1994 Ford Explorer Problems

What owners report

Owners of this model year most often describe fires that start under the hood, behind the dashboard, or at the power mirror switch, along with tire failures and brake problems. Many reports center on older, high-mileage vehicles, and several owners mention that a recall they had heard about did not cover their particular vehicle by VIN.

1. 1
   Electrical system

   Under-hood, dash and mirror-switch fires

   • 348 complaints (29%)
   • median 117,000 mi at 11.8 yrs old (32 state mileage)
   • 114 mention a crash, fire or injury
   • owner-quoted repair $850 (median of 14 quotes)
   • filed 1995–2018

   Complaints describe smoke or flames coming from under the hood, behind the instrument panel, from the air-conditioning vents, or at the power mirror control switch on the door console. In several accounts the vehicle was destroyed; owners sometimes linked the fire to cruise control wiring or to the mirror switch circuit, and say the dealer or manufacturer could not identify a cause. Some report the wiring or alternator output wire was burned. Reported from about 60,000 to 200,000 miles, often in parked vehicles as well as while driving.

   Recall 97V083000

   What to check: Ask whether the power mirror switch recall (97V083000) was performed on this VIN, and have a technician inspect under-hood wiring, the alternator output lead and cruise control components for heat damage or chafing.

   2 excerpts from owner complaints in NHTSA records

   “While driving I turned on air conditioner and immediately light smoke began out of air conditioning vents and then the next moment the smoke was extremely heavy out of the vents and then visible fire underneath front passenger side dashboard. I immediately pulled the vehicle off the side of the road and exited, 10 minutes later it was fully engulfed in flames.”

   NHTSA complaint #10379515, filed 2011-01, 286,000 miles

   “While returning from christmas shopping I disarmed my car alarm. When the driver side door was opened, smoke began emitting from the power mirror switch. Using a screwdriver, I removed the electrical console and swung the screwdriver at the flaming switch assembly until it released. Falling to the ground I quickly smothered the fire and disconnected the battery until all smoke cleared.”

   NHTSA complaint #10000081, filed 2002-12, 60,000 miles
2. 2
   Tires

   Tire tread separation and blowouts

   • 356 complaints (29%)
   • median 91,350 mi at 10.6 yrs old (14 state mileage)
   • 61 mention a crash, fire or injury
   • owner-quoted repair $976 (median of 15 quotes)
   • filed 1995–2013

   Owners describe tires that bulged, shook the vehicle, lost tread, or blew out at highway speed, sometimes leading to loss of control. Several complaints concern the spare tire mounted under the chassis, where the retaining cable snapped and released the tire. Many say tire makers or the dealer declined reimbursement under the tire recalls. Reported from under 15,000 miles to about 120,000 miles on the tires, with several failures at highway speeds.

   What to check: Check tire brand, age (date codes) and sidewall condition, and inspect the spare tire carrier cable under the rear for fraying or rust.

   2 excerpts from owner complaints in NHTSA records

   “I was driving on the pa turnpike. I got off at fort washington exit. I proceeded to ft. Washington expo center. I pulled into a parking place and I heard a loud pop. I got out to find my rear-passenger side tire deflating rapidly. There was a hole in the side wall of the tire. There was nothing on the ground around the tire. It just popped.”

   NHTSA complaint #10013605, filed 2003-03, 108,000 miles

   “My driver-side, rear tire tread separated. (semperit brand p235/75r15 (this brand is not on your drop down menu!)) on my 1994 Ford Explorer causing damage to my car (namely the rear quarter panel.) I was able to control the car and thus not hit anything else. The tires had 24,000 miles on them. This happened during the Ford/firestone news. Ford would not pay to replace the tires and the company semperit in nowhere to be found in the us.”

   NHTSA complaint #10047718, filed 2003-11, 74,000 miles
3. 3
   Brakes

   Brake vibration, caliper and pad problems

   • 296 complaints (25%)
   • median 88,500 mi at 9.9 yrs old (13 state mileage)
   • 33 mention a crash, fire or injury
   • owner-quoted repair $807 (median of 8 quotes)
   • filed 1995–2011

   Complaints describe vibration or noise when braking, sticking or overheated front calipers, and repeated rotor, drum and pad replacements where the symptom returned. One owner reports an inner front pad wearing until it came out of its channel, and another lost brake fluid after a line rubbed against the chassis. Mostly reported between roughly 50,000 and 130,000 miles, often after several prior brake repairs.

   Recall 96V024001

   What to check: Have the front brakes, calipers and brake lines inspected, and ask for service records showing when rotors, pads and fluid were last replaced.

   2 excerpts from owner complaints in NHTSA records

   “I drive a 1994 Ford Explorer 4x4. My complaint is with the front brakes. When the inner brake pads wear to a certain point, they fall out of the channels that they slide in causing brake failure. When this happens, all that is left to stop the vehicle is the piston of the brake caliper. There is no wear indicator to warn the driver that disc pads are worn out. Please let me know if there is a recall on this problem.”

   NHTSA complaint #10287088, filed 2009-10, 150,000 miles

   “I bought my 1994 Ford Explorer (4wd) in may of 1999 and have had numerous problems since. The vehicle had approximately 50900 miles when I bought it. It now has 89000 miles. I have replaced the brake rotors twice and replaced the brake pads three times. The last time I completed brake work was because the left front caliper overheated and failed. I then replaced both front calipers. There is a bad vibration problem at speeds of 55-67 MPH. …”

   NHTSA complaint #10086453, filed 2004-08, 88,500 miles
4. 4
   Transmission and drivetrain

   Unexpected acceleration and cruise control trouble

   • 61 complaints (5%)
   • median 99,999 mi at 12.0 yrs old (11 state mileage)
   • 17 mention a crash, fire or injury
   • filed 1995–2012

   Complaints describe the vehicle gaining speed on its own, or the accelerator cable sticking, with brakes unable to stop it until the key was turned off. Others report cruise control not disengaging when the brake pedal is pressed, and one describes the transmission engaging during an inspection. Owners say the cable was repaired more than once without a lasting fix. Reported from about 57,000 to 180,000 miles, sometimes at low speed after a turn or at idle.

   What to check: Inspect the accelerator cable and throttle linkage for binding or makeshift repairs, and test that cruise control disengages when the brake pedal is pressed.

   2 excerpts from owner complaints in NHTSA records

   “I was sitting at a stop light all of a sudden the truck accelerated forward. The next event I was traveling about 40 miles an hour and the truck accelerated out of control and I was unable to stop it, the brakes wouldn't stop it, finally I turned the key off and it shut down. It's been happening on and off since then. It doesn't happen all the time, but, I never know when it will happen again. …”

   NHTSA complaint #10436124, filed 2011-11, 171,000 miles

   “I already sent a letter about this to Ford with a cc: to you folks. My complaint is regarding the acceloration cable on my Ford Explorer and you should have the letter on file from november 7th. Ford did respond (a month later) but are not taking any action on it.”

   NHTSA complaint #10050990, filed 2003-12, 57,103 miles
5. 5
   Body and structure

   Seat and seat-bracket breakage

   Mentioned in 4 of 60 sampled complaints

   Owners report the driver seat suddenly falling backward when a mounting bolt or bracket broke, and one describes the padded shield on a child seat splitting open. In the seat-bolt cases the seat no longer held the driver in place, and one owner says a related recall did not cover the vehicle. Reported from about 80,000 to 165,000 miles.

   What to check: Rock and recline both front seats and inspect the seat-to-floor brackets and bolts for cracks, rust or looseness.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle is 1994 Ford Explorer. For the third timein two years, the bracket that holds the driver seat to the floor has broken and had to be replaced. No one was injured only because the bracket fracture was noted. If there had been an accident, the entire seat would have separated from the floor and injury would be likely.”

   NHTSA complaint #10036797, filed 2003-08, 84,900 miles

   “While backing into garage the driver's seat suddenly and forcefully fell back. The thick steel seat bolt responsible fro holding the seat securely had broken in half. When the seat collapsed the consumer lost some control of the vehicle which caused the driver's side of the vehicle to scrape against the garage.”

   NHTSA complaint #10111425, filed 2005-02, 98,083 miles

Buying note. Ask for the VIN-specific recall history before buying, since several complaints note that a recall did not cover the vehicle, and have a technician check the wiring, brakes, tires and seat mounts on any high-mileage example.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.