1991 Ford Explorer recalls & complaints

Component: TIRES:TREAD/BELT
Summary: THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.
Consequence: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.
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Component: TIRES:TREAD/BELT
Summary: TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE TIRE TREAD.
Consequence: IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE ASSISTANCE.
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Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
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.
Notes: SYSTEM: VAPOR VENT VALVE CARRIER WELD TO PLASTIC FUEL TANK.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES.

Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
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.
Notes: SYSTEM: FUEL TANK AND HEAT SHIELD.VEHICLE DESCRIPTION : MULTI-PURPOSE PASSENGER VEHICLE.

Component: STRUCTURE:BODY:ROOF AND PILLARS
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.
Notes: OWNER NOTIFICATION BEGAN MARCH 2, 1998. OWNERS WHO DO NOT RECEIVE THE INSTRUCTION BOOKLET AND WARNING LABEL WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

Component: STRUCTURE:BODY:BUMPERS
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.
Notes: SYSTEM: REAR BUMPER REINFORCEMENT.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLE.NOTE: BUMPER MOUNTED TRAILER HITCH BALL ASSEMBLY SHOULD NOT BE USED UNTIL REPAIRPROCEDURE IS COMPLETED.

Component: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC
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.
Notes: SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLY
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.
Notes: SYSTEM: SAFETY BELT BUCKLE.VEHICLE DESCRIPTION: PASSENGER CARS AND UTILITY VEHICLES.NOTE: ONLY THE END RELEASE BUCKLES ON "RIGID" MOUNTINGS ARE SUSCEPTIBLE TO THISMALFUNCTION, THE WEB-MOUNTED FRONT CENTER END RELEASE BUCKLES AND THEWEB-MOUNTED REAR FACING THIRD SEAT END RELEASE BUCKLES IN TAURUS OR SABLEVEHICLES WILL NOT BE REPLACED. ALSO, THE WEB-MOUNTED FRONT CENTER BUCKLES INEXPLORER VEHICLES WILL NOT BE REPLACED.

Component: VISIBILITY:SUN/MOON ROOF ASSEMBLY
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.
Notes: SYSTEM: SUNROOF HINGES.VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER 4-DOOR VEHICLES WITH SUNROOFS.

Component: STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT
Summary: VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. THE CAMPAIGN WILL REINFORCE THE BRACKET ATTACHMENTS OF THE REAR LIFTGATE GAS ASSIST CYLINDERS WHICH COULD PULL AWAY FROM THE INSIDE OF THE LIFTGATE.
Consequence: IF A BRACKET AND GAS ASSIST CYLINDER WERE TO DETACH COMPLETELY FROM THE LIFTGATE AND NO LONGER BEAR AGAINST THE LIFTGATE AS INTENDED, THE REMAINING ASSIST CYLINDER WOULD NOT HOLD THE LIFTGATE IN AN OPEN POSITION. PERSONAL INJURY COULD OCCUR.
Remedy: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.
Notes: FORD HAS DECIDED TO CONDUCT A SAFETY IMPROVEMENT SERVICE CAMPAIGN TO REINFORCE THE BRACKET ATTACHMENTS WITHOUT CHARGE. OWNERS CAN CONTACT FORD AT 1-800-392-3673.

Component: POWER TRAIN:AUTOMATIC TRANSMISSION
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.
Notes: SYSTEM: TRANSMISSION.VEHICLE DESCRIPTION: PICKUP TRUCKS, VANS, AND MULTI-PURPOSE VEHICLES EQUIPPEDWITH A4LD AUTOMATIC TRANSMISSIONS.

12/20/2021 · Brakes · crash
The component that malfunctioned was the abs sensor. It is not available for inspection. I was driving going around 45 in traffic and the drivers side rear brake locked up and spun me out of control and caused me to collide with another vehicle. I only lightly pressed the brakes and it happened suddenly and unexpectedly. It was not inspected before it was t…

05/07/2015 · Seat belts
TL* THE CONTACT OWNS A 1991 FORD EXPLORER. WHILE DRIVING 15 MPH WITH ANOTHER PASSENGER, THE SEAT BELTS DISENGAGED AND CAUSED THE PASSENGER SEAT TO OVERTURN BETWEEN THE SEATS. THE PASSENGER WAS NOT INJURED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 91,000.

07/05/2013 · Fuel system · fire
ON JUNE 4TH MY DAUGHTER AND I WERE DRIVING EAST BOUND ON 62ND AND OVER-HILL IN LOS ANGELES CA. SHORTLY AFTER 12:00PM. WHEN SUDDENLY THE FORD EXPLORER WAS ENGULFED IN FLAMES. MY DAUGHTER AND I WERE ORDERED TO EXIT THE VEHICLE. I WAS NEVER NOTIFIED OF A RECALL. DUE TO INVESTIGATION ON MY OWN I HAVE RECEIVED A RECALL NUMBER. IT IS 96S35. I HAVE ATTEMPTED…

10/21/2011 · Wheels / tires
I PURCHASED TWO MICHELIN LTX MS2 235/75R15 TIRES FROM TIRE RACK.COM, E732381. THEY WERE DELIVERED SEPTEMBER 15, 2011 WITH AN INCORRECTLY COMPLETED OMB CONTROL NO. 2127-0050 TIRE REGISTRATION CARD. THE CARD LISTED THE BRAND AS BF GOODRICH AND THE TIRE IDENTIFICATION NUMBERS AS BETJMX912711. THE TIRES I RECEIVED ARE MICHELIN B3DDDVOX2511 ACCORDING TO…

10/25/2009 · Wheels / tires
UNIROYAL TIRE SIDE WALL CRACKS LT 235 75R15 - NO FAILURE - JUST CRACK. ALL 4 OF MY TIRES HAD A SIDE WALL CRACK THE ENTIRE DIAMETER OF THE TIRE ABOUT 3 INCHES DOWN ON THE SIDE WALL . I NOTICED THE CRACK ON THE INSIDE AS WELL SO IT APPEARS THE TIRES HAD SOME ISSUE. I HAD NEVER APPLIED TIRE FOAM CLEANER(ARMOR ALL TIREFOAM PRIOR ) BUT ONE TIME THIS LAST…

04/30/2009 · Engine · fire
TL*THE CONTACT OWNS A 1991 FORD EXPLORER. WHILE DRIVING 5 MPH ON A DRIVEWAY INCLINE, THE ENGINE IDLED EXCESSIVELY HIGH AND THE VEHICLE STALLED UNEXPECTEDLY. THE ENGINE RESTARTED AND RESUMED NORMAL OPERATION. THE CONTACT DETECTED SMOKE INSIDE AND OUTSIDE OF THE VEHICLE AND IMMEDIATELY TURNED OFF THE ENGINE. THE VEHICLE WAS INSPECTED UNDERNEATH THE HOOD A…

09/08/2008 · Electrical system · fire
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 WAS CONSUMED IN FLAMES. THE VEHICLE WAS DESTROYED AND A POLICE REPORT WAS FILED. THE…

03/27/2008 · Vehicle Speed Control
TL*THE CONTACT OWNS A 1991 FORD EXPLORER. AFTER RECEIVING THE RECALL NOTICE FOR THE VEHICLE SPEED CONTROL: CRUISE CONTROL, THE CONTACT CALLED THE DEALER. THE DEALER STATED THAT THEY DID NOT HAVE THE PART FOR THE REPAIR; HOWEVER, THE RECALL STATED THAT THEY WERE AVAILABLE. THEY DID NOT KNOW WHEN THE PARTS WOULD ARRIVE. THERE HAD BEEN NO FAILURE TO DATE.…