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Body and structurePart report

1991 Ford Explorer Body and structure Problems

Complaints
31about this part
Share
5%of 609 total for the year
Median mileage
161,000miles
Trend
StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.

NHTSA recorded 31 complaints about the body and structure of the 1991 Ford Explorer, 5% of the 609 complaints for this model year. Where a mileage was given, the median is 161,000 miles. 1 of these say a crash was involved and 1 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.

“In 2001 the right side bracket attachment of the rear liftgate gas assist cylinder came off from the inside of the liftgate of my 1991 Ford Explorer. The remaining assist cylinder does not hold the liftgate in an open position. As I understand from NHTSA campaign id no 95i007000 over a million vehicles had the brackets reinforced, but my Explorer wasn't included although in my opinion it clearly should have been. I haven't priced the repairs.”

NHTSA complaint #10072879, filed 2004-05, 198,000 miles

“The rear liftgate was in the up position and it dropped while the consumer was unloading groceries. The right side hinge broke. This vehicle was not included in liftgate recall campaign 04v442000.”

NHTSA complaint #10115396, filed 2005-04, 15,000 miles

“The questionnaire does not fit my complaint. The door handle on the front left and rear right have broken. This makes it nearly impossible to close the doors tightly. I have looked into several other Ford explorers with the same inside door panels and they also have at least one of the handles broken. I feel this must be a defect in design since it seems to have occured in several vehicles. I have not looked into one like mine yet and not found at least one handle broken. …”

NHTSA complaint #723311, filed 2000-05

“The left and right rear rocker panels are rusted through. This is a common problem amoungst Ford Explorer's (1991-1994). Many auto body shops have confimed that this cronic problem is a a result of poor design of not adding drain holes in the rear proportion of the rocker panels. Though this matter is not a saftey factor it is very costly to repair.”

NHTSA complaint #721973, filed 2000-04

“Lift gate open the hydrolic lift bracket snapped off causing the liftgate to fall on my sons head. Bracket was poorly welded. They claim that there was a recall aroung the time the car, but it is no longer in effect. The recall was to be reenforce the brackets. This is still a safety issue.”

NHTSA complaint #9006016, filed 2002-02

Related recalls

Body and structure: other model years

YearComplaintsShare of year
202625%
202577%
2023109%
2022114%
2021256%
2020454%
201915050%
201828839%
201765939%
201659124%
201541123%
201427616%
201343920%
201214417%
20111109%
201011%
200926%
200811%
2007115%
2006112%
200515130%
200442633%
200335431%
200248615%
2001298%
2000293%
1999473%
1998482%
1997503%
1996634%
1995395%
199415813%
1993869%
19926210%
1991315%

Other parts of the 1991 Ford Explorer

Brakes
123 complaints
Tires
102 complaints
Transmission and drivetrain
69 complaints
Electrical system
52 complaints
Engine cooling
52 complaints
Suspension
33 complaints
Visibility (wipers, defrost, mirrors)
32 complaints
Vehicle speed control
30 complaints
Equipment
29 complaints
Fuel system
26 complaints
Seat belts
26 complaints
Other 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 27, 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