1991 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
1991 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Ford Explorer has 6 documented known issues, with 5 rated critical. The most serious are Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk, 4.0L OHV cracked cylinder heads and blown head gaskets from overheating ($1,000-$2,800 repair), Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) ($600-$1,000 repair), Frame, rear subframe, and rocker/body-mount rust ($200-$3,000 repair) and Automatic transmission overdrive failure (A4LD / 4R55E) ($25-$3,500 repair). Across all issues with published estimates, repair costs range from $25 to $3,500. DIY maintenance guides at au7o.io.
EXTERIOR LIGHTING:HEADLIGHTS
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
FUEL SYSTEM, GASOLINE
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
VEHICLE SPEED CONTROL
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
EXTERIOR LIGHTING
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
VEHICLE SPEED CONTROL
ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Ford Explorer has 6 documented issues. The most frequently reported are: Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk, 4.0L OHV cracked cylinder heads and blown head gaskets from overheating, Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023). Of these, 5 are rated critical and should be addressed promptly.
The 1991 Ford Explorer has 6 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: Automatic Transmission Park Pawl May Not Engage (NHTSA Recall 91V189000) — Rollaway Risk and 4.0L OHV cracked cylinder heads and blown head gaskets from overheating and Firestone tire tread separation and rollover safety crisis (NHTSA EA00-023) and Frame, rear subframe, and rocker/body-mount rust and Automatic transmission overdrive failure (A4LD / 4R55E). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Explorer issues range from $25 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
NHTSA safety recall 91V189000 covers automatic-transmission-equipped 1991 Ford Explorers in which the park pawl does not always abut or engage the park gear when the shift lever is moved into Park. Because the lever still moves into the Park detent, an Explorer owner can shut the… Severity: high.
The pushrod 4.0L OHV V6 (Cologne) is otherwise regarded as a durable 'tank,' but the cast heads are intolerant of overheating and are prone to cracking and gasket failure, typically appearing around 100k miles or after any single serious overheat event. The root cause is usually… Repairs typically run $1,000-$2,800. Severity: high.
The defining safety issue of the 1990s Explorer: original-equipment and replacement Firestone ATX, ATX II, and Wilderness AT P235/75R15 tires (notably from the Decatur, IL plant) suffered tread/belt separation at highway speed. Combined with the Explorer's relatively high center… Repairs typically run $600-$1,000. Severity: high.
In salt-belt climates, 1991-1999 Explorers rot in predictable structural areas: the inner rocker panels, the tops of the front leaf-spring hangers (dirt packs between the hanger and inner rocker, which the factory welded only at the bottom), rear spring hangers/shackles, and the… Repairs typically run $200-$3,000. Severity: high.
The 4-speed automatics behind the 4.0L - the early A4LD and the later electronically controlled 4R44E/4R55E - are a known weak point, commonly failing in the 120k-mile range, most often losing 4th gear (overdrive). The overdrive planetary is fragile (early units used a weaker pin… Repairs typically run $25-$3,500. Severity: high.
The 4.0L (both OHV and SOHC) drives the camshaft position sensor off a gear-driven 'synchronizer' assembly in place of a conventional distributor. The synchronizer's shaft/bushing wears or gums up with varnish, developing play and producing a distinctive squeak/chirp that is ofte… Repairs typically run $150-$500. Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
