1991 Ford Explorer Recalls
NHTSA lists 8 recall campaigns for the 1991 Ford Explorer. A recall applies only to vehicles built within the affected range, so check your own VIN at nhtsa.gov/recalls. Repairs for recalls are free at a franchised dealer.
- Structure › Body › Roof and pillarsCovers: Ford Explorer 1991–1993
Reported issue: 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.
Possible 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.
- Service brakes, hydraulic › Power assist › HydraulicCovers: Ford Explorer 1991–1994, Ranger 1991–1994
Reported issue: 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.
Possible 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.
- Seat belts › Front › Buckle assemblyCovers: Ford Explorer 1991, Mercury Sable 1989–1990, Ford Taurus 1989–1990
Reported issue: 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…
Possible 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.
- Power train › Automatic transmissionCovers: Ford Explorer 1991, Aerostar 1989–1991, Ranger 1990–1991 +1 more
Reported issue: When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Possible 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.
- Structure › Body › BumpersCovers: Ford Explorer 1991
Reported issue: Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
Possible 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.
- Fuel system, gasoline › Storage › Tank assemblyCovers: Ford Explorer 1991
Reported issue: The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
Possible 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.
- Fuel system, gasoline › Storage › Tank assemblyCovers: Ford Explorer 1991
Reported issue: 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.
Possible 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.
- Visibility › Sun/moon roof assemblyCovers: Ford Explorer 1991
Reported issue: If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
Possible 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.
NHTSA investigations
- EA00012Spare tire winch cableClosed · Apr 14, 2000
- PE99072Spare tire winch cableClosed · Nov 30, 1999
- RQ99016Liftgate support bracket failureOpen · Jul 29, 1999
- DP98001Heavy lateral vibrationClosed · Jan 6, 1998
- EA97011Sunroof shattering and separationClosed · May 23, 1997
- EA95018Separation of master cylinderClosed · Jun 19, 1995
- PE95001Brake master cylinder/booster separationClosed · Jan 3, 1995
- PE94044Engine cooling fan cracksClosed · Jun 10, 1994
- EA93003Throttle stickingClosed · Jan 15, 1993
- EA91040Vacuum boostr valve failsClosed · Oct 3, 1991
- EA91034Throttle release failureClosed · Jul 17, 1991
- PE91084Vacuum boostr valve failsClosed · Jun 10, 1991
- PE91058Throttle release failureClosed · Mar 6, 1991
← 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.