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 2002-02Related recalls
- 97V235001Dec 18, 1997Vehicle description: multi-purpose passenger vehicles equipped with factory installed sunroof. The sunroof glass panel assembly can separate while the vehicle…Covers: Ford Explorer 1991–1993
- 91V026000Feb 12, 1991Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.Covers: Ford Explorer 1991
Body and structure: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 2 | 5% |
| 2025 | 7 | 7% |
| 2023 | 10 | 9% |
| 2022 | 11 | 4% |
| 2021 | 25 | 6% |
| 2020 | 45 | 4% |
| 2019 | 150 | 50% |
| 2018 | 288 | 39% |
| 2017 | 659 | 39% |
| 2016 | 591 | 24% |
| 2015 | 411 | 23% |
| 2014 | 276 | 16% |
| 2013 | 439 | 20% |
| 2012 | 144 | 17% |
| 2011 | 110 | 9% |
| 2010 | 1 | 1% |
| 2009 | 2 | 6% |
| 2008 | 1 | 1% |
| 2007 | 11 | 5% |
| 2006 | 11 | 2% |
| 2005 | 151 | 30% |
| 2004 | 426 | 33% |
| 2003 | 354 | 31% |
| 2002 | 486 | 15% |
| 2001 | 29 | 8% |
| 2000 | 29 | 3% |
| 1999 | 47 | 3% |
| 1998 | 48 | 2% |
| 1997 | 50 | 3% |
| 1996 | 63 | 4% |
| 1995 | 39 | 5% |
| 1994 | 158 | 13% |
| 1993 | 86 | 9% |
| 1992 | 62 | 10% |
| 1991 | 31 | 5% |
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 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 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