1991 Ford Explorer Electrical system Problems
- Complaints
- 52about this part
- Share
- 9%of 609 total for the year
- Median mileage
- 135,651miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 52 complaints about the electrical system of the 1991 Ford Explorer, 9% of the 609 complaints for this model year. Where a mileage was given, the median is 135,651 miles. 32 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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“Dt: the consumer smell smoke, and then some smoke started coming out of the left side of the hood. All of the gauges looked okay and the consumer thought it was overheating. Then the car caught on fire fast with smoke on the left and fire on the right of the hood and burned all the way to the back of my car, and the two cars on either side. This happened in a denny's parking lot in fairbanks on 6/30/05. Fire department case number: 051947. Towed vehicle to the mechanic.”
NHTSA complaint #10128368, filed 2005-08, 138,000 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“Consumer stated that there was a fire in the vehicle in the instrument panel area. This happened after the consumer had parked the vehicle for the night. Contacted dealer and the dealer is not willing to do anything. Photos attached.”
NHTSA complaint #8020023, filed 2002-10, 159,000 miles“The contact owned a 1991 Ford Explorer. While driving 40 MPH, the contact noticed smoke coming from the instrument panel. The vehicle failed to restart. She managed to maneuver the vehicle to the shoulder and left to call for help. Upon returning to the vehicle, it was consumed in flames. The vehicle was destroyed and a police report was filed. The failure and current mileages were over 100,000.”
NHTSA complaint #10241375, filed 2008-09, 100,000 milesElectrical system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 9 | 21% |
| 2025 | 23 | 22% |
| 2024 | 2 | 10% |
| 2023 | 14 | 13% |
| 2022 | 39 | 14% |
| 2021 | 48 | 11% |
| 2020 | 188 | 15% |
| 2019 | 20 | 7% |
| 2018 | 58 | 8% |
| 2017 | 94 | 6% |
| 2016 | 129 | 5% |
| 2015 | 93 | 5% |
| 2014 | 100 | 6% |
| 2013 | 163 | 7% |
| 2012 | 64 | 8% |
| 2011 | 95 | 8% |
| 2010 | 12 | 10% |
| 2009 | 2 | 6% |
| 2008 | 38 | 26% |
| 2007 | 25 | 12% |
| 2006 | 39 | 6% |
| 2005 | 36 | 7% |
| 2004 | 55 | 4% |
| 2003 | 54 | 5% |
| 2002 | 148 | 4% |
| 2001 | 29 | 8% |
| 2000 | 78 | 8% |
| 1999 | 92 | 7% |
| 1998 | 114 | 6% |
| 1997 | 80 | 5% |
| 1996 | 47 | 3% |
| 1995 | 55 | 7% |
| 1994 | 75 | 6% |
| 1993 | 45 | 5% |
| 1992 | 45 | 7% |
| 1991 | 52 | 9% |
Other parts of the 1991 Ford Explorer
123 complaintsTires
102 complaintsTransmission and drivetrain
69 complaintsEngine cooling
52 complaintsSuspension
33 complaintsVisibility (wipers, defrost, mirrors)
32 complaintsBody and structure
31 complaintsVehicle speed control
30 complaintsEquipment
29 complaintsFuel system
26 complaintsSeat belts
26 complaintsOther or unknown
16 complaints
← All problems reported for the 1991 Ford Explorer
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology