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.
Data synced from NHTSA on May 4, 2026
WHILE RIDING ON THE FREEWAY IN STOP & GO TRAFFIC, OWNER STATES WHEN ABS BRAKES WERE USED DRIVER LOST CONTROL OF THE VEHICLE AND PEDAL WENT TO THE FLOOR, RESULTING IN AN ACCIDENT. *AK
FAN BLADE CRACKED.
SUDDEN ACCELERATION.
THE EMERGENCY BRAKE CABLE HAS BROKEN IN THE REAR RIGHT SIDE. *AK
SPRING UNDERNEATH ACCELERATOR PEDAL FRACTURED DURING ACCELERATION, CAUSING SPLINTERED END TO CATCH IN CARPETING, HOLDING PEDAL IN DOWN POSITION/UNEXPECTED ACCELERATION.
REAR SUSPENSION FAILED.
MAN-TRAN: WHILE DRIVING ON FREEWAY, TRANSMISSION FROZE UP IN 4TH GEAR, GEARS JAMMED, DRIVER UNABLE TO SHIFT GEARS. *AK
FUEL PUMP FAILED.
UNDER RECALL NOTIFICATION, HAD BELT BUCKLES REPAIRED, NOW THE LEFT REAR SEAT BELT BUCKLE DOES NOT WORK, CONSUMER STATES THE OTHER THREE TEND TO JAM UP MAKING THEM ALL UNSAFE TO USE. *SLC
METAL RADIUS ARM FRAME HANGER IS CRACKED AND METAL CRYSTALLIZED. *AK CONSUMER STTES THIS PART HOLDS THE AXLE IN PLACE.*JB
GAS TANK LEAKS.
THE VEHICLE HAD FIRESTONE TIRES ON THE VEHICLE, THE VEHICLE HAD EXTENSIVE PROBLEMS WITH THE FRONT END, POSSIBLY DUE TO THE DEFECTIVE TIRES. *MJS
CONSUMER WAS TRAVELING 65MPH ON HIGHWAY, AND DRIVER LOST CONTROL OF VEHICLE, RESULTING IN A COLLISION. MOTORIZED SEAT BELTS DID NOT PROTECT OCCUPANT; THEY DID NOT OPERATE. *AK
1991 FORD EXPLORER COOLING SYSTEM WAS INADEQUATE TO COOL THE 4.0L V-6 ENGINE ADAPTED FROM THE FORD F100 SERIES TRUCK. I HAVE TALKED TO NUMEROUS OWNERS WHO EXPERIENCED THE SAME PROBLEM. THE ENGINE COOKS THERMOSTATS ABOUT EVERY 2 YEARS OR 30000 MILES. A AM A MARINE AND WHILE I WAS DEPLOYED OVERSEAS FOR 6 MONTHS, MY WIFE NOTICED THAT THE TEMPERATURE GAUGE WAS FLUCTUATING SIGNIFICANTLY. SHE REPORTED THIS TO SANDERS FORD IN JACKSONVILLE, NC AND WAS TOLD IT WAS NORMAL. SHE EXPLAINED THAT THE TEMP GAUGE HAD NEVER MOVED BEFORE BUT THEY INSISTED THAT IT NORMALLY FLUCTUATES. ABOUT 2 WKS LATER, MY WIFE NOTICED THAT IT WAS LOOSING COOLANT CONSTANTLY. SHE TOOK THE TRUCK BACK TO SANDER FORD, IN JACKSONVILLE, NC AND AFTER FORFEITING $1478.32 AND 2 DAYS LOSS OF THE VEHICLE, HER SUSPICION WAS CONFIRMED THAT THE CYLINDER HEAD HAD WARPED. THIS COMMON PROBLEM TO THE EARLY MODEL FORD EXPLORERS HAS NEVER BEEN RECALLED BY FORD. MORE ALARMING IS THE PROPENSITY OF FORD DEALERSHIPS TO BE DISHONEST AND MONOPOLIZING IN OVERPRICING PARTS AND SERVICE. WE HAVE OBSERVED THIS IN CA, VA, NC, AND HI. FORD MOTOR CO APPEARS UNABLE TO CONTROL QUALITY OF SERVICE IN ITS FRANCHISE DEALERSHIPS.*AK
FUEL SENDING UNIT FUEL PUMP NECK ROTTED, CAUSING LEAK.
WHEN ENTERING THE FREEWAY VEHICLE ACCELERATED WITHOUT APPLYING GAS PEDAL, WHEN APPLYING THE BRAKES NOTHING HAPPENED, PUT EMERGENCY BRAKE ON AND TURNED CAR OFF TO STOP IT. *AK
PARKED VEHICLE STARTED UP BY ITSELF AND CAUGHT ON FIRE, THE FLAMES CAME FROM DASHBOARD AREA POSSIBLY DUE TO DEFECTIVE IGNITION.*AK
WHEN DRIVING VEHICLE STARTED PULLING TO THE LEFT. CAME TO STOP SIGN AND WHEEL STARTED SHAKING AND FRONT LEFT BRAKE LOCKED UP.*AK
CONSUMER HAS EXPERIENCED PROBLEM WITH VEHICLE ABS SYSTEM LOCKING UP WHENEVER THE BRAKES ARE APPLIED IN AN EMERGENCY SITUATION. DEALER/MFR WAS NOT NOTIFIED. *AK *NLM
VEHICLE WAS DAMAGED IN FLAMES AND BURNED UP. *AK CONSUMER STATES THAT THE WHOLE DASHBOARD WAS ON FIRE, THE DASHBOARD HAD TO BE RIPPED OUT TO GET THE FIRE OUT. *SLC
ELECTRICAL FIRE DUE TO FAULTY MIRRORSWITCH/WIRING. *AK
FIRESTONE ATX TIRES EXPERIENCED TREAD SEPARATION CAUSING SIGNIFICANT DAMAGE TO THE FRONT FENDER. *SLC
WHILE DRIVING VEHICLE OUT OF OFFICE GARAGE, GAS PEDAL SUDDENLY WENT STRAIGHT TO THE FLOOR, THE ENGINE WAS RACING, VEHICLE TOOK OFF, TRIED TO STOP VEHICLE BY APPLYING BRAKES, VEHICLE SLAMMED INTO A BUILDING, SMASHING THE FRONT OF VEHICLE. *AK
SEAT BELT LATCH BUTTON CAME OFF.
VEHICLE WAS PARKED FOR PERIOD 36 HRS, UNDER THE HOOD ENGINE COMPARTMENT FIRE/FIRE DEPT INDICATED THAT IT WAS ELECTRICAL . *AK
LIFT GATE OPEN THE HYDROLIC LIFT BRACKET SNAPPED OFF CAUSING THE LIFTGATE TO FALL ON MY SONS HEAD. BRACKET WAS POORLY WELDED. THEY CLAIM THAT THERE WAS A RECALL AROUNG THE TIME THE CAR, BUT IT IS NO LONGER IN EFFECT. THE RECALL WAS TO BE REENFORCE THE BRACKETS. THIS IS STILL A SAFETY ISSUE.
WHEN TRYING TO COME TO A COMPLETE STOP HE EXPERIENCED A BRAKE FAILURE. *AK
ABS, REAR WHEEL BRAKE LOCKUP, WHEN APPLYING BRAKES VERY FORCEFULLY EXPERICENCED LOCKUP.
VEHICLE WAS PARKED, CAUGHT ON FIRE, FAILURE OF FUEL PRESSURE REGULATOR GOT STUCK, CAUSING ENGINE COMPARTMENT FIRE, *AK
SUDDEN ACCELERATION WHEN FORCE IS NOT APPLIED TO THE GAS PEDAL, CAUSING THE CONSUMER TO HAVE AN ACCIDENT. *AK
HATCH LATCHES FAILED DUE TO CORROSION. *DH
WHEN THE ORIGINAL FIRESTONE TIRES WORE OUT ON MY FORD EXPLORER, I REPLACED THEM WITH WHAT THE DEALER RECOMMENDED, NAMELY FI RESTONE ATX TIRES. BOTH REAR ATX TIRES DEVELOPED CRACKS ON THE SIDEWALLS AND HAD BEGUN TO SEPARATE. THE FIRESTONE DEALER BLAMED ME FOR THE PROBLEM, SAYING THAT I MUST HAVE HIT A CURB WHEN PARKING. WHEN I POINT OUT THAT THE REAR DRIVER'S SIDE ALSO HAD THE SAME PROBLEM HE MADE THE SAME EXCUSE AND TOLD ME THAT NOTHING WAS WRONG WITH THE TIRES AND THAT THE WEAR ON THE SIDEWALLS WAS MY FAULT. I GOT SO DISGUSTED AT THE FIRESTONE TIRE DEALER'S LACK OF RESPONSIBILITY AND FAILURE TO TAKE ANY CORRECTIVE STEPS THAT I DROVE TO COSTCO AND HAD THEM REPLACE ALL 4 FIRESTONE ATX TIRES WITH MICHLEANS. *AK( DOT NUMBER: TIRE SIZE: 70 X 15 )
FAILURE OF THE BRAKES, CONSUMER WAS DRIVING AND THE VEHICLE SUDDENLY ACCELERATED THE CONSUMER WAS NOT ABLE TO STOP THE VEHICLE. *AK
TRANSMISSION FAILED.
PE00 020; CONSUMER WAS TRAVELING ABOUT 65MPH ON HIGHWAY WHEN THE TREAD SEPARATED FROM TIRE. DRIVER LOST CONTROL OF VEHICLE, AND IT FLIPPED OVER. THERE WERE SIX PASSENGERS INSIDE OF VEHICLE. VEHICLE WAS TOTALED . THEY WERE ON THE ROAD ABOUT TWO HOURS BEFORE ACCIDENT STARTED, IT WAS A HOT CLASSIC HOT DAY. ALL PASSENGERS EXCEPT DRIVER WERE EJECTED, RESULTING IN ONE DEATH AND FIVE INJURIES. *AK MJS (TIRE MAKE/MODEL NOT PROVIDED) ATTORNEY FOR IGNACIO FLORES, SR., OWNER.
THE ENGINE FAN IS FRACTURED ALL THE WAY AROUND AND COULD CAUSE INJURY TO SOME ONE WORKING ON THE TRUCK. PLEASE DESCRIBE*AK
THE TRUCK WAS TRAVELING AT 60MPH AND THE TRANSMISSION LOCKED UP. THE TRANSMISSION IS A STANDARD. PLEASE DESCRIBE.*AK
MY LEFT REAR TIRE BLEW UP ON MY EXPLORER AS I WAS DRIVING. IT CAUSED DAMAGE TO THE LEFT REAR DOOR , THE WHEEL WELL, AND THE FENDER. I TOOK PICTURES OF THE DAMAGE AND OF THE TIRE. I ALSO HAVE THE RECEIPTS OF THE WORK THAT WAS DONE.( DOT NUMBER: )
5 SPEED TRANSMISSION LOCKED IN 4TH GEAR DURING MODERATE DRIVING/ WILL NOT SHIFT INTO NEUTRAL OR ANY OTHER GEAR DUE TO A BROKEN GEAR TOOTH. *AK
ENGINE LIGHT FLASHED FIVE SECONDS LATER TEMPERATURE CHANGED, BLACK SMOKE ENTERED INTO INTERIOR, RESULTING IN ENGINE COMPARTMENT FIRE. *AK
ACCELERATOR PEDAL SPRING BROKE. *SD
RADIUS ARM BUSHINGS MALFUNCTIONED. IN ADDITION, PREMATURE WEAR OF BRAKE PADS. *AK
VEHICLE CAUGHT ON FIRE CAUSED BY IGNITION. PLEASE DESCRIBE. *AK
ENGINE COOLING SYSTEM: ALUMINUM HEAD CRACKED BLOCK WHICH FORCED ANTI-FREEZE TO GET SUCKED INTO ENGINE. TOOK IN FOR DEALER TO LOOK AT AND THEY SAID THEY THE GET THEM ALL THE TIME. *AK
I TOOK THE TIRE TO MY LOCAL FIRESTONE DEALER. THEY REFUSED TO LOOK AT IT. THEY SAID I MUST CALL THEIR LOS ANGELES OFFICE. THE LA OFFICE SAID I MUST CALL THE TENNESSEE OFFICE. THE TENN. OFFICE SAID I MUST SEND THE TIRE TO THEM. I MAILED THE SEPARATED TIRE AND PARTS, AT MY EXPENSE, ON 09/23/96. THEIR LETTER ACKNOWLEDED RECEIPT OF THE TIRE AND SAID THEY WOULD CONTACT ME AFTER THEIR ANALYSIS. I NEVER HEARD FROM THEM AGIIN. MY INSURANCE COMPANY, USAA, ARRANGED FOR THE MASSIVE REPAIRS. I REPLACED ALL 4 FIRESTONE TIRES BECAUSE I FEARD FOR OUR SAFETY WHEN DRIVING ON THEM. I WANT TO BE REIMBURSED FOR THE 4 TIRES AND THE COST OF MAILING THE SEPARATED TIRE TO TENNESSE. THE COST OF MY TIME AND MENTAL ANGUISH IS DIFFICULT TO DETERMINE.*AK (TIRESIZE: 235-75-R15)
I TOOK THE TIRE TO MY LOCAL FIRESTONE DEALER. THEY REFUSED TO LOOK AT IT. THEY SAID I MUST CALL THEIR LOS ANGELES OFFICE. THE LA OFFICE SAID I MUST CALL THE TENNESSEE OFFICE. THE TENN. OFFICE SAID I MUST SEND THE TIRE TO THEM. I MAILED THE SEPARATED TIRE AND PARTS, AT MY EXPENSE, ON 09/23/96. THEIR LETTER ACKNOWLEDED RECEIPT OF THE TIRE AND SAID THEY WOULD CONTACT ME AFTER THEIR ANALYSIS. I NEVER HEARD FROM THEM AGIIN. MY INSURANCE COMPANY, USAA, ARRANGED FOR THE MASSIVE REPAIRS. I REPLACED ALL 4 FIRESTONE TIRES BECAUSE I FEARD FOR OUR SAFETY WHEN DRIVING ON THEM. I WANT TO BE REIMBURSED FOR THE 4 TIRES AND THE COST OF MAILING THE SEPARATED TIRE TO TENNESSE. THE COST OF MY TIME AND MENTAL ANGUISH IS DIFFICULT TO DETERMINE.*AK (TIRESIZE: 235-75-R15)
THE RIGHT REAR TIRE SEPARATED WHILE DRIVING ON AN UNOBSTRUCTED INTERSTATE HIGHWAY, CAUSING DAMAGE TO THE VEHICLE. CONSUMER WANTS TO BE REMBURSED (FIRESTONE TIRE SIZE P235-75-R15,DOT W2HL 1MO 270).
FRONT PASSENGER SIDE SEAT BELT BUCKLE WILL NOT RELEASE. *AK
SEAT BELT RETRACTOR; FAILURE ON THE REAR PASSENGER SIDE SEAT BELT RETRACTOR, RETRACTOR DOES NOT HOLD THE CSS DUE TO A BROKEN BUTTON. *AK
POOR DESIGN OF HUBS PREVENTED VEHICLE FROM SWITCHING TO 4-WHEEL DRIVE WHILE DRIVING UPHILL. *DH