1991 Ford Explorer Fuel system Problems
- Complaints
- 26about this part
- Share
- 4%of 609 total for the year
- Median mileage
- 104,650miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 26 complaints about the fuel system of the 1991 Ford Explorer, 4% of the 609 complaints for this model year. Where a mileage was given, the median is 104,650 miles. 5 a fire, according to the filers. 2 recall campaigns on record are filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“On june 4th my daughter and I were driving east bound on 62nd and over-hill in los angeles ca. Shortly after 12:00pm. When suddenly the Ford Explorer was engulfed in flames. My daughter and I were ordered to exit the vehicle. I was never notified of a recall. Due to investigation on my own I have received a recall number. It is 96s35. I have attempted to resolve this matter with Ford however I just received a letter from them refusing to assist me. My daughter and I could have been burned alive. I would like to know if you could assist me. The vehicle has since been destroyed. …”
NHTSA complaint #10523299, filed 2013-07, 15,000 miles“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. Also I would like to know if this has been reported on previously, ii have been unable to fingd anything on it. Thank you”
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“Fuel is spilling out from the fuel tank. There's a recall 91v024000 for the fuel tank assembly. The manufacturer is not providing proper information. They are indicating that the VIN number may not be included or the recall was already performed.”
NHTSA complaint #10048454, filed 2003-11, 250,000 miles“After trying to figure where the fuel smell at times was coming from the problem got worse . Gas was leaking out rapidly from top of gas tank. Upon inspection the fuel sending unit corroded out at the tubes that protrude fron sending unit cover. The cover and the retainer are also very rotted along with the tabs that the retainer(lock ring) slides under to hold the sending unit in the tank. While I have been in the auto business many years I have made some calls and have talked to some other mechanics ,and customers, they have had the same problem with their explorers too. …”
NHTSA complaint #720047, filed 2000-03Related recalls
- 91V024000Feb 11, 1991The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.Covers: Ford Explorer 1991
- 91V025000Feb 11, 1991The 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…Covers: Ford Explorer 1991
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 3 | 7% |
| 2025 | 3 | 3% |
| 2023 | 3 | 3% |
| 2022 | 37 | 14% |
| 2021 | 28 | 6% |
| 2020 | 42 | 3% |
| 2019 | 17 | 6% |
| 2018 | 23 | 3% |
| 2017 | 49 | 3% |
| 2016 | 112 | 5% |
| 2015 | 94 | 5% |
| 2014 | 72 | 4% |
| 2013 | 153 | 7% |
| 2012 | 34 | 4% |
| 2011 | 40 | 3% |
| 2010 | 9 | 8% |
| 2009 | 2 | 6% |
| 2008 | 2 | 1% |
| 2007 | 4 | 2% |
| 2006 | 27 | 4% |
| 2005 | 66 | 13% |
| 2004 | 33 | 3% |
| 2003 | 11 | 1% |
| 2002 | 72 | 2% |
| 2001 | 11 | 3% |
| 2000 | 19 | 2% |
| 1999 | 34 | 3% |
| 1998 | 63 | 3% |
| 1997 | 56 | 3% |
| 1996 | 23 | 2% |
| 1995 | 16 | 2% |
| 1994 | 33 | 3% |
| 1993 | 12 | 1% |
| 1992 | 18 | 3% |
| 1991 | 26 | 4% |
| 1990 | 2 | 17% |
Other parts of the 1991 Ford Explorer
123 complaintsTires
102 complaintsTransmission and drivetrain
69 complaintsElectrical system
52 complaintsEngine cooling
52 complaintsSuspension
33 complaintsVisibility (wipers, defrost, mirrors)
32 complaintsBody and structure
31 complaintsVehicle speed control
30 complaintsEquipment
29 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 30, 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