1991 Ford Explorer Body & Structure Problems

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 CAMPAIGN. REBECCA (#6048) AT THE FORD CUSTOMER SERVICE CALL CENTER TOLD ME THE CAMPAIGN HAD EXPIRED, AND COULDN'T OFFER ASSISTANCE. YOUR COMPANY'S RESPONSE TO DATE IS NOT ACCEPTABLE. THE BRACKET WAS ATTACHED TO THE HATCH BY ONLY TWO SMALL SPOT WELDS, AS IS THE LEFT-SIDE BRACKET. THE FAILURE STILL HAS THE POTENTIAL FOR CAUSING SERIOUS INJURY, ESPECIALLY IF THE LEFT-SIDE BRACKET WERE TO FAIL. THE VEHICLE WAS APPARENTLY NOT REPAIRED UNDER THIS SAFETY IMPROVEMENT CAMPAIGN. I WAS NOT NOTIFIED OF THE CAMPAIGN NOR OFFERED AN OPPORTUNITY TO HAVE THIS DEFECT REPAIRED. SINCE THE SAFETY HAZARD THAT THIS SAFETY IMPROVEMENT CAMPAIGN SOUGHT TO RESOLVE STILL EXISTS ON MY VEHICLE, I REQUEST THAT THE BROKEN BRACKET BE REPAIRED AND THE REMAINING BRACKET REINFORCED AT NO CHARGE TO ME, PER THE INTENT OF THE SAFETY IMPROVEMENT CAMPAIGN. THANK YOU FOR YOUR ASSISTANCE. [XXX] *NM UPDATED 07/12/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

THE REAR LIFTGATE WAS IN THE UP POSITION AND IT DROPPED WHILE THE CONSUMER WAS UNLOADING GROCERIES. THE RIGHT SIDE HINGE BROKE. THIS VEHICLE WAS NOT INCLUDED IN LIFTGATE RECALL CAMPAIGN 04V442000. *AK *SC *JB

BOTH REAR DOOR LATCHS FAILED. CAUSING THE REAR DOOR TO OPEN WHILE DRIVING. DOES NOT SHUT PROPERLY WHEN CLOSED. DT

DRIVER'S SIDE AND PASSENGER SIDE DOORS ARE COMING OFF THE HINGES. DEALER HAS BEEN CONTATCED. PLEASE PROVIDE FURTHER DETAILS.*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

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

DRIVER'S AND THE PASSENGER'S SIDE DOORS DID NOT SHUT ALL THE WAY. OWNER HAD TRUCK CHECKED BY AN AUTO BODY SHOP. MECHANIC STATED THAT TRUCK WAS MOST LIKELY IN A CRASH. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK

I WAS DRIVING ON A FREEWAY TRANSITION WHEN THE HOOD FLEW OPEN AND HIT THE WINDSHIELD. THE HOOD DID NOT DETACH FROM THE VEHICLE. THE HOOD, WINDSHIELD, WIPERS AND PLATE BETWEEN THE WINDSHIED AND HOOD REQUIRE REPLACEMENT.

THERE ARE HUGE CORROSION HOLES UNDER BOTH REAR DOORS. I NOTICED THE SAME CORROSION PROBLEM ON ALL 1991-1993 FORD EXPLORERS DRIVEN AROUND.

VEHICLE'S STRUCTURAL COMPONENT IS RUSTED. *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.

RIGHT/REAR INSIDE DOOR HANDLES CRACKED AT ATTACTACHMENT TO DOOR, UNABLE TO CLOSE DOOR. *AK

VEHICLE DOOR HANDLE HAS COME OFF FOR THE THIRD(3RD) TIME. TT

ROD THAT HOLDS UP RIGHT REAR TAIL LIFT GATE UP BROKE, RESULTING IN A HIT ON THE HEAT BY THE GATE, REPLACE SHOCKS IN LIFT GATE. TT

THE REAR HATCH FELL. TT WHEN HATCH WAS OPENING THE SPOT WELDS HOLDING THE UPPER LEFT GAS STRUT MOUNT TO THE HATCH BROKE. THIS ALLOWED THE HATCH TO FALL STRIKING ME ON THE SHOULDER. THE GAS STRUT ALSO EXTENDED SUDDENLY STRICKING AND SCRATCHING THE BODY OF THE VEHICLE.

ARM REST SUPPORT FAILED TO WORK PROPERLY. *AK

COWL DESIGN ALLOWED LEAVES TO ENTER VEHICLE ONTO HEATER COIL, CAUSING HEATER TO CATCH FIRE. *TW

VEHICLE REAR PASSENGER DOORS ARE EXTREMELY HARD TO OPEN DUE TO DESIGN. DEALER IS AWARE OF PROBLEM. TT

SHEET METAL ROOF IS RUSTING BADLY AT THE POINT OF THREE OF FIVE SCREWS WHICH HOLD LUGGAGE RACK TO VEHICLE.

DOORS WILL NOT OPEN FROM INSIDE. CHILD SAFETY LOCKS ARE NOT ON. THE PROBLEM BECAME INCREASINGLY WORSE OVER TIME, ONE DOOR AND THEN THE OTHER. THE ENTIRE HANDLE EVENTUALLY BROKE FROM HAVING TO BE PULLED ON SO HARD.