Recalls & safety ratings

1991 FORD EXPLORER

Every NHTSA recall campaign covering the 1991 FORD EXPLORER, and the crash-test ratings for the body styles that were tested.
  • 11
    Recalls
  • 699
    Owner complaints
  • 18
    Investigations

Sourced from NHTSA recall and safety-rating data — last checked 21 August 2026.

11 recall campaigns

A campaign usually covers only part of a model year's production, so it may not apply to a particular car. Check the VIN to be certain.

TIRES:TREAD/BELT

NHTSA campaign 01X001000 · FORD MOTOR COMPANY

Summary

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 PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.

Consequence

SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

Remedy

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.

TIRES:TREAD/BELT

NHTSA campaign 00T005000 · BRIDGESTONE/FIRESTONE, INC.

Summary

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.

Consequence

IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.

Remedy

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.

STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

NHTSA campaign 95I007000 · FORD MOTOR COMPANY

Summary

VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. 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.

Consequence

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.

Remedy

FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.

Notes

FORD HAS DECIDED TO CONDUCT A SAFETY IMPROVEMENT SERVICE CAMPAIGN TO REINFORCE THE BRACKET ATTACHMENTS WITHOUT CHARGE. OWNERS CAN CONTACT FORD AT 1-800-392-3673.

STRUCTURE:BODY:ROOF AND PILLARS

NHTSA campaign 97V235001 · FORD MOTOR COMPANY

Summary

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.

Consequence

UNEXPECTED SEPARATION OF THE SUNROOF GLASS PANEL COULD POSSIBLY DISTRACT THE DRIVER INCREASING THE RISK OF A VEHICLE CRASH OR LOSS OF VEHICLE CONTROL.

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.

Notes

OWNER NOTIFICATION BEGAN MARCH 2, 1998. OWNERS WHO DO NOT RECEIVE THE INSTRUCTION BOOKLET AND WARNING LABEL WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC

NHTSA campaign 96V024001 · FORD MOTOR COMPANY

Summary

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.

Consequence

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.

Remedy

DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

Notes

SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

SEAT BELTS:FRONT:BUCKLE ASSEMBLY

NHTSA campaign 92V113000 · FORD MOTOR COMPANY

Summary

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.

Consequence

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.

Remedy

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

Notes

SYSTEM: SAFETY BELT BUCKLE.VEHICLE DESCRIPTION: PASSENGER CARS AND UTILITY VEHICLES.NOTE: ONLY THE END RELEASE BUCKLES ON "RIGID" MOUNTINGS ARE SUSCEPTIBLE TO THISMALFUNCTION, THE WEB-MOUNTED FRONT CENTER END RELEASE BUCKLES AND THEWEB-MOUNTED REAR FACING THIRD SEAT END RELEASE BUCKLES IN TAURUS OR SABLEVEHICLES WILL NOT BE REPLACED. ALSO, THE WEB-MOUNTED FRONT CENTER BUCKLES INEXPLORER VEHICLES WILL NOT BE REPLACED.

STRUCTURE:BODY:BUMPERS

NHTSA campaign 91V026000 · FORD MOTOR COMPANY

Summary

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

Consequence

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

Remedy

INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.

Notes

SYSTEM: REAR BUMPER REINFORCEMENT.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLE.NOTE: BUMPER MOUNTED TRAILER HITCH BALL ASSEMBLY SHOULD NOT BE USED UNTIL REPAIRPROCEDURE IS COMPLETED.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

NHTSA campaign 91V025000 · FORD MOTOR COMPANY

Summary

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.

Consequence

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

Remedy

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

Notes

SYSTEM: VAPOR VENT VALVE CARRIER WELD TO PLASTIC FUEL TANK.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

NHTSA campaign 91V024000 · FORD MOTOR COMPANY

Summary

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

Consequence

THIS PENETRATION OF THE FUEL TANK CAUSES VAPORS TO ESCAPEAND POSSIBLY FUEL TO SPILL, WHICH COULD CATCH FIRE IN THE PRESENCE OF ANIGNITION SOURCE.

Remedy

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

Notes

SYSTEM: FUEL TANK AND HEAT SHIELD.VEHICLE DESCRIPTION : MULTI-PURPOSE PASSENGER VEHICLE.

VISIBILITY:SUN/MOON ROOF ASSEMBLY

NHTSA campaign 90V098000 · FORD MOTOR COMPANY

Summary

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

Consequence

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.

Remedy

INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.

Notes

SYSTEM: SUNROOF HINGES.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER 4-DOOR VEHICLES WITH SUNROOFS.

POWER TRAIN:AUTOMATIC TRANSMISSION

NHTSA campaign 91V189000 · FORD MOTOR COMPANY

Summary

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

Consequence

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.

Remedy

REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

Notes

SYSTEM: TRANSMISSION.VEHICLE DESCRIPTION: PICKUP TRUCKS, VANS, AND MULTI-PURPOSE VEHICLES EQUIPPEDWITH A4LD AUTOMATIC TRANSMISSIONS.

NHTSA 5-Star Safety Ratings

NHTSA crash-tests vehicles and rates them out of five stars. More stars mean a safer car. Ratings are per body style, so a model can appear more than once below.

1991 Ford Explorer 4-DR. 4x4

Overall
Not rated

Frontal crash

Not rated
Driver
Passenger
Not rated

Side crash

Not rated
Driver
Not rated
Passenger
Not rated
Pole
Not rated

Rollover

Not rated

0% chance of rollover in a single-vehicle crash.

  • Electronic stability control: No
  • Forward collision warning: No
  • Lane departure warning: No

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