1991 FORD EXPLORER

11 recalls, 764 complaints - 64 TSBs

TIRES:TREAD/BELT

Defect Description

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... Read more

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.

13,000,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

TIRES:TREAD/BELT

Defect Description

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 T... Read more

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.

14,400,000 vehicles affected

Manufacturer: BRIDGESTONE/FIRESTONE, INC.

STRUCTURE:BODY:ROOF AND PILLARS

Defect Description

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.

185,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC

Defect Description

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.

108,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

Defect Description

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 COU... Read more

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.

1,029,380 vehicles affected

Manufacturer: FORD MOTOR COMPANY

SEAT BELTS:FRONT:BUCKLE ASSEMBLY

Defect Description

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 MA... Read more

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.

565,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

POWER TRAIN:AUTOMATIC TRANSMISSION

Defect Description

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 VEH... Read more

Remedy

REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

792,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

STRUCTURE:BODY:BUMPERS

Defect Description

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.

220,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

Defect Description

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.

18,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

Defect Description

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.

25,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

VISIBILITY:SUN/MOON ROOF ASSEMBLY

Defect Description

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.

2,500 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

764 total complaints 70 crashes 73 fires 60 injuries 4 deaths

Top Reported Components

Component	Complaints
TIRES:TREAD/BELT	54
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	52
TIRES	52
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	25
POWER TRAIN:AUTOMATIC TRANSMISSION	22
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER	20
VEHICLE SPEED CONTROL	20
ENGINE AND ENGINE COOLING:ENGINE	18
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	17
ELECTRICAL SYSTEM:IGNITION:SWITCH	16

Incident date: Dec 16, 2021

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 sudd... Read more

Crash

Incident date: May 7, 2015

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. T... Read more

Incident date: Jun 4, 2010

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 HAV... Read more

Fire

Incident date: Sep 15, 2011

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. ... Read more

Incident date: Oct 25, 2009

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 FOA... Read more

Incident date: Apr 28, 2009

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 T... Read more

Fire 1 injured

Incident date: Sep 3, 2008

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. TH... Read more

Fire

Incident date: Aug 7, 2007

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 T... Read more

Incident date: Aug 16, 2007

TL*THE CONTACT OWNS A 1991 FORD EXPLORER. THE CONTACT EXPERIENCED AUTOMATIC TRANSMISSION FAILURE. HE TOOK THE VEHICLE TO A MECHANIC AND THEY CLAIMED TO REPAIR IT, BUT ACTUALLY DID NOT. THE VEHICLE FAILED AND WAS TOWED TO A FORD DEALER AND THEY REPLACED THE CRUISE CONTROL SWITCH. THE AUTOMATIC TR... Read more

Incident date: Aug 16, 2007

Incident date: Nov 22, 2006

COPY OF LETTER TO FMC: I OWN A 1991 FORD EXPLORER 4WD XLT [XXX]. I PURCHASED THIS VEHICLE ON 11/9/96, FROM CROWN DODGE, VENTURA, CALIFORNIA. THE SELLING DEALER ASSURED ME AT THE TIME THAT NO RECALLS WERE OUTSTANDING ON THIS VEHICLE. ON NOVEMBER 11/22/06, AS I CLOSED THE HATCH ON THIS VEHIC... Read more

Incident date: Sep 25, 2006

I HAVE JUST PURCHASED A VEHICLE NOT TOO LONG AGO THAT HAS THE WILDERNESS HT TIRES ON IT THAT LOOK VERY UNSAFE. I LOOKED THEM UP ON YOUR WEBSITE AND THEY WERE RECALLED. IS THERE ANYWAY I COULD GET A RECALL INFO SHEET TO REPLACE THE TIRES ON THE VEHICLE...THERE ARE HARDLY ANY MILES ON THE TIRES AND I... Read more

Incident date: May 15, 2006

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 RECALL # 92V113000, PERTA... Read more

Incident date: Jan 1, 2006

I HAVE CONTACTED THE LOCAL DEALERSHIP IE.. HANSEL FORD AND CURTIS FORD. THE SERVICE DEPARTMENT STATED THAT SINCE MY VEHICLE (1991) FORD EXPLORER WAS OVER 10 YEARS. OLD THEY NO LONGER HAD ANY INFORMATION ON RECALLED PARTS OR RECALLED PAINT ECT. PLEASE MAIL OR E-MAIL ME A COMPLETET LIST OF ALL RECALLS... Read more

Incident date: Jun 10, 2005

VEHICLE CAUGHT FIRE AND WAS A TOTAL LOSS

Fire

Incident date: Jun 30, 2005

DT: THE CONSUMER SMELL SMOKE, AND THEN SOME SMOKE STARTED COMING OUT OF THE LEFT SIDE OF THE HOOD. ALL OF THE GAUGES LOOKED OKAY AND THE CONSUMER THOUGHT IT WAS OVERHEATING. THEN THE CAR CAUGHT ON FIRE FAST WITH SMOKE ON THE LEFT AND FIRE ON THE RIGHT OF THE HOOD AND BURNED ALL THE WAY TO THE BAC... Read more

Fire

Incident date: Apr 7, 2005

SPARE TIRE WINCH CABLE ON 1991 FORD EXPLORER FAILED AT INTERSECTION FOLLOWING BUMP ON REAR FROM ANOTHER MOTORIST. NO DAMAGE TO REAR BUT CORRODED CABLE BROKE AND TIRE FELL TO GROUND.*AK

Incident date: Apr 5, 2005

I FOUND SEVERAL RECALLS FOR MY VEHICLE. IT IS AN OLD VEHICLE, BUT I ONLY BOUGHT IT IN 2003. I KNOW SOME OF THEM EXPIRED, AND IT SAYS TO CONTACT FOD. I DID VIA WEB SITE. THEY DO NOT SHOW ANY RECALLS. BUT, YOU SHOWED ME OVER 5 RECALLS? CAN I STILL GET THEM FIXED? MY TIRES I GUESS, HAVE BEEN REPLACED B... Read more

Incident date: Apr 5, 2005

Incident date: Mar 29, 2005

PENINSULA FORD, SUNNYVALE, CA REFUSED TO SERVICE EXISTING SAFETY RECALL, WITHOUT EXPLANATION. NHTSA CAMPAIGN 92V113000. THE VEHICLE IN QUESTION FITS ALL APPLICABILITY CRITIERIA LISTED IN RECALL DOCUMENTS. ONE OF THREE SYMPTOMS (UNEXPLAINED AND REPEATED, SUDDEN FRONT SEAT BELT RELEASE) DESCRIBED B... Read more

Incident date: Feb 2, 2004

MY WIFE [XXX] WAS DRIVING MY 1991 FORD EXPLORER TO SEE HER SON ON 2-2-04( AND NEVER USES CRUISE CONTROL)WHEN ON HWY 161 HEADING NORTH THE CRUISE CONTROL TOOK OVER AND MADE THE THROTTLE STICK WIDE OPEN, THE BRAKES WOULD NOT HOLD AND VEHICLE WENT UP TO ABOUT 70 BEFORE SHE FINALLY TURNED OFF KEY, THE B... Read more

Crash 1 injured

Incident date: Jan 28, 2003

AFTER PURCHASING THIS FORD EXPLORER I CHECK ALL FLUIDS AND ADDED AND CHANGED AS NESSASARY ABOUT 2 WEEKS AFTER I PURCHASED IT MY STEPSON AND MY WIFE AND LARGE DOG WENT ON A LITTLE TRIP TO CHECK OUT THIS THING, AFTER LETTING OUT THE WIFE AND DOG MY STEPSON AND MYSELF TRIED TO GO UP A SLIGHT HILL IN 4 ... Read more

1 injured

Incident date: Dec 23, 2004

ON DEC 23, 2004, MY 1991 FORD EXPLORER CAUGHT FIRE WHILE I WAS DRIVING IT. THE VEHICLE WAS DESTROYED. THE VEHICLE HAD 208,000 MILES ON IT. IT HAD BEEN PROFESSIONALY SERVICED A WEEK PRIOR TO THE FIRE. WHILE I WAS DRIVING, I NOTICED A BURNING SMELL. I LOOKED IN THE REAR-VIEW MIRROR & SAW SOME WHITE ... Read more

Fire

Incident date: Mar 17, 2005

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

Incident date: Jan 29, 2005

COMPLAINT RECEIVED VIA E-MAIL. THE BRAKE LIGHTS ON MY 1991 FORD EXPLORER CANNOT BE MADE TO WORK CONSISTENTLY. THIS PRESENTS AN OBVIOUS SAFETY HAZARD TO THE DRIVERS FOLLOWING MY VEHICLE. WHEN I HIT MY BRAKES THEY CAN'T TELL. I HAVE BEEN REAR ENDED TWICE ALREADY, AND I AM TIRED OF IT. BUT FORTUNATEL... Read more

Crash

Incident date: Jan 31, 2005

I WAS DRIVING AND ALL OF A SUDDEN THE TRASMISSION SLIPPED AND I WOUDNT GO FORWARD TEN SMOKED POURED OUT AND PEOPLE IN THE STREETS STARTED YELLING SAYING "THERE'S FIRE COMING OUT THE HOOD!!" I PULLED OVER AND JUMPED OUT AND THE WHOLE ENGINE WAS ENGULFED IN FLAMES!!! VEHICLE TOTALLED. *AK

Fire

Incident date: Dec 14, 2004

TRANSMISSION WENT OUT, THEN THE FRONT MAIN SEAL. IT HASN'T BEEN TWO MONTHS AND THEN MY HEATER CORE WENT OUT AND AT THE SAME TIME MY HEATER FAN. ALSO, BEFORE THE FRONT MAIN SEAL WENT OUT THE ROTORS WENT BAD AND I STILL HAVE PROBLEMS WITH THE BRAKING SYSTEM. THIS HAS ALL HAPPENED WITHIN A YEARS TIME. ... Read more

Incident date: Dec 14, 2004

Incident date: Nov 8, 2004

THE CONSUMER HAD TAKEN THE VEHICLE TO THE DEALER FOR ENGINE REPAIRS. THE CONSUMER WAS TOLD THAT THE VEHICLE WAS READY TO BE DRIVEN. THE CONSUMER WENT TO THE GAS STATION BECAUSE THERE WAS NO FUEL IN IT. WHEN THE CONSUMER WAS LEAVING THE GAS STATION, THE VEHICLE LOST ITS FRONT WHEEL. IT WAS THEN D... Read more

Incident date: Nov 8, 2004

Incident date: Oct 8, 2004

TRAVELING 40 MPH IN NORMAL WEATHER IN MODERATE TRAFFIC. HOOD LATCH FAILED CAUSING HOOD TO FLY OPEN AND BLOCK VISIBILITY. WAS ABLE TO COME TO A SAFE STOP AND CLOSE THE HOOD. RESULTED DAMAGE TO THE HOOD, HINGES AND COWLING,(IN ADDITION TO SCARING ME BADLY). PRESENTLY BEING INSPECTED BY A MECHANIC.... Read more

Incident date: Jul 26, 2004

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 PRESSURE TO THE BRAKE PEDAL IS ... Read more

Incident date: Jan 1, 1901

LETTER REGARDING RECALL 03S04 SEAT RECLINER BOLT..*MR (NAR) *CB THE CONSUMER STATED THE AIR BAG LIGHT ILLUMINATED. IT WAS DISCOVERED THAT A NEW WIRING HARNESS WAS NEEDED. *JB

Incident date: Jan 1, 1901

LETTER REGARDING RECALL 03S04 SEAT RECLINER BOLT..*MR (NAR) *CB THE CONSUMER STATED THE AIR BAG LIGHT ILLUMINATED. IT WAS DISCOVERED THAT A NEW WIRING HARNESS WAS NEEDED. *JB

Incident date: Jan 1, 1901

TIRE BLOW OUT OCCURRED. NAR 07/02/2003. *MR FORD INITIATED A PROGRAM TO GIVE AWAY TIRES TO THEIR CUSTOMERS. WHEN THE CUSTOMERS WANTED TO RECEIVE THE TIRES, THE DEALERSHIP DID NOT HAVE THEM AVAILABLE. NOW THAT THE PROGRAM HAS EXPIRED THEY HAVE NOT GIVEN OUT ANY OF THE REPLACEMENT TIRES TO THE CONS... Read more

Incident date: Jan 1, 2001

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 VEHI... Read more

Incident date: Apr 2, 2004

I HAVE A FIRESTONE ATX SPARE TIRE AS ORIGINAL EQUIPMENT ON MY 1991 FORD EXPLORER. BOTH FORD AND FIRESTONE PARTICIPATED IN A RECALL OF THESE TIRES. I WAS NEVER CONTACTED ABOUT THE RECALL. I HAVE CONTACTED BOTH FORD AND FIRESTONE CUSTOMER SERVICE TO GET THIS TIRE REPLACED AND THEY SAY THEY CAN NO LON... Read more

Incident date: Mar 15, 2004

THE RIGHT SUPPORT GAS ASSIST CYLINDER ON THE LIFTGATE FAILED AND PULLED AWAY AND BROKE OFF COMPLETELY, THEREFORE THE LIFTGATE WILL NOT HOLD ON ITS OWN. *AK

Incident date: Jan 1, 2004

SEAT BELTS ARE REQUIRED BY LAW. CHILD SAFETY RESTRAINT IS REQUIRED BY LAW. I OWN A 1991 FORD EXPLORER, OH YES, THE ONE SO MANY PEOPLE HAVE BEEN INJURED OR KILLED IN BECAUSE OF FIRESTONE TIRES?????, OR MAYBE IT WAS THE SEAT BELTS. FORD MOTOR COMPANY HAS OBSOLETED THE SEAT BELT BUCKLE FOR THE CENT... Read more

Incident date: Nov 27, 2003

SUN ROOF FAILURE . *AK

Incident date: Dec 21, 2003

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

Incident date: Dec 21, 2003

WHILE DRIVING 10 MPH AFTER HEARING A STRANGE DRAGGING NOISE MY LEFT WHEEL CAME OFF AFTER RETREIVING THE TIRE I NOTICED THE ROTOR BRAKE CHAMBER WAS STILL BOLTED TIGHTLY TO THE WHEEL SOME BEARINGS LOOKED LIKE THEY HAD FALLEN OUT THE BRAKE LINE WAS SNAPPED THE SUSPENTION AROUND THE WHEEL WAS BROKEN I H... Read more

Incident date: Dec 1, 2003

I BOUGHT A 1991 FORD EXPLORER 1 1/2 YEARS AGO FROM A NEIGHBOR WHO SAID HE WAS TIRED OF PUTTING BRAKES ON IT. SINCE HE HAD JUST DONE IT AGAIN, I DIDN'T EXPECT ANY TROUBLE FOR A WHILE. 17,000 MILES LATER, ALL BRAKE PADS, CALIPERS ETC., NEEDED TO BE REPLACED AGAIN. IT IS AVERAGING 20,000 MILES ON THIS ... Read more

WHILE DRIVING THE VEHICLE THE DRIVER SMELLED GAS COMING FROM THE VEHICLE. THE CONSUMER STOPPED THE VEHICLE AND NOTICED GAS LEAKING FROM THE FUEL TANK. THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALERSHIP. PLEASE ADD ANY FURTHER DETAILS. *NLM

FUEL IS SPILLING OUT FROM THE FUEL TANK. THERE'S A RECALL 91V024000 FOR THE FUEL TANK ASSEMBLY. THE MANUFACTURER IS NOT PROVIDING PROPER INFORMATION. THEY ARE INDICATING THAT THE VIN NUMBER MAY NOT BE INCLUDED OR THE RECALL WAS ALREADY PERFORMED. *NLM

Showing 50 of 764 complaints.

Technical Service Bulletins, 1991 FORD EXPLORER

64 manufacturer communications from 63 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	6
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	6
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER	5
190000 TIRES	5
980000 UNKNOWN OR OTHER	3
105000 POWER TRAIN:DRIVELINE	3
106000 POWER TRAIN:AXLE ASSEMBLY	3
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	2

022000 SUSPENSION:REAR

VARIOUS NOISE ISSUES FROM THE REAR LEAF SPRINGS WHILE DRIVING. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT

190000 TIRES

OWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF WILDERNESS AT TIRES. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT

138600 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

980000 UNKNOWN OR OTHER

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

181000 VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

ON SOME VEHICLES, THE ACCELERATOR PEDAL BRACKET MAY BECOME LOOSE OR SEPARATED FROM THE DASH PANEL. THIS MAY BE CAUSED BY REPEATED EXCESSIVE FORCE ON THE ACCELERATOR PEDAL, RESULTING IN CRACKING OF THE DASH PANEL SHEET METAL AT THE ACCELER

355100 EQUIPMENT:OTHER:LABELS

SUBJECT PERTAINING TO SUPPLEMENTAL TIRE INFLATION LABEL. *JB

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS

102000 POWER TRAIN:MANUAL TRANSMISSION

SOME VEHICLES EQUIPPED WITH MANUAL TRANSMISSION MAY EXHIBIT NEUTRAL GEAR ROLLOVER NOISE (A LIGHT METALLIC RATTLING SOUND FROM THE TRANSMISSION) WHICH OCCURS AT IDLE WITH TRANSMISSION IN NEUTRAL CLUTCH ENGAGED (CLUTCH PEDAL UP). *TT

114000 ELECTRICAL SYSTEM:WIRING

SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

CONCERNS WITH BURNING ODOR OR SMOKE, AND / OR RUSTLING NOISE WHILE BLOWER MOTOR IS ON. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

SOME VEHICLES MAY EXHIBIT A BURNING ODOR OR SMOKE, AND / OR RUSTLING NOISE OCCURING WHEN THE BLOWER MOTOR IS RUNNING IF LEAVES OR FOREIGN MATERIAL ENTERS THE BLOWER CASE. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT

105000 POWER TRAIN:DRIVELINE

SOME VEHICLES MAY EXHIBIT AN AUDIBLE PINGING OR CREAKING NOISE THAT MAY BE HEARD FROM THE DRIVELINE WHEN ENGINE TORQUE IS INITIALLY APPLIED TO THE DRIVELINE. *TT

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

SOME VEHICLES MAY EXPERIENCE AXLE WIND UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS ON VEHICLES EQUIPPED WITH A FOUR WHEEL DRIVE HI OR LOW RANGE MODE. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT

190000 TIRES

INFORMATION ON MAINTAINING TIRE PRESSURE. *TT

110000 ELECTRICAL SYSTEM

FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK

190000 TIRES

INFORMATION REGARDING THE TIRE INFLATION PRESSURE FOR ALL MODELS DURING PREDELIVERY PROCESS AND DURING MAINTENANCE INTERVALS. *MJS

190000 TIRES

INFORMATION ON SETTING THE TIRE INFLATION PRESSURE FOR 1991 THROUGH 1999 MODEL YEAR VEHICLES IN THE PRE-DELIVERY PROCESS AND DURING MAINTENANCE INTERVALS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT

190000 TIRES

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

A GRABBING AND/OR STICKING CONDITION DURING THE FIRST FEW BRAKE APPLICATIONS WHEN THE BRAKES ARE COLD OR IN THE MORNING AFTER AN OVERNIGHT RAIN MAY OCCUR ON SOME VEHICLES. *YC

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

A COMPREHENSIVE PULL AND DRIFT DIAGNOSTIC PROCEDURE HAS BEEN DEVELOPED TO ASSIST TECHNICIANS WITH VEHICLE SERVICE. *YC

034500 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC

354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

ANNOUNCING THE FORD OEM AIR CONDITIONING RETROFIT KIT AVAILABILITY. *YC

106000 POWER TRAIN:AXLE ASSEMBLY

CONCERNS WITH AXLE WIND-UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED. *TT

020000 SUSPENSION

INFORMATION REGARDING COMPREHENSIVE PULL AND DRIFT DIAGNOSTIC PROCEDURE DEVELOPED TO ASSIST TECHNICIANS WITH VEHICLE SERVICE. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

CUSTOMER COMPLAINT OF ENGINE MISS UNDER LOAD WHILE GOING UP STEEP HILLS. *TT

105000 POWER TRAIN:DRIVELINE

CONCERNS WITH "PINGING" OR "CREAKING" BEING HEARD FROM THE DRIVELINE WHEN SHIFTING FROM PARK TO DRIVE OR REVERSE, BETWEEN DRIVE AND REVERSE, OR WHEN ENGAGING THE CLUTCH. *YC

980000 UNKNOWN OR OTHER

AUTHORIZED WARRANTY PART REPLACEMENT OF BRAKE PADS TO CORRECT EXCESSIVE BRAKE NOISE. *TW

980000 UNKNOWN OR OTHER

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD

160000 STRUCTURE

FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPNIED WITH A THUMPING NOISE OR FEEL IN THE COOLANT HOSES WITH THE ENGINE AT NORMAL OPERATING TEMPERATURE. *JD

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPANIED WITH A THUMPING NOISE OR FEEL IN THE COOLANT HOSE WITH THE ENGINE AT NORMAL OPERATING TEMPERATURE. *JD

161000 STRUCTURE:FRAME AND MEMBERS

BODY - RUST PERFORATION - QUARTER PANEL - SERVICE TIPS. *TW

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW

034420 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

CONCERNS WITH REAR BRAKE GRAB DURING THE FIRST FEW BRAKE APPLICATIONS WHEN THE BRAKES ARE COLD OR IN THE MORNING AFTER AN OVERNIGHT RAIN. *TW

105000 POWER TRAIN:DRIVELINE

NOISE - PINGING OR CREAKING FROM DRIVELINE WHEN VEHICLE IS PUT INTO GEAR. *TW

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW

114000 ELECTRICAL SYSTEM:WIRING

WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW

131000 VISIBILITY:WINDSHIELD

WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW

105300 POWER TRAIN:DRIVELINE:DRIVESHAFT

VEHICLES MAY EXPERIENCE A VIBRATION DURING WIDE OPEN THROTTLE ACCELERATION OR WHILE CRUISING AT HIGHWAY SPEEDS. REVISED FRONT DRIVESHAFT. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

4X4 FRONT AXLES MUST USE HYPOID 4X4 GEAR OIL P/N F1TZ-19580-A & HIGH TEMP 4X4 FRONT AXLE & WHEEL BEARING GREASE WHEN SERVICING. IT IS NOT RECOMMENDED TO USE HEAVIER WEIGHT LUBES IN THESE FRONT AXLES.

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE INCOMPATIBLE WITH THE RUBBER MATERIAL USED IN THE DISC BRAKE SYSTEM. IF PETROLEUM-BASED GREASE IS USED TO LUBRICATE ANY PAR

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

HIGH ALTITUDE TRANSMISSION AVAILABLE. *TW

162000 STRUCTURE:BODY

SHEET METAL-ROOF PANEL AND DRIP RAIL REPLACEMENT- SEAM SEALER APPLICATION PROCEDURE.*SD

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

TEMPERATURE GAUGE - FLUCTUATING AND /OR INACCURATE HIGH READINGS. *SD

116000 ELECTRICAL SYSTEM:IGNITION

VEHICLES MAY HAVE A DISCONNECT OF THE IGNITION CONTROL MODULE (ICM) CONNECTOR OR MOISTURE BUILDUP WITHIN THE CONNECTOR. *TW

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

ANNOUNCEMENT LETTER FOR RECALL 94M85. *TW

061000 ENGINE AND ENGINE COOLING:ENGINE

ANNOUNCEMENT LETTER FOR RECALL 94M85. *TW

162300 STRUCTURE:BODY:DOOR

INSIDE DOOR HANDLE BREAKS WHEN OPENING. *TW

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

INSUFFICIENT AIR FLOW THROUGH CONDENSER. *TW

NHTSA Safety Investigations, FORD EXPLORER

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

DP, Closed , Model Year: 2020

Underbody shields detachment

The Office of Defects Investigation (ODI) received a petition on August 22, 2025, requesting a defect investigation into an alleged defect of the “underbody shields” on model year (MY) 2020 Ford Explorer vehicles. The petition alleges premature degradation and detachment of the plastic underbody... Read more

RQ, Closed , Model Year: 2020

Rear Axle Bolt Failure

On July 17, 2023, the Office of Defect Investigation (ODI) opened this Recall Query (RQ) after receiving 2 consumer complaints alleging loss of vehicle forward power and/or loss of transmission torque of the rear wheels in model year (MY) 2020-2022 Ford Explorer vehicles (subject vehicles). The RQ w... as opened to focus on the effectiveness of the remedies of Recalls 22V-255 and 23V-199 related to the alleged problem. Recall 22V-255 involved replacing the bushing and axle cover in the following subject vehicles: 3.3L FHEV Police built before October 14, 2020, and 3.3L Gas Police vehicle built before January 31, 2021. For 2.3L RWD, 3.0L PHEV, 3.3LFHEV, and 3.0LST retail (non-police) vehicles, the recall provided an PCM software update to engage the Electronic Park Brake (EPB) when Park is commanded. The recall addressed a breakage of the rear axle bolt that can cause the driveshaft/half shafts to disconnect, resulting in a loss of transmission torque to the rear wheels necessary to hold park. If the parking brake is not applied, the loss of the primary park torque will allow the vehicle to roll in park increasing the risk of crash and injury. Recall 23V-199 addressed 674 of the subject vehicles produced from February 2, 2019 to April 4, 2022, which received an incorrect remedy under Recall 22V-255. The affected vehicles had received a previous Powertrain Control Module (PCM) update which did not include an automatic EPB engagement when vehicle is shifted to park. On October 17, 2023, Ford filed a new safety recall (Recall 23V-675) covering 238,364 MY 2020-2022 Explorer vehicles with the following powertrains: 3.3L FHEV Police, 3.3L Gas Police, 3.0L Gas Police, 2.3L RWD, 3.0L PHEV, 3.3L FHEV, 3.0L RWD and 3.0L AWD, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. Ford stated that the cause of the bolt fracture is due to joint design not robust to peak axle input torques and manufacturing variability. The primary contributor is insufficient bearings for maximum joint loads. This can result in bearing deformation, increasing bending stress on the bolt, which may lead to fatigue failure. On January 19, 2023, Ford amended Recall 23V-675 to add 1,942 MY 2020-2022 Explorer vehicles with the following powertrain: 3.0L RWD Platinum and King Ranch variant, produced from October 22, 2018 to July 6, 2022, equipped with a 3-point mounted axle design. In addition to the safety recall, Ford will conduct a customer satisfaction program for the following MY 2020-2022 Explorer vehicles with the following powertrains: 2.3L AWD, 3.3L Gas Retail, 3.0L Gas AWD Platinum and King Ranch, produced from October 22, 2018 to July 6, 2022. Ford stated that the Explorer powerpack variants not covered under Recalled 23V-675 do not present an unreasonable risk to motor vehicle safety due to the combination of lower peak torque levels and torque management strategies to share inputs between front and rear axles, reducing occurrence of higher torque. According to Ford, this is also evidenced by the lower current and projected failure rates. In view of the recall action being taken by Ford, ODI is closing this RQ. NHTSA will continue to monitor complaints from the customer satisfaction program vehicles and reopen this issue, if necessary. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.Read more

PE, Closed , Model Year: 2011

Windshield trim molding Item detachment

On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23-001 to investigate allegations of A-pillar trim panel detachment on model year (MY) 2011-2019 Ford Explorer vehicles. At the time of opening, the office had received 164 Vehicle Owner Questionnaires (VOQs) reporting this fail... ure. ODI has received 671 VOQs regarding this failure, including 1 alleged crash and 2 alleged injuries. Some consumers have reported that the failure occurred while they were driving at highway speeds, with the detached trim panel entering the path of travel of the vehicle behind them, requiring the driver of the following vehicle to take evasive action. It is noteworthy that motorists who experience this type of road hazard are less likely to accurately identify the subject vehicle the item detached from and report the event to the NHTSA. In its April 17, 2023 response to ODI’s information request, Ford provided 175 consumer complaints (including field reports) and 14,162 warranty claims related to A-pillar trim panel detachment. Ford relayed that the subject vehicles utilize a plastic A-pillar bracket, which is bolted to the vehicle structure during assembly. The A-pillar trim panel is attached to the bracket utilizing 7 plastic clips. Contributory factors which have been identified by Ford as leading to the subject defect include incomplete installation at the assembly plant, inadequate part stack up, damage to fasteners during installation, and failure to follow proper repair procedure during windshield replacements or other services. On January 19, 2024, Ford filed safety recall 24V-031 for MY 2011-2019 Ford Explorer vehicles to address the subject defect. In the Part 573 Safety Recall Report, Ford identified that a detached A-pillar trim panel can create a road hazard for other road users, increasing the risk of a crash. The recall remedy includes an inspection of the existing A-pillar trim panel and, if necessary, the replacement of the component. The remedy A-pillar trim panels will be installed with an additional adhesive for robustness and utilize an inspection procedure to ensure full engagement of all the retention clips during installation. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.Read more

AQ, Open , Model Year: 2018

Hertz/Vehicles Rented with Open Recalls

NHTSA is opening this audit query to investigate whether The Hertz Corporation (Hertz) has complied with the requirements of the National Traffic and Motor Vehicle Safety Act (Safety Act). The Safety Act requires, among other things, that a rental company shall not rent a vehicle subject to a safety... Read more

EA, Closed , Model Year: 2011

Exhaust Odor in Passenger Cab

During the EA17-002 investigation, the agency reviewed and analyzed reports of exhaust odors in the passenger cabins of Model Year 2011 to 2017 Ford Explorers. This investigation required an approach that incorporated knowledge and expertise from the automotive, medical, environmental health, and oc... cupational safety fields. The agency conducted an in-depth investigation that encompassed the review of over 6,500 consumer complaints, conducting field inspections, and testing the relevant vehicles, both independently and in coordination with Ford and other entities. During the investigation, the evolution of Ford service bulletins intended to reduce the level of exhaust odors and carbon monoxide (CO) entering the occupant compartment was examined and independent tests to evaluate the effectiveness of the final Field Service Actions (FSA) for both consumer and police vehicles were conducted. As part of the investigation, the agency also examined the effects of cracked exhaust mani-cats on the measured CO levels in the vehicles and tested the FSA repairs to ensure they did not adversely impact occupant compartment CO levels due to cracked mani-cats.The investigation identified upfitting issues for Police Interceptor vehicles. Upfitting (sirens, lights, cages, auxiliary power, etc.) is typically performed by governmental fleet operations, independent repair facilities, or local Ford dealers after the sale of the new vehicle. Sealing issues caused by upfitting were responsible for the highest measured carbon monoxide levels in tested vehicles. The police FSA instructs how to inspect the quality of the vehicle upfits and how to properly seal any leaks caused by these upfits, at no cost to the police agency. Similarly, the highest CO levels measured in consumer vehicles were usually traced to sealing issues caused by rear crash damage where the repairs did not ensure sealing integrity. The most recent Ford FSA procedure for both the police (17B25) and consumer vehicles (17N03) includes an HVAC reprogramming operation. Tests by Ford and NHTSA have demonstrated a substantial reduction of CO levels due solely to the HVAC reprogramming. Other FSA repairs also demonstrated measurable contributions to CO level reductions during controlled tests.Throughout the investigation, vehicles accurately measured with higher levels of carbon monoxide were almost always affected by upfitter alterations, damage, or other causes compromising rear passenger cabin seals.NHTSA received thousands of reports alleging odors which triggered a variety of physiological responses, predominately nausea, headaches, and lightheadedness. NHTSA focused the investigation on accurately measuring vehicle CO levels, and accurately measuring carboxyhemoglobin (COHB) levels from properly administered blood tests. Using rigorous test methods to produce exhaust gas intrusion in vehicles with a properly performed FSA, occupant compartment CO levels remained below current environmental limits for CO in any environment (EPA ambient air quality standards). Furthermore, even without FSA repairs, no vehicles unaffected by upfitter issues or prior crash damage were identified with CO levels that exceed accepted occupational CO exposure levels. This investigation finds that the 2011-2017 Ford Explorer vehicles when accurately measured produce occupant compartment CO levels which fall below current accepted health standards, and could not identify COHB levels for vehicle drivers or other occupants, which exceeded thresholds for acute physiological effects. Therefore, the agency has not identified a defect that represents an unreasonable risk to motor vehicle safety.This inveRead more

PE, Closed , Model Year: 2011

Ford Explorer Exhaust Odor

During the National Highway Traffic Safety Administration?s (NHTSA?s) investigation into the Ford carbon monoxide allegations, the Office of Defects Investigation (ODI) identified additional Vehicle Owner Questionnaire (VOQ) reports with similar exhaust odor claims.Presently, ODI has identified 791 ... Read more

EA, Closed , Model Year: 2013

Front Brake Hose Failure

On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate a report alleging incidents of front brake hose failure in model year (MY) 2015 Ford Explorer Police Interceptor vehicles used by the Sacramento Police Department in its pursuit driving training program (VOQ ... Read more

PE, Closed , Model Year: 2015

Front brake hose failure

On April 29, 2015, the Office of Defects Investigation (ODI) opened PE15-017 to investigate reports of low-mileage failures of front brake jounce hoses in model year (MY) 2015 Ford Explorer Police Interceptor vehicles operated as training vehicles by the City of Sacramento, California (ODI VOQ No. 1... 0705832). To date, the Sacramento police fleet has reported a total of 7 front hose failures in 5 different Explorer Police Interceptor vehicles used for its Emergency Vehicle Operation Course (EVOC) training. Most of the failures occurred within the first few miles of service on a closed course used for the EVOC program, which includes evasive accident avoidance and pursuit maneuver training. The hose assemblies either leaked at, or pulled completely free from, the caliper-end attachment where the hose is crimped to the steel end fitting. Most of the failures resulted in a sudden loss of braking performance that caused the vehicle to run off the intended course. None of the failures resulted in any crashes, injuries or property damage.The subject MY 2015 hose assemblies are similar in design to hoses used on MY 2013 through 2014 Explorer Police Interceptor and civilian vehicles. The 5 vehicles used by Sacramento EVOC have all been repaired using MY 2016 front hose assemblies that have been changed to incorporate a short steel tube attached to the caliper end banjo block. No failures have been experienced by the Sacramento fleet to date in the other 37 MY 2014-2015 Explorer Police Interceptor vehicles (2 MY 2014 and 35 MY 2015) used by the fleet in regular law enforcement duty cycles unrelated to the EVOC training. In its response to ODI's information request letter for PE15-017, Ford provided information about 2 additional failures reported by other fleets, including 1 involving a Sacramento Regional Transit vehicle that occurred while being driven on the street.Based on its analysis of failed parts returned from the Sacramento fleet and the fleet's EVOC training duty cycle, Ford attributes the Sacramento fleet hose failures to excessive temperatures produced during hot-soak portions of the EVOC training duty cycle (when the vehicles are stationary after hard braking exercises, with no cooling air flow through the brake rotor vents and across the other brake components). During testing conducted to replicate the EVOC duty cycle, Ford measured temperatures at the subject crimp fittings that exceeded the design limits of the brake hose material after several successive training intervals and hot soaks. Ford has provided the Sacramento fleet with modified replacement hose assemblies for all of its MY 2014-15 Explorer Police Interceptor vehicles. The replacement hose assemblies were developed for use in MY 2016 Explorer vehicles and were modified slightly to accommodate the addition of a ride height sensor in those vehicles. The revised assemblies have an additional length of brake pipe between the caliper end connection and the subject crimp ferrule that results in additional heat dissipation and makes the assemblies more robust to the severe thermal effects experienced during the EVOC testing (the hose material is the same in both assemblies). Ford believes that the excessive temperatures experienced at the crimp fitting in the subject vehicles are unique to the EVOC duty cycle, have not been observed in the standard on-road severe duty cycle testing performed by Ford and police fleets who routinely conduct such testing and are not likely to occur in service usage for on-road Explorer Police Interceptor vehicles.This preliminary evaluation is closed, an Engineering Analysis (EA15-005) has been opened to conduct testing and furtherRead more

PE, Closed , Model Year: 2013

Front brake hose failure

The Office of Defects Investigation (ODI) opened PE14-027 based on a report of 13 front brake hose (jounce hose) failures in 11 vehicles in the District of Columbia Metropolitan Police Department (DCMPD) fleet of 46 model year (MY) 2013 Ford Explorer Police Interceptor (PI) vehicles (VOQ 10621634).T... he DCMPD fleet provided Ford with 71 jounce hoses for analysis, including 4 of the 13 failed hoses.Inspection of each of the failed hoses identified a small tear in the outer cover on the body end of the hoses on the outboard side. Ford?s lab analysis of these hoses identified splits in the inner liners 1.5-2.0mm from the end of the nipple (outside of the crimped ferrule joint).Ford conducted pressure testing of 10 randomly selected samples of the remaining 67 hoses that had not experienced leaks and 9 of the samples leaked at 6,000 psi.Ford?s examination of the 9 hoses that leaked in the pressure tests found 4 that failed on the outboard side of the hose (similar to the 4 leaking field parts) and 5 that failed on the body end of the hose on the inboard side.Four additional non-leaking hoses were sent to the hose supplier, Hitachi, for analysis.Broken yarn was observed in scanning electron microscope examinations at both the body side and caliper side hose to ferrule crimps, indicating severe bending stress had occurred at these locations. Hitachi supplied an additional set of non-leaking field return hoses and a brand new set of hoses to an outside laboratory (Element Materials Technology) for analysis.The lab did not identify any manufacturing or material deficiencies in the hoses and concluded that the hose failures were caused by excessive bending stresses.Based on the examinations of the returned jounce hoses, Ford conducted durability testing on new hoses that were the same design as those found on the subject vehicles.Ford first determined the worst case conditions for the hoses; jounce bumpers removed, internal rebound stops fully compressed, and shock absorbers attached. With the jounce hose installed, the steering was rotated to the maximum turn angle while the suspension was translated from full jounce to full rebound.This determined the maximum hose length of 13.0in (331mm) and a minimum hose bending radius of 1.6in (40mm).Using these conditions hoses tested on a Suspension Motion Simulator far surpassed Ford?s performance specifications. Twenty (20) complaints of front brake jounce hose failure were identified on a total of 18 Explorer PI vehicles, including the 13 hose failures in 11 vehicles from the DCMPD fleet that prompted PE14-027.The remaining 7 complaints included 3 from one fleet that reportedly occurred on the banjo block end of the hose assembly and single complaints from 4 other fleets.Only two brake hose assemblies were used in the subject and peer Explorer vehicles, with the BB53 level hose used until June 20, 2012, and an updated DB53 level hose used thereafter.No pattern of failures was observed by hose assembly, with 15 of failures involving the BB53 hose assembly (including the 13 from DCMPD manufactured in March 2012) and 5 the DB53 hose assembly built after June 20, 2012. No root cause was determined for the reported Explorer PI jounce hose failures, but Ford identified improper service repair procedures (e.g., hanging the brake caliper from the brake hose during brake pad replacement) as a possible contributor to higher than expected rate of front brake jounce hose leaks. ODI?s analysis of field data, hose inspection and test data did not identify evidence of any defects in hose material, manufacture or vehicle installation.The closing of this investRead more

PE, Closed , Model Year: 2011

Electric power steering failure

On May 27, 2014 and amended June 2, 2014, Ford Motor Company (Ford) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 179,027 model year (MY) 2011 through 2013 Ford Explorer vehicles equipped wit... h electric power assisted steering (EPAS), including 82,328 MY 2011 Explorersthat are the subject of PE12-017.Ford has assigned the recall number 14S06.The NHTSA recall number is 14V-286.Ford's DIR indicates that loss of power steering assist while driving would require higher steering effort at lower vehicle speeds, which may result in an increased risk of a crash.Sudden loss of power steering assist while driving can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe mode, which removes power from the EPAS motor and defaults to manual steering.Ford's DIR indicates that the majority of steering assist failures in the recalled vehicles have been caused by an intermittent electrical connection in the Power Steering Control Module (PSCM) that can lead to a loss of the motor position sensor signal.Ford's remedy instructs dealers to check the PSCM for diagnostic trouble codes (DTC).If upon initial inspection a loss of steering assist DTC is present, dealers will replace the steering gear at no charge to the owner and update the PSCM with revised software.Following detection of a motor position sensor signal fault, the revised software will provide audible and visual warnings to the driver that a power steering system fault has been detected and will maintain steering assist for the remainder of that drive cycle.If no DTC is present, dealers will reprogram the PSCM with the revised software. Analysis of information from all sources identified a total of 969 complaints and 4,059 warranty claims related to loss of power steering assist while driving in the MY 2011 through 2012 Explorer vehicles, resulting in a complaint rate of 5.4 incidents per thousand vehicles and a warranty claim rate of 2.3 percent.ODI identified 15 crashes with evidence indicating loss of power steering assist may have been a factor.All 15 crashes involved low-speed impacts with roadside objects during turning maneuvers, resulting in minor vehicle damage or no damage.In one incident that occurred in a low-speed curve, the driver attempted to brake in response to the sudden increase in steering effort and inadvertently applied the accelerator pedal instead.This caused the vehicle to run off the side of the road and strike a wooden pole at approximately 15 mph.Another incident occurred when the driver was unable to to negotiate a left-turn at an intersection and ran off the road into a shallow ditch, resulting in moderate front-end damage to the vehicle and minor injuries to the driver that did not require medical treatment. This investigation is closed.All ODI complaints associated with this closing resume are listed in the Attachment 1.Read more

EA, Closed , Model Year: 2002

Vehicle Rollaway Allegations

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of... Read more

PE, Closed , Model Year: 2002

VEHICLE ROLLAWAY ALLEGATIONS

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM ... Read more

RQ, Closed , Model Year: 2004

REAR LIFTGATE GLASS HATCH FAILURE

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS ... Read more

PE, Closed , Model Year: 2002

STUCK ENGINE THROTTLE

ON JULY 7, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE COMPLAINTS IN CERTAIN MODEL YEAR (MY) 2002 FORD EXPLORER AND MERCURY MOUNTAINEER VEHICLES EQUIPPED WITH THE STANDARD AVAILABLE 4.0L SOHC V6 ENGINE.AT THAT TIME, ODI WAS AW... ARE OF 15 COMPLAINTS THAT ALLEGED STUCK ENGINE THROTTLE CAUSING UNWANTED VEHICLE ACCELERATION AND 1 ALLEGED CRASH AS A RESULT.SIX COMPLAINANTS REPORTED THAT THROTTLE CONTROL CABLE REPLACEMENT REMEDIED THE ALLEGED STUCK THROTTLE CONDITION.ADDITIONALLY, ODI WAS AWARE OF A TECHNICAL SERVICE BULLETIN ISSUED BY THE MANUFACTURER THAT REFERRED TO AN ACCELERATOR CABLE DESIGN CHANGE.ODI SENT A LETTER TO THE MANUFACTURER ON JULY 18, 2005 REQUESTING CERTAIN INFORMATION ABOUT THESE VEHICLES. ACCORDING TO FORD, APPROXIMATELY 234,092 SUBJECT VEHICLES BUILT FROM AUGUST 14, 2000 (?JOB 1?) THROUGH OCTOBER 31, 2001 USED A PARTICULAR ACCELERATOR CABLE KNOWN AS A 16 LAY WIRE DESIGN.THIS DESIGN IS COMPRISED OF THE THROTTLE CABLE SURROUNDED BY A CONDUIT MADE OF SEVERAL CONCENTRIC LAYERS INCLUDING A TEFLON LINER, A NYLON TUBE EXTRUDED OVER THE TEFLON LINER, 16 LAY WIRES WRAPPED AROUND THE NYLON TUBE, AND FINALLY A NYLON JACKET EXTRUDED OVER AND AROUND THE LAY WIRES. FORD REPORTS THAT THROTTLE CONTROL CONCERNS RELATED TO THE ACCELERATOR CABLE ARE LIKELY CAUSED BY A MIGRATION OF THE INNER TEFLON LINER OUT OF THE CONDUIT AT THE DASH PANEL FITTING.SHOULD THE TEFLON LINER MIGRATE OUTWARD SUFFICIENTLY TO CONTACT THE ACCELERATOR PEDAL ARM IT COULD INTERFERE WITH THE PEDAL?S ABILITY TO RETURN TO IDLE.IN NOVEMBER 2001, FORD BEGAN USING A NEW 12 LAY WIRE DESIGN ACCELERATOR CABLE.THIS CHANGE WAS IMPLEMENTED TO ALLOW FOR INSTALLATION OF OPTIONALLY AVAILABLE POWER-ADJUSTABLE PEDALS. FIELD DATA SUGGESTS THAT THE CONDITION WITH THE SUBJECT CABLE IS MORE PREVALENT IN COLD (WINTER) CLIMATES.OF THE 396 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT, NEARLY 68% OCCURRED IN WINTER MONTHS AND MOST WARRANTY CLAIMS ARE ASSOCIATED WITH VEHICLES SOLD IN THE NORTHEASTERN, NORTHERN INTERIOR (MIDWEST), AND ROCKY MOUNTAIN REGIONS OF THE UNITED STATES.THIS SEASONAL TREND APPEARS TO BE IN DECLINE WITH FEWER WARRANTY CLAIMS PAID IN WINTER 2005 THAN IN PREVIOUS WINTERS.THERE ARE NO KNOWN CRASHES RELATED TO THE ALLEGED DEFECT ON THE SUBJECT VEHICLES, THE COMPLAINT RATE IS LOW AFTER APPROXIMATELY FOUR YEARS IN SERVICE (3.0 INCIDENTS PER 100,000 VEHICLES) AND THE FAILURE TREND IS DECLINING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2005.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.ODI WILL CONTINUE TO MONITOR ITS COMPLAINT DATABASE AND WILL RECEIVE UPDATED COMPLAINT AND WARRANTY DATA FROM FORD IN SPRING 2006 TO VERIFY THE TREND ANALYSIS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.Read more

PE, Closed , Model Year: 2002

REAR LIFTGATE GLASS ASSEMBLY

COMPLAINTS REPORT FAILURE OF THE REAR LIFTGATE GLASS SUPPORT WHILE THE OPERATOR IS OPENING OR CLOSING THE GLASS.THE FALLING GLASS CAN STRIKE THE OPERATOR OR BYSTANDER.THE INJURIES REPORTED ARE BRUISES TO THE HEAD, NECK OR BACK, CUTS TO THE FACE, ARM OR HAND.ON SEPTEMBER 9, 2004, FORD NOTIFIED THE AG... Read more

PE, Closed , Model Year: 1998

FRONT SEAT BACK RECLINER ATTACHMENT

BY LETTER DATED AUGUST 4, 2003, FORD NOTIFIED THE AGENCY THAT IT IS CONDUCTING A VOLUNTARY SAFETY RECALL (NHTSA RECALL NO. 03V281) INVOLVING CERTAIN MODEL YEAR (MY) 1998-2001 FORD EXPLORER / MERCURY MOUNTAINEER 4-DOOR, MY 1998-2000 FORD EXPLORER 2-DOOR AND MY 2001-2002 FORD EXPLORER SPORT AND SPORT ... Read more

EA, Closed , Model Year: 2002

MIS-ASSEMBLED AIRBAG CLOCKSPRING

IN JULY 2001, FORD ISSUED A SPECIAL SERVICE MESSAGE ANNOUNCING THAT SOME AIR BAGCLOCKSPRING DEVICES MAY PRODUCE NOISE WHEN THE STEERING WHEEL IS TURNED FULL LEFT OR RIGHT.FORD WAS AWARE THAT SOME CLOCKSPRINGS MAY HAVE BEEN IMPROPERLY INSTALLED.THE IMPROPER INSTALLATION MAY ALSO CAUSE AN OPEN CIRCUIT... Read more

EA, Closed , Model Year: 1995

SAFETY BELT ASSEMBLY FAILURE

ODI RECEIVED 18 CONSUMER COMPLAINTS AND FORD IDENTIFIED ANOTHER FOUR REPORTS ASSOCIATED WITH THE ALLEGED DEFECT.MOST OF THE COMPLAINTS INDICATE INABILITY TO LATCH THE DRIVER SEAT BELT BUCKLE CAUSED BY A BROKEN LATCH RELEASE SPRING.NONE OF THESE 22 REPORTS RESULTED IN ANY INJURIES OR CRASHES.NO COMPL... Read more

PE, Closed , Model Year: 1995

SAFETY BELT ASSEMBLY

SQ, Closed , Model Year: 2002

INOPERATIVE AIR BAG SYSTEM

EA, Closed , Model Year: 1999

SEAT BELT WEBBING

ODI OPENED PE00-044INVESTIGATION ON NOVEMBER 3, 2000, BASED ON A REPORT REGARDING THE DEATH OF THE OCCUPANT OF THE RIGHT FRONT SEAT IN A 2000 MODEL YEAR FORD EXPLORER XLS INVOLVED IN A ROLL-OVER CRASH.IT IS ALLEGED THAT THE WEBBING OF THE BUCKLE PORTION OF THE SEAT BELT ASSEMBLY FAILED DURING THE CR... Read more

PE, Closed , Model Year: 2000

SEAT BELT WEBBING

ODI OPENED THIS INVESTIGATION ON NOVEMBER 3, 2000, BASED ON A REPORT REGARDING THE DEATH OF THE OCCUPANT OF THE RIGHT FRONT SEAT IN A 2000 MODEL YEAR FORD EXPLORER XLS INVOLVED IN A ROLL-OVER CRASH.IT IS ALLEGED THAT THE WEBBING OF THE BUCKLE PORTION OF THE SEAT BELT ASSEMBLY FAILED DURING THE CRASH... Read more

PE, Closed , Model Year: 1995

FRONT SUSPENSION STABILIZER BAR LINK

There is no summary currently available

EA, Closed , Model Year: 1991

SPARE TIRE WINCH CABLE

There is no summary currently available

PE, Closed , Model Year: 1991

SPARE TIRE WINCH CABLE

FROM THE BEGINNING OF THE 1991 MODEL YEAR PRODUCTION UNTIL THE MIDDLE OF THE 1994 MODEL YEAR PRODUCTION, FORD USED A GALVANIZED STEEL CABLE TO LIFT AND HOLD IN STORED POSITION, THE EXPLORER SPARE TIRE.ON MAY 19, 1994, BASED ON THE RESULTS OF FORD DURABILITY TESTING , FORD CHANGED TO A 4.00MM STAINLE... Read more

SQ, Closed , Model Year: 1999

AIRBAG SYSTEM'S LIGHT DYSFUNCTIONAL

There is no summary currently available

PE, Closed , Model Year: 1995

ACCELERATOR PEDAL

There is no summary currently available

RQ, Open , Model Year: 1991

LIFTGATE SUPPORT BRACKET FAILURE

SUMMARY:ON AUGUST 22, 1995, FORD CONDUCTED SAFETY RECALL, 95V-164, ON 1992 AND 1993 MODEL YEAR EXPLORER DUE TO LIFTGATE FAILURES.THE REAR LIFTGATE HYDRAULIC CYLINDER BRACKET CAN BECOME UNATTACHED ALLOWING THE LIFTGATE TO SUDDENLY DROP.THE RECALL REMEDY WAS TO INSTALL REINFORCEMENTS ON THE BRACKETS.F... Read more

PE, Closed , Model Year: 1997

WINDSHIELD WIPER MALFUNCTION

There is no summary currently available

PE, Closed , Model Year: 1997

STEERING KNUCKLE SEPARATIONS

There is no summary currently available

SQ, Closed , Model Year: 1998

VEHICLE HESITATION/STALLING

There is no summary currently available

EA, Closed , Model Year: 1992

BLOWER ASSEMBLY FIRES

BASED ON THE RELATIVELY LOW FAILURE FREQUENCY MEASURED OVER AN EXTENDED EXPOSURE TIME AND THE FACT THAT THE GREAT MAJOITY OF INCIDENTS ARE CONFINED WITHIN THE BLOWER HOUSING, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF THE AGENCY RESOURCES DOES NOT APPEAR TO... Read more

EA, Closed , Model Year: 1997

THROTTLE STICKING

ON JANUARY 23, 1997, FORD MOTOR COMPANY ISSUED SPECIAL SERVICE MESSAGE (SSM) 10240, ANNOUNCING THAT A REVISED THROTTLE BODY WOULD BE AVAILABLE DURING THE FIRST QUARTER OF 1997 FOR 1997 MODEL YEAR FORD EXPLORERS EQUIPPED WITH THE 4.0L SINGLE OVERHEAD CAM (SOHC) ENGINE.THE SSM STATED THE REVISED THROT... Read more

RQ, Closed , Model Year: 1997

FUEL LINE DAMAGE FROM JUMP STARTING

There is no summary currently available

DP, Closed , Model Year: 1992

HEATER BLOWER ASSEMBLY FIRE

There is no summary currently available

PE, Closed , Model Year: 1992

BLOWER ASSEMBLY FIRES

There is no summary currently available

SQ, Closed , Model Year: 1997

THROTTLE STICKING

There is no summary currently available

DP, Closed , Model Year: 1991

HEAVY LATERAL VIBRATION

NHTSA WAS PETITIONED TO COMMENCE A DEFECT INVESTIGATION OF THE SUBJECT VEHICLES ON JANUARY 6, 1998.THE PETITION ALLEGES THAT EARLY MODEL FORD EXPLORER SPORT UTILITY VEHICLES DEVELOP HEAVY LATERAL VIBRATIONS AT SPEEDS ABOVE 55 MPH AND WHEN ENCOUNTERING BUMPS AT LOW SPEEDS.THE PETITION FURTHER ALLEGES... Read more

EA, Closed , Model Year: 1991

SUNROOF SHATTERING AND SEPARATION

There is no summary currently available

PE, Closed , Model Year: 1995

ELECTRICAL FIRE IN CENTER CONSOLE

THIS INVESTIGATION REVEALED THAT CONSOLE FIRES IN THE SUBJECT VEHICLES MOST OFTEN OCCURRED WHILE VEHICLES EQUIPPED WITH THE LAMP OUTAGE MODULE (LOM), WHICH IS PART OF THE MESSAGE CENTER, WERE TOWING A TRAILER AND WHICH HAD BEEN MODIFIED BY ADDING AN AFTERMARKET TRAILER WIRING HARNESS INTO THE VEHICL... Read more

PE, Closed , Model Year: 1992

SUNROOF (AIR ROOF) SHATTER

THE SUNROOF SHATTERED OR WAS BLOWN OFF.IN ALL BUT ONE CASE THIS OCCURRED WHILE DRIVING.

PE, Closed , Model Year: 1993

DRIVER DOOR ELECTRICAL FIRE

THE CONTACT ASSEMBLY FOR THE REMOTE POWER MIRROR CONTROL SWITCH MAY DEVELOP A SHORT CIRCUIT BETWEEN THE SWITCH POSITIVE PAD AND CHASSIS GROUND PAD AS A RESULT OF WATER INTRUSION.EXCESS CURRENT FLOW RESULTING FROM THE SHORT CIRCUIT CONDITION MAY OVERHEAT THE REMOTE POWER MIRROR CONTROL SWITCH CIRCUIT... Read more

EA, Closed , Model Year: 1993

BRAKE SYSTEM MALFUNCTION

There is no summary currently available

PE, Closed , Model Year: 1993

WHEEL LOCKUP WITH ANTILOCK BRAKE SYSTEM

ODI HAS RECEIVED OND HUNDRED SEVENTY-THREE (173) CONSUMER COMPLAINTS OF ALLEGED FAILURES OR MALFUNCTIONS IN THE BRAKING SYSTEM ON CERTAIN 1993 AND 1994 FORD EXPLORERS.THESE ALLEGED FAILURES OR MALFUNCTIONS ARE REPORTED TO HAVE CAUSED THIRTY-SIX (36) ACCIDENTS RESULTING FROM VEHICLE LOSS OF DIRECTION... Read more

EA, Closed , Model Year: 1991

SEPARATION OF MASTER CYLINDER

FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY.LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS.IF EVIDENCE INDICATES THE SCOPE SHOULD ... Read more

PE, Closed , Model Year: 1991

BRAKE MASTER CYLINDER/BOOSTER SEPARATION

There is no summary currently available

PE, Closed , Model Year: 1991

ENGINE COOLING FAN CRACKS

There is no summary currently available

EA, Closed , Model Year: 1992

AUTO TRANS PRNDL MISALIGN

There is no summary currently available

EA, Closed , Model Year: 1991

THROTTLE STICKING

There is no summary currently available

PE, Closed , Model Year: 1992

AUTO TRANS.PRNDL MISALIGN

There is no summary currently available

EA, Closed , Model Year: 1991

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

EA, Closed , Model Year: 1991

THROTTLE RELEASE FAILURE

There is no summary currently available

PE, Closed , Model Year: 1991

VACUUM BOOSTR VALVE FAILS

There is no summary currently available

PE, Closed , Model Year: 1991

THROTTLE RELEASE FAILURE

There is no summary currently available

FORD EXPLORER - All Years Overview

Complete safety history for the FORD EXPLORER across all model years (1991, 2027).

386 Total Recalls

43,121 Total Complaints

54 Investigations

2,520 Reported Crashes

1,069 Reported Fires

301 Reported Deaths

FORD EXPLORER - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2027	1	0	View
2026	11	29	View
2025	19	135	View
2024	10	26	View
2023	15	147	View
2022	24	342	View
2021	26	532	View
2020	33	1,638	View
2019	6	328	View
2018	7	864	View
2017	14	2,021	View
2016	15	3,007	View
2015	9	2,190	View
2014	7	2,040	View
2013	12	2,781	View
2012	7	1,027	View
2011	8	1,495	View
2010	2	155	View
2009	1	49	View
2008	3	216	View
2007	3	271	View
2006	4	788	View
2005	3	604	View
2004	4	1,647	View
2003	7	1,369	View
2002	10	4,096	View
2001	12	503	View
2000	15	1,203	View
1999	15	1,737	View
1998	14	2,374	View
1997	12	2,150	View
1996	11	1,818	View
1995	12	1,048	View
1994	7	1,531	View
1993	9	1,151	View
1992	7	848	View
1991 (current)	11	764
1990	0	12	View
1989	0	1	View
1988	0	7	View
1987	0	3	View
1986	0	3	View
1985	0	1	View
1984	0	1	View
1977	0	2	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-150	692	46,142	View
F-450 SD	692	624	View
F-250 SD	638	3,635	View
F-550 SD	578	603	View
EXPEDITION	555	11,534	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

1991 FORD EXPLORER

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 1991 FORD EXPLORER

Most Affected Components

NHTSA Safety Investigations, FORD EXPLORER

FORD EXPLORER - All Years Overview

FORD EXPLORER - Year by Year

Other FORD Models