1991 Ford Explorer Problems

What owners report

Complaints on this model year are dominated by two long-running themes: repeated brake work and early tire failures, with a smaller but consistent group of reports about the automatic transmission and about fuel smells or leaks around the tank. Many of the sampled complaints were filed years after purchase on high-mileage vehicles, so a large part of what owners describe is wear and repair history rather than problems that show up when the vehicle is new.

1. 1
   Tires

   Tire tread separation and sidewall cracking

   • 102 complaints (17%)
   • median 117,750 mi at 13.2 yrs old (4 state mileage, few)
   • 19 mention a crash, fire or injury
   • filed 1995–2011

   Owners describe tread separating from the tire at highway speed, blowouts, and cracking around the sidewall on tires with plenty of tread left. Several complaints name a specific Firestone ATX size and mention tread separation, and one mentions that a dealer declined a defect claim and offered only partial credit toward new tires. Another owner describes all four tires developing sidewall cracks found during an alignment. Most reports involve tires with relatively low mileage, and several were filed in 2000-2001 during the wider tire recall period.

   What to check: Check tire brand, size and DOT date codes on any vehicle you look at, look for sidewall cracks or bulges, and ask whether the tires were replaced under the tire recall.

   2 excerpts from owner complaints in NHTSA records

   “Uniroyal tire side wall cracks lt 235 75r15 - no failure - just crack. All 4 of my tires had a side wall crack the entire diameter of the tire about 3 inches down on the side wall . I noticed the crack on the inside as well so it appears the tires had some issue. I had never applied tire foam cleaner(armor all tirefoam prior ) but one time this last week I did apply some and found the crack. …”

   NHTSA complaint #10289739, filed 2009-10, 2,000 miles

   “Pe00 020; consumer was traveling about 55mph on the highway and heard a loud banging noise . She pulled over and saw left rear tread separated from tire. Tire tread was slapping up against vehicle. Tire was still inflated, and the tread was separated. Firestone #fr480, p215/70 r15 DOT # w200tmx. There were no injuries. The tires failed three times due to tread separation, crack and internal separations.”

   NHTSA complaint #868030, filed 2000-08
2. 2
   Electrical system

   Under-dash and engine bay electrical fires

   • 37 complaints (6%)
   • median 135,651 mi at 13.1 yrs old (8 state mileage, few)
   • 31 mention a crash, fire or injury
   • filed 1995–2008

   Complaints describe smoke and fire originating in the instrument panel area or under the hood, in some cases while the vehicle was parked overnight and in others while driving. One owner reports the ignition switch and wiring were replaced after smoke came from under the steering column, and another describes the wiring harness contacting the engine block and igniting. Owners also report gauges and headlights blinking intermittently. Reported mostly above 100,000 miles, with several vehicles in the 130,000-200,000 mile range.

   What to check: Inspect under the dash and in the engine bay for chafed, brittle or spliced wiring, check that fuses are correct, and ask whether the ignition switch or any wiring has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Headlights & dash lights blink. They will be fine for a while but then just start blinking. Turning them off, then on again, makes them stay on for a few minutes until they start blinking again. Sometimes they don't blink. Sometimes they won't go on at all and I have to hold the brights switch back if I want to have light. My sister had this same problem on her 1993 Ford thunderbird.”

   NHTSA complaint #10037273, filed 2003-09, 229,000 miles

   “Air conditioner caught fire under the hood. Fire started inside the air conditioner probably the fan speed resistors. Melted the left side of the housing where the resistors and fan are housed letting smoke and fumes in the car. In feeling around inside the blower hole you can reach up and feel the sheet metal where the wiper arms are and I think probably leaves got in and were blown on to the resistors when they were hot starting the fire. …”

   NHTSA complaint #10016702, filed 2003-04, 133,302 miles
3. 3
   Brakes

   Brakes wearing out quickly and rear brakes grabbing or

   • 87 complaints (14%)
   • median 145,150 mi at 13.5 yrs old (2 state mileage, few)
   • 15 mention a crash, fire or injury
   • filed 1995–2021

   Owners describe brake pads, calipers and related hardware needing replacement far more often than they expected, often around every 20,000 miles, with one owner noting the mechanic remarked that this model was hard on pads. Others report the rear wheels locking or dragging after a normal brake application and staying locked until the pedal is held down for several seconds, and some describe the ABS warning light coming on while driving. One complaint describes an abrupt lock-up of a rear brake in traffic that led to a collision. Reported from roughly 100,000 miles upward, including one vehicle at about 160,000 miles and another with repeated brake jobs over 17,000 miles of use.

   Recall 96V024001

   What to check: Ask for brake service records and check the condition of pads, calipers and rear drums; have a mechanic drive the vehicle and test moderate stops to see whether a rear wheel drags or locks. A campaign covering brake master cylinder studs on some vehicles exists, so ask whether it was completed.

   2 excerpts from owner complaints in NHTSA records

   “I bought a 1991 Ford Explorer 1 1/2 years ago from a neighbor who said he was tired of putting brakes on it. Since he had just done it again, I didn't expect any trouble for a while. 17,000 miles later, all brake pads, calipers etc., needed to be replaced again. It is averaging 20,000 miles on this vehicle. The mechanic said this model was bad for pushing the pads off the shoes. While paying my bill, I noticed another similar vehicle on the rack getting the same thing done. Is this an epidemic or am I just unlucky? …”

   NHTSA complaint #10049517, filed 2003-12, 160,300 miles

   “The component that malfunctioned was the abs sensor. It is not available for inspection. I was driving going around 45 in traffic and the drivers side rear brake locked up and spun me out of control and caused me to collide with another vehicle. I only lightly pressed the brakes and it happened suddenly and unexpectedly. It was not inspected before it was towed after the accident. There were no warning lamps.”

   NHTSA complaint #11444373, filed 2021-12
4. 4
   Transmission and drivetrain

   Automatic transmission and clutch problems

   • 47 complaints (8%)
   • median 87,600 mi at 12.7 yrs old (4 state mileage, few)
   • 6 mention a crash, fire or injury
   • filed 1995–2008

   Complaints describe automatic transmission failure, transmission work that did not resolve the problem, and on manual trucks a clutch that failed repeatedly and was replaced more than once. One owner reports that 4-wheel drive engaged on its own and pulled the steering, and another describes a front hub failure that let the wheel and brake assembly come off. Mostly reported between about 75,000 and 100,000 miles, with several vehicles over 100,000 miles.

   Recall 91V189000

   What to check: Drive the truck through shifts and check for slipping or delayed engagement, test that park holds on a slope, and on 4x4 models confirm the transfer case and front hubs engage and disengage properly.

   2 excerpts from owner complaints in NHTSA records

   “After purchasing this Ford Explorer I check all fluids and added and changed as nessasary about 2 weeks after I purchased it my stepson and my wife and large dog went on a little trip to check out this thing, after letting out the wife and dog my stepson and myself tried to go up a slight hill in 4 wheel drive to see if it worked, after it wouldn't make it up the hill we backed it down and headed back for my wife when the left front tire wheel and brake assy fell off due to the plastic piece failing inside automatic hubs causing c clip to …”

   NHTSA complaint #10114819, filed 2005-03, 75,200 miles

   “I bought the truck from a respectable dealership in new jersey in oct. 1995. The clutch failed me in may 1997. It was repaired for approx. 600.00. It then failed me again in aug. 1998. It was repaired again but this time it costed me 1200.00. I was amazed the price doubled. The company that fixed it said the other company failed to do it the correct way. Now once again it has failed me on sept. 1999. I am very disturbed about this. I cannot take my truck back to the previous company because they were replaced by midas. Does this seem right?”

   NHTSA complaint #711369, filed 1999-09
5. 5
   Brakes

   Fuel smell, leaks and tank or line corrosion

   • 24 complaints (4%)
   • median 130,000 mi at 12.3 yrs old (3 state mileage, few)
   • 4 mention a crash, fire or injury
   • filed 1995–2003

   Owners report smelling gasoline after driving or seeing fuel dripping onto the ground, traced to a rusted metal plate on top of the plastic tank where the lines and pump mount, and to a leaking feed line to the pressure regulator. Others describe a vapor vent valve fitting separating from the tank top, and several note that a recall covering fuel tank issues did not apply to their vehicle. One complaint reports an engine compartment fire traced to a stuck fuel pressure regulator. Reported across a wide mileage range, from low-mileage examples to vehicles over 200,000 miles, and often noticed while the engine was running or just after parking.

   Recall 91V024000Recall 91V025000

   What to check: Look under the vehicle for damp or rusted areas around the tank and lines, check for a fuel smell after a drive or with the engine running, and ask whether the fuel tank campaigns were performed on this vehicle.

   2 excerpts from owner complaints in NHTSA records

   “Gas feeder line to regulator started leaking while the vehicle was running outside to warm up. Upon coming out to the vehicle I found a pool of gas circumferencing my vehicle. I immediately jumped into it an d moved it away from my home. After doing so shut it off. This was a very dangerous situation. My home ,my car and loss of life could have resulted form this. I feel it needs to be looked into. I purchased this car in october 1990. …”

   NHTSA complaint #10002892, filed 2003-01, 130,000 miles

   “Fuel tank-vapor vent valve carrier weld failed. Dealer failed to diagnose problem. Independent repair facility found fuel leak, replaced fuel tank at my expense. I recently learned of recall no. 91v025000. Ford states that this is advisory bulletin only and not a recall, and in any case, does not apply to my vehicle. I ordered my vehicle in may 1990 and took delivery in september 1990. I believe that my vehicle should have been included in recall, and that dealer the should have diagnosed the problem considering recall bulletin. …”

   NHTSA complaint #10007047, filed 2001-05, 79,300 miles

Buying note. On a vehicle this old the condition of the brakes, tires, wiring and fuel system matters more than the model's reputation, so have those areas inspected before purchase and ask for service records for the brake, tire and fuel tank campaigns. Repeated brake work and tire replacement are the costs most owners describe, and rust in the tank area is worth checking closely on trucks that have lived in wet or coastal climates.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.