING LOCKED UP, AND REAR END LIFTED UP . DEALERSHIP WAS AWARE OF PROBLEM.*AK
WHILE DRIVING 60 MPH VEHICLE HIT A POLE ON DRIVER'S SIDE AND ROLLED OVER. DRIVER'S AIR BAG DID NOT DEPOLY. DEALER / MANUFACTURER WERE NOT NOTIFIED AT THIS TIME. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
FRAME HAS BROKEN AT RADIUS ARM. *AK *JB
THE AUTOMATIC TRANSMISSION FAILED. *JB
WAS DRIVING BETWEEN 30-35MPH ON WET ROAD WENT TO APPLY THE BRAKES AND PEDAL WENT TO FLOOR. STEERED VEHICLE TO LEFT TO SLOW DOWN. VEHICLE STARTED SKIDDING. HIT A TREE STUMP AND VEHICLE FLIPPED OVER. VEHICLE WAS TOTALED. OUT OF VEHICLE, AND NOTICED PADS HAD FALLEN OFF INTO ROTORS. PADS HAD GOUGES. DISC PADS WERE MISSING.*AK
CONSUMER WAS TRAVELING ABOUT 35MPH ON A SIDE STREET AND HEARD A JINGLE NOISE. HE PULLED OVER TO SHOULDER, AND LOOKED ALL OVER THE VEHICLE. WHEN HE APPLIED BRAKES PEDAL WENT ALL THE WAY TO THE FLOOR, AND VEHICLE SWERVED/ HIT A TREE STUMP, AND ROLLED OVER. VEHICLE WAS TOTALED. MANUFACTURER WAS NOTIFIED. *AK
I HAVE QUESTIONS TO WHY THERE ARE THESE FAILURES IN THESE 4 IMPORTANT AREAS OF MY VEHICLE, AND WOULD LIKE SOME ANSWERS! THANK YOU, I. E. STOWELL. NO SAFETY DEFEC TLISTED. *AK (DOT NUMBER: LT1018-D5 TIRESIZE: P235/75R15)
REAR BRAKES FAILED WITHOUT ANY WARNING OR INDICATION LATER CAUSING FRONT BRAKES TO FAIL. *AK
WHILE WAITING AT A STOP LIGHT AFTER DRIVING ONLY 2 MILES CONSUMER NOTICED SMOKE FROM UNDER THE HOOD, SHE PULLED OVER AND SAW FLAMES FROM UNDER THE HOOD ON LEFT SIDE. FIRE DEPARTMENT PUT OUT FIRE. VEHICLE WAS TOTALLED. ALSO DASH BURNED. *AK THE INSURANCE COMPANY STATED THAT THE WIRING HARNESS MADE CONTACT WITH THE ENGINE BLOCK MAKING A SPARK IGNITE. *YD
WHILE DRIVING SPARE TIRE CARRIER, LOCATED UNDERNEATH VEHICLE, SEPARATED DUE TO CORROSION. DEALER HAS BEEN NOTIFIED.*AK THE TIRE IS HELD BY A SINGLE METAL ROPE WITH NO PROVISION FOR BACK UP IN CASE OF FAILURE. *NLM
DRIVER'S SIDE AND PASSENGER SIDE DOORS ARE COMING OFF THE HINGES. DEALER HAS BEEN CONTATCED. PLEASE PROVIDE FURTHER DETAILS.*AK
WHILE DRIVING ABOUT 10 MPH THERE WAS SMOKE COMING FROM UNDERNEATH THE STEERING COLUMN NEAR PEDALS. CONSUMER PULLED OVER, AND CALLED FIRE DEPARTMENT. BATTERY WAS DISCONNECTED AND FIRE PUT OUT. DEALER REPLACED IGNITION SWITCH AND WIRING.*AK
RECALL 90 V 098 000/SUN ROOF HINGES: SUN ROOF WAS DETACHING FROM VEHICLE. DEALER NOTIFIED, AND INFORMED CONSUMER THAT THIS VEHICLE WAS NOT COVERED UNDER RECALL DUE TO VIN. FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER.
WAS DRIVING HOME FROM WORK AROUND 5:30 PM AT ABOUT 65 MPH. SLOWED TO ABOU 50 MPH TO ENTER IH-10. TIRE TREAD SEPARATED FROM TIRE. I STILL HAVE THE TIRE BUT WILL NEED TO REPLACE IT IN THE NEAR FUTURE. THIS IS THE SECOND INCIDENT. THE FIRST FIRESTONE TREAD SEPARATION OCCURRED WHILE MY WIFE WAS DRIVING THE EXPLORER ON HER WAY TO CLEVELAND, TX ABOUT 2 YEARS AGO. *AK (DOT NUMBER: W2UU1MX043 TIRESIZE: P225/70R15)
WHILE DRIVING 55 MPH WHEEL ON THE RIGHT REAR CAME OFF. ONLY WARNING WAS THAT VEHICLE STARTED TO VIBRATE. CONTACTED DEALER, AND DEALER SAID THIS THIS WAS NOT A DEFECT. *AK
AIR CONDITION (A/C) WORKS OFF AND ON. IT WILL RUN FOR A WHILE THEN IT STARTS BLOWING HOT AIR, PUSH THE A/C BUTTON AND GO TO VENT AND 5-10 MIN. LATER YOU CAN TURN A/C BACK ON AGAIN FOR AWHILE UNTIL YOU HAVE TO DO IT AGAIN. THIS WAS HAPPENING BEFORE I HAD IT SWITCHED OVER FROM FREON AND IT IS STILL DOING IT. IT HAS BEEN TO 2 DIFFERENT SHOPS AND BOTH SAY THE "FREON" LEVEL IS FINE AND THAT THEY CANT FIND A PROBLEM WITH IT. *LA
WHILE DRIVING APPROXIMATELY 65 MPH FRONT RIGHT TIRE BROKE OFF TRUCK AND BOUNCED AWAY. VEHICLE THAN FELL ON RIGHT SIDE AND DRAGGED UNTIL VECHICLE STOPPED. ENTIRE FRAME WAS DESTROYED.
WHILE TRAVELING AT APPROXIMATELY 60 MPH FACTORY INSTALLED LUGGAGE RACK ON TOP OF VEHICLE BROKE, AND PIECES OF RACK FLEW OFF WITH 6 FOOT LADDER THAT WAS ON RACK. THERE WAS NO CRASH OR DAMAGE RESULTING FROM THIS TO OTHER VEHICLES. *AK *SLC
FIRESTONE ATX P235/75R15 TIRES WITH UNKNOWN DOT NUMBER ARE ON RECALL ACCORDING TO DEALERSHIP. HOWEVER, FIRESTONE INFORMED CONSUMER THAT THEY WOULD ONLY REPLACE TIRES PURCHASED AFTER JANUARY 1ST 2000 WITH PROOF OF PURCHASE. *AK *JB
COMPLETE BRAKE FAILURE OCCURRED WHEN BACKING OUT OF PARKING SLOT. WAS ABLE TO STOP VEHICLE WITH THE PARKING BRAKE. FAILURE OF BRAKE PIPE, DUE TO CORROSION, JUST FORWARD OF REAR AXLE. THE TWO PIPES FROM THE JUNCTION BLOCK AT THE DIFFERENTIAL ALSO BADLY CORRODED BUT NOT LEAKING. CHANGED THESE ALSO AS A PRECAUTION. TOTAL LOSS OF BRAKING POWER WAS UNEXPECTED SINCE I BELIEVED THAT THERE WAS A DIAGONAL BRAKE SYSTEN OR OTHER BACKUP. IN ATTEMPTING TO PUMP THE BRAKE ONCE I STOPED ALL I SUCCESSED IN DOING WAS PUMPING BRAKE FLUID ON THE GROUND. THIS HAD THE PONTENTIAL FOR A SERIOUS ACCIDENT SINCE I WOULD HAVE BEEN HAULING A TRAILER IN A FEW DATS ON A LONG TRIP.*AK
CRACKS DEVELOPING IN CROSSMEMBER FRAME AROUND RADIUS ARM BUSHINGS ON BOTH SIDES. BUSHINGS HAVE BEEN REPLACED BEFORE SO THE EXCUSE OF WORN BUSHINGS IS BULL.*AK
TRANSMISSION WAS NOISY AND CAUSING A VIBRATION DURING OPERATION OF VEHICLE. A PRIVATE MECHANIC EXAMINED VEHICLE AND DETERMINED THAT LOWER END SHAFT BEARINGS WENT, AND HAS REPLACED TRANSMISSION FOR A TEMPORARY FIX. PLEASE PROVIDE ANY ADDITIONAL INFORMATION/ATTACHMENTS. *AK
INTERMITTENTLY VEHICLE STALLS OUT AND DIES. MECHANIC HAS REPLACED CFI MODULE TWICE, AND THE PROBLEM HAS REOCCURRED. PLEASE PROVIDE ADDITIONAL INFORMATION.*AK
STEEL BELTED RADIAL LT, P235/75R15, DOT BFHKBL1408, 1994 REPLACEMENT TIRES WITH APPROXIMATELY 20000 MILES; ALL 4 TIRES SHOWED PATCHY/UNEVEN WEAR. *AK *SLC
HAVE HAD 3 CERTIFIED MECHANICS LOOK AT THIS VECHICAL ALL WITH THE SAME CONCLUSION THE RADIAL ARM BUSHINGS HAVE PREMATURLY FAILED DUE TO A DEFFECT WHEN CAR WAS BUILT.*AK
PASSENGER'S SIDE SEATBELT IN NOT OPERABLE. SEATBELT ITSELF, WHOLE COMPONENT IS DEFECTED. RETRACTOR IS OKAY. ALSO, WHEN FILLING UP FUEL TANK GAS NOZZLE CAN SMELL GASOLINE. DEALERSHIP WAS AWARE OF PROBLEMS. *SLC
IN 2001 THE RIGHT SIDE BRACKET ATTACHMENT OF THE REAR LIFTGATE GAS ASSIST CYLINDER CAME OFF FROM THE INSIDE OF THE LIFTGATE OF MY 1991 FORD EXPLORER. THE REMAINING ASSIST CYLINDER DOES NOT HOLD THE LIFTGATE IN AN OPEN POSITION. AS I UNDERSTAND FROM NHTSA CAMPAIGN ID NO 95I007000 OVER A MILLION VEHICLES HAD THE BRACKETS REINFORCED, BUT MY EXPLORER WASN'T INCLUDED ALTHOUGH IN MY OPINION IT CLEARLY SHOULD HAVE BEEN. I HAVEN'T PRICED THE REPAIRS.*AK
WHILE COMING AROUND A CURVE ON A WET ROAD AND APPLYING BRAKES TO SLOW DOWN, REAR WHEELS LOCKED UP, CAUSING VEHICLE TO ROLLOVER. NO INJURIES REPORTED. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK
CABLE THAT HOLDS SPARE TIRE UNDER REAR OF VEHICLE BROKE, CAUSING SPARE TIRE TO FALL. CONSUMER WAS NOT AWARE OF THIS UNTIL VEHICLE WAS TAKEN IN TO HAVE SPARE TIRE REPLACED.*AK UPON INSPECTION, THE CABLE WAS FOUND RUSTED THROUGH AND THE TIRE SUPPORT MECHANISM WAS MISSING. *SLC
WHEN ATTEMPTING TO LATCH SEATBELTS IN THE FRONT OF VEHICLE LATCH IS NOT SECURING SEATBELT. SOMETIMES IT SEEMS TO BE LATCHED AND WHILE DRIVING DOWN THE ROAD THE SEATBELT BUCKLE PULLS OUT OF THE LATCH.*AK
TIRE SEPARATION OCCURED ON INTERSTATE 66, VA. I DID NOT LOSE CONTROL OF THE VEHICLE, BECAUSE I WAS DRIVING WITHIN THE SPEED LIMIT. HOWEVER, THE NOISE FROM TIRE SEPARATION CAUSED SOME EMOTIONAL STRESS. THESE TIRES ARE IDENTICAL TO "ORIGINAL EQUIPMENT" WHEN I PURCHASED THE VEHICLE. I WOULD LIKE TO KNOW IF THERE HAVE BEEN ANY REPORTED INCIDENTS WITH THESE TIRES, OR POSSIBLE RECALL. *AK (DOT NUMBER: W2UUIMX034 TIRESIZE: P225/70R15)
FAN THAT COOLS ENGINE IS MADE OF NYLON, IF IT FAILS IT COULD COME THROUGH FAN BLADES AND THROUGH RADIATOR. CONSUMER FEELS ITS A MANUFACTURER'S DEFECT.*AK FAILURE OF NYLON FAN COULD CAUSE SEVERE DAMAGE TO RADIATOR, HOSES AND THE HOOD. *YH
THE FAULTY ALUMINIUM HEADS CRACKED CAUSING THE VEHICLE TO OVERHEAT RESULTING IN THE NUMBER ONE PISTON MELTING AND DAMAGE TO THE CYLINDERS. *YH
ALL FIVE FIRESTONE RECALLED TIRES WERE REPLACED WITH UNIROYAL TIGER PAW TIRES, 3 TIRES WITHIN 3 MONTHS EXPERIENCED BEAD SEPARATION, FIRST TIRE BLEW OUT WHILE CONSUMER WAS SITTING IN DRIVEWAY, SECOND TIRE FORMED A BUBBLE NEAR THE BEAD, AND THE THIRD TIRE WENT FLAT BECAUSE THE BEAD SEPARATED FROM THE TIRE, CONSUMER IS CONCERNED THE OTHER 2 TIRES THAT HAVEN'T FAILED, WILL AND CAUSE AN ACCIDENT. *SLC
I HAD THE ATX RADIAL TIRES AND THEY WERE REPLACE WITH THE FIREHAWKS BY FIRESTONE. ON 10/18/2000,THE FIREHAWKS SEAL AROUND THE OUTSIDE RIM DETACHED ITSELF FROM THE OUTSIDE RIM AND I LOST CONTROL OF MY FORD EPLORER. SENDING ME CRASHING INTO THE REAR END OF A CAR AND THEN INTO A CONCERET RAIL. ON INTERSTATE 94 EASTBOUND DOWNTOWN CHICAGO. BEAR IN MIND THESE ARE THE REPLACMENTS FOR THE RECALL FIRESTONE TIRES ATX. I HAD THE TIRE REPLACED ON 9/15/2000. NOT EVEN A GOOD MONTH,JUST A FEW DAYS OVER A MONTH. NOW MY EXPLORER IS BASICLY TOTAL AND I DON'T KNOW WHAT TO DO,AS FAR AS REPLACEMENT AND ALL MY DOCTOR BILL. I REALIZE, ITS ONLY BEEN A WEEK,BUT I'VE BEEN UNABLE TO RETURN BACK TO MY JOB.COULD YOU DIRECT ME IN THE RIGHT DIRECTION OR GIVE ME THE CONTACT PEOPLE WHO WILL HELP ME. THANK YOU. (TIRESIZE: P23575R15)( DOT NUMBER: TIRE SIZE: P23575R15 )
NO SUMMARY
RIGHT FRONT TIRE EXPERIENCED A BLOWOUT WHILE TRAVELING AT 40 MPH, VEHICLE LOST CONTROL AND STRUCK A TREE. A 1991, FORD, EXPLORER; AFTERMARKET EQUIPMENT INSTALLED AT 98,000 MILES, P235/75R15, DOT# HYBNDFA219. FIRESTON WAS NOT NOTIFIED AT THIS TIME. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS. *AK DOT # H4BNDFA219. *SLC
LEFT REAR TIRE HAS BLOWN OUT. IT IS A FIRESTONE WILDERNESS HT. THE SIZE IS P235/75R15. INSURED CLAIMED THAT THE TIRE BLEW OUT WHICH IS WHAT CAUSED ACCIDENT. IT APPEARS THAT THIS TIRE HAD BEEN RUN LOW FOR QUITE SOME TIME. IT LOOKED LIKE THE SIDES OF THE TIRE HAD GOTTEN HOT. IT MAY PAY TO TAKE THIS TIRE OFF OF THE RIM AND CHECK AND SEE IF THERE IS A NAIL OR SOMETHING IN IT THAT WOULD HAVE CAUSED THIS TIRE TO HAVE GONE FLAT. THERE IS A SPOT ON THE BACK SIDE. THERE LOOKS LIKE THERE IS A HOLE IN THE BACK SIDE OF THE TIRE. THE FRONT SIDE OF THE TIRE LOOKS LIKE THE TIRE HAS BEEN RUN LOW FOR A LONG TIME. (CLAIM# 25-5432-593) *MW
A PART WITHIN THE SEAT BELT ASSEMBLY HAS MALFUNCTIONED, CAUSING SEAT BELTS TO BECOME INOPERABLE. *AK DRIVER'S SEAT BELT BUCKLE WOULD NOT LATCH. *YH
SPARE TIRE DROPPED OFF VEHICLE UNEXPECTEDLY, CABLE BROKE. UNAWARE OF EXACTLY WHEN AND WHERE IT HAPPENED. AM NOT AWARE OF ANY INCIDENT CAUSED BY THE LOSS OF THE SPARE TIRE. MY EXPLORER HAS NOT BEEN EXPOSED TO SALT/RUST AS MUCH AS OTHERS I HAVE SEEN IN OUR AREA. POTENTIALLY, THERE MAY BE A LOT OF UNDERBODY MOUNTED SPARE TIRES POISED TO DROP OFF UNEXPECTEDLY. I LOST MY SPARE WHEEL/TIRE CAUSE I DID NOT KNOW IT DROPPED OFF.
Data synced from NHTSA on May 4, 2026