Recalls
8campaigns
2 structure · 2 fuel system · 1 brake
Source: NHTSA
Complaints
609filed
Owner reports, 1987–1996 shown
Source: NHTSA ODI
Fuel economy
18mpg combined
$3,628/yr at this week's prices
Source: EPA · EIA
Specs
4 L 6-cyl· 5-speed manual
4 engine and transmission configurations
Source: NHTSA vPIC
Recalls (8)
NHTSA lists 8 recall campaigns for the 1991 Ford Explorer. Check whether yours was repaired with NHTSA's free VIN lookup ↗
Only NHTSA and your automaker know whether your specific car was repaired. PlainVIN shows every recall campaign listed for a model year, with the official text and how many cars have been fixed so far.
Check on NHTSA ↗Listed for 1991 Ford Explorer. Not checked against your VIN.
FORD/SUNROOF LABEL
Structure · body · roof and pillars
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported185,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 97V235001
Listed for 1991 Ford Explorer. Not checked against your VIN.
FORD/BRAKES:POWER ASSIST:PRIMARY:BOOSTER
Service brakes, hydraulic · power assist · hydraulic
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported108,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 96V024001
Listed for 1991 Ford Explorer. Not checked against your VIN.
INTERIOR SYSTEMS:ACTIVE RESTRAINTS:BELT BUCKLES
Seat belts · front · buckle assembly
Official NHTSA text
- Summary
- 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 SUFFICIENTLY TO PROVIDE OCCUPANT PROTECTION.
- 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.
Repair progress not yet reported565,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 92V113000
Listed for 1991 Ford Explorer. Not checked against your VIN.
POWER TRAIN:TRANSMISSION:AUTOMATIC
Power train · automatic transmission
Official NHTSA text
- Summary
- WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
- 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.
Repair progress not yet reported792,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 91V189000
Listed for 1991 Ford Explorer. Not checked against your VIN.
STRUCTURE:BUMPER ASSEMBLY:ATTACHMENTS/SUPPORT BARS
Structure · body · bumpers
Official NHTSA text
- Summary
- REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.
- 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.
Repair progress not yet reported220,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 91V026000
Listed for 1991 Ford Explorer. Not checked against your VIN.
FUEL:FUEL TANK ASSEMBLY:TANK
Fuel system, gasoline · storage · tank assembly
Official NHTSA text
- Summary
- THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.
- 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.
Repair progress not yet reported25,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 91V024000
Listed for 1991 Ford Explorer. Not checked against your VIN.
FUEL:FUEL TANK ASSEMBLY:TANK
Fuel system, gasoline · storage · tank assembly
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported18,000 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 91V025000
Listed for 1991 Ford Explorer. Not checked against your VIN.
VISUAL SYSTEMS:SUN ROOF HINGES (8/82)
Visibility · sun/moon roof assembly
Official NHTSA text
- Summary
- IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.
- 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.
Repair progress not yet reported2,500 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 90V098000
PlainVIN shows public government records for education. It isn't a vehicle inspection or legal advice. Check your own VIN with NHTSA or your dealer.
Owner complaints (609)
609 complaints filed with NHTSA (owner reports, not verified findings). The service brakes is mentioned most often.
57involved a crash
64involved a fire
44injuries reported
4deaths reported
As reported by owners in their complaints. These are reports, not NHTSA findings.
Most-reported components
| Component | Complaints | % of 609 |
|---|---|---|
| Service brakes | 120 | 19.7% |
| Tires | 102 | 16.7% |
| Power train | 69 | 11.3% |
| Electrical system | 52 | 8.5% |
| Engine and engine cooling | 52 | 8.5% |
| Suspension | 33 | 5.4% |
| Visibility | 32 | 5.3% |
| Structure | 31 | 5.1% |
| Vehicle speed control | 30 | 4.9% |
| Equipment | 29 | 4.8% |
How 1991 compares with other Explorer years
Best and worst Explorer years →19873
19884
19891
199012
1991609
1992633
1993939
19941,207
1995843
19961,450
| Model year | Complaints | Recall campaigns |
|---|---|---|
| 1987 | 3 | 0 |
| 1988 | 4 | 0 |
| 1989 | 1 | 0 |
| 1990 | 12 | 0 |
| 1991 | 609 | 8 |
| 1992 | 633 | 4 |
| 1993 | 939 | 6 |
| 1994 | 1,207 | 4 |
| 1995 | 843 | 5 |
| 1996 | 1,450 | 6 |
This year (1991)Other yearsStill collecting reports
Counts are owner reports, not failure rates. Higher sales years tend to draw more reports. Owners are still filing reports for recent model years, so these counts will grow. Source: NHTSA ODI, retrieved Oct 6, 2026.
Fuel economy: up to 18 mpg combined
18
mpg combined
16
city
21
highway
- EPA annual fuel cost
- $3,700
- CO₂ tailpipe
- 494 g/mi
- EPA class
- Special Purpose Vehicle
What it costs you to run
$3,628per year
$302per month
833gallons a year
Miles ÷ 18 mpg × $4.354 (EIA US average regular, week of Oct 5, 2026, all taxes included). Source: EPA · EIA.
EPA label estimates from lab tests; your mileage will vary.
Specs by configuration
| Engine · transmission | Drive | City / Hwy / Comb | EPA $/yr | CO₂ g/mi |
|---|---|---|---|---|
| 4 L 6-cyl · 5-speed manual | Rear-Wheel Drive | 16 / 21 / 18 | $3,700 | 494 |
| 4 L 6-cyl · 4-speed automatic | Rear-Wheel Drive | 15 / 20 / 16 | $4,200 | 555 |
| 4 L 6-cyl · 4-speed automatic | 4-Wheel or All-Wheel Drive | 14 / 19 / 16 | $4,200 | 555 |
| 4 L 6-cyl · 5-speed manual | 4-Wheel or All-Wheel Drive | 15 / 19 / 16 | $4,200 | 555 |
Source: EPA fuel economy data, retrieved Oct 6, 2026. Configurations are listed when EPA and NHTSA records match.
Looking at a 1991 Explorer for sale?
Print a one-page buyer's checklist: each recall campaign with a box to tick when the seller shows proof of repair, the top complaint areas to inspect, crash stars, MPG, and a link back to this page.
Where to next
1991 Ford Explorer FAQ
How many recalls does the 1991 Ford Explorer have?
NHTSA lists 8 recall campaigns: 97V235001 (structure), 96V024001 (brake), 92V113000 (seat belt), 91V189000 (power train), 91V026000 (structure), 91V024000 (fuel system), 91V025000 (fuel system), 90V098000 (visibility). Use NHTSA's VIN lookup to see whether a specific car was repaired.
What are the most common 1991 Ford Explorer problems?
Owners filed 609 complaints with NHTSA. Service brakes (120), Tires (102), Power train (69) are mentioned most. These are owner reports, not verified findings.
What mpg does the 1991 Ford Explorer get?
EPA rates the 4 L 6-cyl · 5-speed manual version at 16 city, 21 highway and 18 combined mpg. Other configurations are listed in the fuel economy section.
How does the 1991 Explorer compare with other years?
Among the 1987–1996 Ford Explorer model years at least five years old, the 1989 drew the fewest complaints (1) and the 1996 the most (1,450). The 1991 drew 609. Counts are owner reports, not failure rates.
How this page was madeSources, processing, limits, review and changes
Data sources
- NHTSA recalls by vehicle
Retrieved Oct 6, 2026 - US DOT recall completion rates (data.transportation.gov)
Retrieved Oct 6, 2026 - NHTSA ODI owner complaints
Retrieved Oct 6, 2026 - NHTSA NCAP 5-Star Safety Ratings
Retrieved Oct 6, 2026 - EPA fuel economy data (licence confirmation pending)
Retrieved Oct 6, 2026 - EIA weekly retail gasoline prices
Weekly, all taxes included
Processing
- Complaints are counted per component. One complaint can list several, so component totals add up to more than the total.
- Fuel cost = miles per year ÷ EPA combined mpg × EIA weekly price for your region.
Limitations
- Complaint counts are owner reports, not verified findings or failure rates. There is no sales denominator.
- Recall campaigns are listed for the model year. Only NHTSA and the automaker know whether a specific car was repaired.
- Recent model years are still collecting reports.
Review
Data compiled automatically from the official files listed here.
Changelog
- 2026-10-06 Data refreshed from the official files.
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