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1991 Ford Explorer Recalls, Problems & Maintenance

The 1991 Ford Explorer has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Spare tire carrier cable corrosion and detachment.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 1991 Ford Explorer.

Reported to NHTSA

Spare tire carrier cable corrosion and detachment

EQUIPMENT

6 NHTSA complaints · 2000-11 → 2005-04

“WHILE DRIVING SPARE TIRE CARRIER, LOCATED UNDERNEATH VEHICLE, SEPARATED DUE TO CORROSION. DEALER HAS BEEN NOTIFIED.*AK THE TIRE IS HELD BY A SINGLE METAL ROPE WITH NO PROVISION FOR BACK UP IN CASE OF FAILURE. *NLM”
— Owner report, NHTSA ODI #896503
“CABLE THAT HOLDS SPARE TIRE UNDER REAR OF VEHICLE BROKE, CAUSING SPARE TIRE TO FALL. CONSUMER WAS NOT AWARE OF THIS UNTIL VEHICLE WAS TAKEN IN TO HAVE SPARE TIRE REPLACED.*AK UPON INSPECTION, THE CABLE WAS FOUND RUSTED THROUGH AND THE TIRE SUPPORT MECHANISM WAS MISSING. *SLC”
— Owner report, NHTSA ODI #875772
“DUE TO CLIMAX OF WEATHER IN THIS STATE WIRE THAT USED TO SUPPORT SPARE TIRE UNDERNEATH VEHICLE RUSTED, AND BROKE, CAUSING SPARE TIRE TO DROP IN MIDDLE OF ROAD. DEALER HAS BEEN CONTACTED.*AK”
— Owner report, NHTSA ODI #876138

Read all complaints on NHTSA →

Liftgate gas-assist cylinder bracket failure

STRUCTURE

5 NHTSA complaints · 2002-02 → 2006-11

“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. *AK *SC *JB”
— Owner report, NHTSA ODI #10115396
“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”
— Owner report, NHTSA ODI #10072879
“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”
— Owner report, NHTSA ODI #9006016

Read all complaints on NHTSA →

Seat belt buckle latching and release failures

SEAT BELTS

8 NHTSA complaints · 2000-10 → 2015-05

“DT*: THE CONTACT STATED 4 OUT OF THE 5 SAFETY BELTS IN THE VEHICLE WOULD NOT LATCH PROPERLY. IF THEY WERE SHAKEN, OR IF THERE WAS ANY FORCE APPLIED TO THEM THEY BECAME UNLATCHED. THE VEHICLE WAS NOT TAKEN IN FOR SERVICE. THE MANUFACTURER WAS NOTIFIED. THERE WAS A NHTSA”
— Owner report, NHTSA ODI #10167153
“WHEN ATTEMPTING TO LATCH SEATBELTS IN THE FRONT OF VEHICLE LATCH IS NOT SECURING SEATBELT. SOMETIMES IT SEEMS TO BE LATCHED AND WHILE DRIVING DOWN THE ROAD THE SEATBELT BUCKLE PULLS OUT OF THE LATCH.*AK”
— Owner report, NHTSA ODI #739763
“VEHICLE NOT INCLUDED IN RECALL 92V113000. SEAT BUCKLE WILL NOT UNLATCH WHEN RELEASE BUTTON IS DEPRESSED, RESULTING FROM A MALFUNCTION WITHIN BUCKLE INJECTOR. PLEASE GIVE ANY FURTHER DETAILS.*AK”
— Owner report, NHTSA ODI #891283

Read all complaints on NHTSA →

Wheel and bearing separation while driving

WHEELS

11 NHTSA complaints · 2001-01 → 2005-03

“WHILE DRIVING AT A LOW SPEED CONSUMER HEARD A DRAGGING NOISE. UPON PULLING OVER TO INSPECT THE VEHICLE THE LEFT FRONT WHEEL AND ITS ATTACHMENTS SEPARATED AND FELL OFF. *AK”
— Owner report, NHTSA ODI #10051880
“THE FRONT WHEEL BROKE OFF, WHICH CAUSED CONSUMER TO LOSE CONTROL OF THE VEHICLE. *JB”
— Owner report, NHTSA ODI #10008921
“WHILE DRIVING 55 MPH WHEEL ON THE RIGHT REAR CAME OFF. ONLY WARNING WAS THAT VEHICLE STARTED TO VIBRATE. CONTACTED DEALER, AND DEALER SAID THIS THIS WAS NOT A DEFECT. *AK”
— Owner report, NHTSA ODI #891248

Read all complaints on NHTSA →

Radius arm bushing and bracket failure

SUSPENSION

5 NHTSA complaints · 2001-01 → 2002-07

“MANUFACTURER'S RECALL 94M85 REPAIRS FOR RADIUS ARM BUSHING ON RIGHT SIDE WAS PERFORMED IN JANUARY 1995. RADIUS ARM BUSHING ON RIGHT SIDE FAILED AGAIN, ALLOWING VEHICLE TO HAVE POOR STABILITY AFTER ROLLING OVER UNEVEN PAVEMENTS/BUMPS. MANUFACTURER WAS DENYING ANY”
— Owner report, NHTSA ODI #8014509
“HAVE HAD TO REPLACE RADIUS ARM BRACKETS TWICE ALREADY SINCE WE HAVE OWNED THIS VEHICLE IN THE PAST 3 YRS AND THE BUSHINGS ARE SQUEAKING AGAIN SO I AM SURE THE BRACKETS ARE CRACKED AGAIN. THIS IS GETTING REDICULOUS AND I WOULD LIKE TO KNOW WHY THESE CRACK SO EASILY AND”
— Owner report, NHTSA ODI #746534
“HAVE HAD 3 CERTIFIED MECHANICS LOOK AT THIS VECHICAL ALL WITH THE SAME CONCLUSION THE RADIAL ARM BUSHINGS HAVE PREMATURLY FAILED DUE TO A DEFFECT WHEN CAR WAS BUILT.*AK”
— Owner report, NHTSA ODI #739810

Read all complaints on NHTSA →

Tire tread separation and blowouts

TIRES

47 NHTSA complaints · 2000-09 → 2004-04

“AFTERM ARKET FIRESTONE ATX TIRE P235/75R15 SIZE. LEFT FRONT AND LEFT REAR TREAD SEPARATED AT HIGHWAY SPEEDS, CAUSING VEHICLE TO ROLL OVER, EJECTING AND KILLING THE DRIVER.*AK *MJS”
— Owner report, NHTSA ODI #872101
“PE00 020; CONSUMER WAS TRAVELING ABOUT 65MPH ON HIGHWAY WHEN THE TREAD SEPARATED FROM TIRE. DRIVER LOST CONTROL OF VEHICLE, AND IT FLIPPED OVER. THERE WERE SIX PASSENGERS INSIDE OF VEHICLE. VEHICLE WAS TOTALED . THEY WERE ON THE ROAD ABOUT TWO HOURS BEFORE ACCIDENT”
— Owner report, NHTSA ODI #873299
“LEFT REAR FIRESTONE ATX TIRE EXPERIENCED BLOWOUT, VEHICLE FISHTAILED AND CONSUMER LOST CONTROL OF VEHICLE, VEHICLE ROLLED AND CONSUMER WAS INJURED AND PINNED UNDER VEHICLE, VEHICLE WAS TOTALED, TIRE SIZE IS P235/75R15, DOT VDHL1PM136. *SLC”
— Owner report, NHTSA ODI #882125

Read all complaints on NHTSA →

Fires originating in the electrical system

ELECTRICAL SYSTEM

11 NHTSA complaints · 2001-08 → 2008-09

“TL*THE CONTACT OWNED A 1991 FORD EXPLORER. WHILE DRIVING 40 MPH, THE CONTACT NOTICED SMOKE COMING FROM THE INSTRUMENT PANEL. THE VEHICLE FAILED TO RESTART. SHE MANAGED TO MANEUVER THE VEHICLE TO THE SHOULDER AND LEFT TO CALL FOR HELP. UPON RETURNING TO THE VEHICLE, IT”
— Owner report, NHTSA ODI #10241375
“WHILE WAITING AT A STOP LIGHT AFTER DRIVING ONLY 2 MILES CONSUMER NOTICED SMOKE FROM UNDER THE HOOD, SHE PULLED OVER AND SAW FLAMES FROM UNDER THE HOOD ON LEFT SIDE. FIRE DEPARTMENT PUT OUT FIRE. VEHICLE WAS TOTALLED. ALSO DASH BURNED. *AK THE INSURANCE COMPANY STATED”
— Owner report, NHTSA ODI #898759
“ELECTRICAL WIRING HARNESS INSIDE THE DASHBOARD IGNITED, AND VEHICLE CAUGHT ON FIRE. THIS OCCURRED WHILE VEHICLE WAS PARKED IN THE DRIVEWAY. *AK”
— Owner report, NHTSA ODI #10044955

Read all complaints on NHTSA →

Brake pedal, pad and rear lockup failures

SERVICE BRAKES, HYDRAULIC

13 NHTSA complaints · 2000-12 → 2021-12

“WAS DRIVING BETWEEN 30-35MPH ON WET ROAD WENT TO APPLY THE BRAKES AND PEDAL WENT TO FLOOR. STEERED VEHICLE TO LEFT TO SLOW DOWN. VEHICLE STARTED SKIDDING. HIT A TREE STUMP AND VEHICLE FLIPPED OVER. VEHICLE WAS TOTALED. OUT OF VEHICLE, AND NOTICED PADS HAD FALLEN OFF”
— Owner report, NHTSA ODI #6900646
“VEHICLE IS A 1991 FORD EXPLORER XLT EDDIE BAUER EDITION, 4X4 5-SPEED MANUAL TRANSAXLE, 4.0L V6. VEHICLE IS EQUIPPED WITH REAR-WHEEL ANTI-LOCK BRAKES. BOTH REAR WHEELS PERFORM UNCOMMANDED FULL LOCKUP AFTER MEDIUM APPLICATION OF BRAKE PEDAL. CONDITION PERSISTS EVEN WHEN”
— Owner report, NHTSA ODI #10082713
“REAR BRAKES FAILED WITHOUT ANY WARNING OR INDICATION LATER CAUSING FRONT BRAKES TO FAIL. *AK”
— Owner report, NHTSA ODI #754765

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

659 crashes 1990–2024

How the 659 occupant deaths break down

430

driver deaths

229

passenger deaths

659

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 1991 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

57

complaints mentioning a crash

73

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 1991 Ford Explorer reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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