FaultScore

1991 Ford Explorer brake problems

151 of the 764 complaints about the 1991 Ford Explorer are about the braking system — 20% of everything reported for this model year. Half of the failures with a mileage on record happened before 145,150 miles.

F

151

Complaints

19

Crashes

0

Fires

4

Injuries

Exactly what failed

Antilock/Traction Control/Electronic Limited Slip 52 34.4%
Master Cylinder 20 13.2%
Foundation Components 17 11.3%
Rotor 10 6.6%
Disc 8 5.3%
Caliper 8 5.3%
Pads 7 4.6%
Vacuum 7 4.6%
Drum 4 2.6%
Conventional 3 2.0%

Brakes across every Ford Explorer year

1991 151 6.9%
1992 142 6.5%
1993 276 12.6%
1994 310 14.1%
1995 94 4.3%
1996 149 6.8%
1997 106 4.8%
1998 102 4.6%
1999 89 4.1%
2000 72 3.3%
2001 37 1.7%
2002 136 6.2%
2003 49 2.2%
2004 54 2.5%
2005 18 0.8%
2006 41 1.9%
2007 12 0.5%
2010 15 0.7%
2011 29 1.3%
2012 20 0.9%
2013 40 1.8%
2014 27 1.2%
2015 33 1.5%
2016 19 0.9%
2017 22 1.0%
2018 11 0.5%
2020 86 3.9%
2021 24 1.1%
2022 14 0.6%
2025 16 0.7%

What owners said

Filed with NHTSA, in their own words.

Carbondale, CO Crash

SERVICE BRAKES

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 towed after the accident. There were no warning lamps.

NHTSA complaint #11444373 — an unverified report by a vehicle owner.

Draper, UT

SERVICE BRAKES, AIR:DISC:ROTOR

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. I AM THOROUGHLY DISGUSTED AND BROKE. I PRAISED FORD BEFORE THIS, NOW I WOULDN'T RECOMMEND FORD TO ANYONE I KNOW. I AM A SINGLE MOTHER TRYING TO MAKE ENDS MEET AND NOW I HAVE NO TRANSPORTATION BECAUSE I CAN NO LONGER AFFORD TO FIX THIS TRUCK. I HAVE REPLACED THE TRANSMISSION, FRONT MAIN SEAL, WATER PUMP, STARTER, ROTORS, ALTERNATOR, AND THE LOW WHEEL DRIVE ON MY TRUCK BUT NOW ITS THE HEATER CORE AND I HAVE BEEN QUOTED OVER 600-800 TO FIX THIS! THAT IS IF I CAN FIND ANYONE WHO WANTS TO DO IT WHICH BY THE WAY NO ONE DOES. WHAT DO I DO NOW?

NHTSA complaint #10106282 — an unverified report by a vehicle owner.

Draper, UT

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT

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. I AM THOROUGHLY DISGUSTED AND BROKE. I PRAISED FORD BEFORE THIS, NOW I WOULDN'T RECOMMEND FORD TO ANYONE I KNOW. I AM A SINGLE MOTHER TRYING TO MAKE ENDS MEET AND NOW I HAVE NO TRANSPORTATION BECAUSE I CAN NO LONGER AFFORD TO FIX THIS TRUCK. I HAVE REPLACED THE TRANSMISSION, FRONT MAIN SEAL, WATER PUMP, STARTER, ROTORS, ALTERNATOR, AND THE LOW WHEEL DRIVE ON MY TRUCK BUT NOW ITS THE HEATER CORE AND I HAVE BEEN QUOTED OVER 600-800 TO FIX THIS! THAT IS IF I CAN FIND ANYONE WHO WANTS TO DO IT WHICH BY THE WAY NO ONE DOES. WHAT DO I DO NOW?

NHTSA complaint #10106282 — an unverified report by a vehicle owner.

at 130,000 miles Boca Raton, FL

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

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 REMOVED. VEHICLE SKIDS TO A STOP. FULL APPLICATION OF THE BRAKES FOR SEVERAL SECONDS IS REQUIRED TO RELEASE THE REAR WHEEL BRAKE DRUMS AND RESTORE NORMAL CONTROL TO THE DRIVER. THIS COULD EASILY RESULT IN LOSS OF VEHICLE CONTROL. SYMPTOMS PRESENT REGARDLESS OF WEATHER/ROAD CONDITIONS, VEHICLE SPEED, OR MANEUVER TYPE.

NHTSA complaint #10082713 — an unverified report by a vehicle owner.

at 160,300 miles Chapel Hill, NC

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

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 VEHICLE. THE MECHANIC SAID THIS MODEL WAS "BAD FOR PUSHING THE PADS OFF THE SHOES." WHILE PAYING MY BILL, I NOTICED ANOTHER SIMILAR VEHICLE ON THE RACK GETTING THE SAME THING DONE. IS THIS AN EPIDEMIC OR AM I JUST UNLUCKY? I HAVE CONTACTED FORD CUSTOMER ASSISTANCE AND THEY SAY THERE ARE NO RECALLS ON THIS SUBJECT AND NOTHING IS WRONG. RIGHT! VIN IS [XXX] I CAN'T GET THIS TO SEND WITHOUT ENTERING SOMETHING ON THE EQUIPMENT PAGES WHICH DOES NOT APPLY. PLEASE IGNORE. *LA INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #10049517 — an unverified report by a vehicle owner.

Tucson, AZ

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

WHILE DRIVING 55MPH BRAKE PEDAL WAS HARD, AND HAD EXTENDED STOPPING DISTANCE.

NHTSA complaint #8018452 — an unverified report by a vehicle owner.

Fort Wayne, IN

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:PADS

WHILE DRIVING FRONT PAD CAME OFF, AND FELL UNDER THE TRUCK, CAUSING MAJOR DAMGE TO VEHICLE.

NHTSA complaint #8015017 — an unverified report by a vehicle owner.

Stockton, CA

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

WHILE DRIVING ABOUT ANY MPH WOULD STEP ON BRAKE PEDAL TO STOP OR TO REDUCE VEHICLE SPEED, BUT VEHICLE WOULD NOT STOP ON TIME, RESULTING IN EXTENDED STOPPING DISTANCE. ALSO, ROTORS HAD BEEN REPLACED A COUPLE OF TIMES. PLEASE PROVIDE MORE INFORMATION.

NHTSA complaint #8004617 — an unverified report by a vehicle owner.

Stockton, CA

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

WHILE DRIVING ABOUT ANY MPH WOULD STEP ON BRAKE PEDAL TO STOP OR TO REDUCE VEHICLE SPEED, BUT VEHICLE WOULD NOT STOP ON TIME, RESULTING IN EXTENDED STOPPING DISTANCE. ALSO, ROTORS HAD BEEN REPLACED A COUPLE OF TIMES. PLEASE PROVIDE MORE INFORMATION.

NHTSA complaint #8004617 — an unverified report by a vehicle owner.

Hilo, HI Crash

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

CONSUMER WAS TRAVELING ABOUT 35MPH ON A SIDE STREET AND HEARD A JINGLE NOISE. HE PULLED OVER TO SHOULDER, AND LOOKED ALL OVER THE VEHICLE. WHEN HE APPLIED BRAKES PEDAL WENT ALL THE WAY TO THE FLOOR, AND VEHICLE SWERVED/ HIT A TREE STUMP, AND ROLLED OVER. VEHICLE WAS TOTALED. MANUFACTURER WAS NOTIFIED.

NHTSA complaint #8000821 — an unverified report by a vehicle owner.

Hilo, HI

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

WAS DRIVING BETWEEN 30-35MPH ON WET ROAD WENT TO APPLY THE BRAKES AND PEDAL WENT TO FLOOR. STEERED VEHICLE TO LEFT TO SLOW DOWN. VEHICLE STARTED SKIDDING. HIT A TREE STUMP AND VEHICLE FLIPPED OVER. VEHICLE WAS TOTALED. OUT OF VEHICLE, AND NOTICED PADS HAD FALLEN OFF INTO ROTORS. PADS HAD GOUGES. DISC PADS WERE MISSING.

NHTSA complaint #6900646 — an unverified report by a vehicle owner.

Hilo, HI

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

WAS DRIVING BETWEEN 30-35MPH ON WET ROAD WENT TO APPLY THE BRAKES AND PEDAL WENT TO FLOOR. STEERED VEHICLE TO LEFT TO SLOW DOWN. VEHICLE STARTED SKIDDING. HIT A TREE STUMP AND VEHICLE FLIPPED OVER. VEHICLE WAS TOTALED. OUT OF VEHICLE, AND NOTICED PADS HAD FALLEN OFF INTO ROTORS. PADS HAD GOUGES. DISC PADS WERE MISSING.

NHTSA complaint #6900646 — an unverified report by a vehicle owner.

Allen, TX

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

REAR BRAKES FAILED WITHOUT ANY WARNING OR INDICATION LATER CAUSING FRONT BRAKES TO FAIL.

NHTSA complaint #754765 — an unverified report by a vehicle owner.

Chipley, FL

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

I HAVE QUESTIONS TO WHY THERE ARE THESE FAILURES IN THESE 4 IMPORTANT AREAS OF MY VEHICLE, AND WOULD LIKE SOME ANSWERS! THANK YOU, I. E. STOWELL. NO SAFETY DEFEC TLISTED. *AK (DOT NUMBER: LT1018-D5 TIRESIZE: P235/75R15)

NHTSA complaint #754538 — an unverified report by a vehicle owner.

Lansing, MI

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

BRAKES ARE GRINDING LOUDLY, PEDAL FEELS SPONGY WHEN APPLYING BRAKES. DEALER REPLACED FRONT AND REAR PADS/ CALIPERS/ DRUMS, AND ROTORS. WHEN MAKING TURNS GRINDING BECAME WORSE. BRAKES WERE WEARING OUT FAR SOONER THAN NORMAL.

NHTSA complaint #887452 — an unverified report by a vehicle owner.

Lansing, MI

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:DRUM

BRAKES ARE GRINDING LOUDLY, PEDAL FEELS SPONGY WHEN APPLYING BRAKES. DEALER REPLACED FRONT AND REAR PADS/ CALIPERS/ DRUMS, AND ROTORS. WHEN MAKING TURNS GRINDING BECAME WORSE. BRAKES WERE WEARING OUT FAR SOONER THAN NORMAL.

NHTSA complaint #887452 — an unverified report by a vehicle owner.

Lansing, MI

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

BRAKES ARE GRINDING LOUDLY, PEDAL FEELS SPONGY WHEN APPLYING BRAKES. DEALER REPLACED FRONT AND REAR PADS/ CALIPERS/ DRUMS, AND ROTORS. WHEN MAKING TURNS GRINDING BECAME WORSE. BRAKES WERE WEARING OUT FAR SOONER THAN NORMAL.

NHTSA complaint #887452 — an unverified report by a vehicle owner.

West Caldwell, NJ

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

COMPLETE BRAKE FAILURE OCCURRED WHEN BACKING OUT OF PARKING SLOT. WAS ABLE TO STOP VEHICLE WITH THE PARKING BRAKE. FAILURE OF BRAKE PIPE, DUE TO CORROSION, JUST FORWARD OF REAR AXLE. THE TWO PIPES FROM THE JUNCTION BLOCK AT THE DIFFERENTIAL ALSO BADLY CORRODED BUT NOT LEAKING. CHANGED THESE ALSO AS A PRECAUTION. TOTAL LOSS OF BRAKING POWER WAS UNEXPECTED SINCE I BELIEVED THAT THERE WAS A DIAGONAL BRAKE SYSTEN OR OTHER BACKUP. IN ATTEMPTING TO PUMP THE BRAKE ONCE I STOPED ALL I SUCCESSED IN DOING WAS PUMPING BRAKE FLUID ON THE GROUND. THIS HAD THE PONTENTIAL FOR A SERIOUS ACCIDENT SINCE I WOULD HAVE BEEN HAULING A TRAILER IN A FEW DATS ON A LONG TRIP.

NHTSA complaint #744498 — an unverified report by a vehicle owner.

Ronkonkoma, NY

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

STARTER FAILED. *SLC RADIUS ARM NEEDED REPLACED. AIR CONDITIONER NEEDED REPLACED. HYDRAULIC CONTROL UNIT NEEDED REPLACED. *SLC

NHTSA complaint #559986 — an unverified report by a vehicle owner.

Wentzville, MO

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DIFFERENTIAL PROPORTIONAL VALVE

THE PROPORTIONING VALVE DOES NOT FUNCTION PROPERLY (SELF ADJUSTING MECHANISM) CAUSING POOR STOPPING ABILITY. *MJS

NHTSA complaint #558325 — an unverified report by a vehicle owner.

Racine, OH Crash

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

WHILE COMING AROUND A CURVE ON A WET ROAD AND APPLYING BRAKES TO SLOW DOWN, REAR WHEELS LOCKED UP, CAUSING VEHICLE TO ROLLOVER. NO INJURIES REPORTED. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER.

NHTSA complaint #876071 — an unverified report by a vehicle owner.

Birmingham, MI Crash

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

ACCIDENT OCCURRED IN THE AFTERNOON OF AUGUST 28TH, 1999 IN DURHAM, NORTH CAROLINA. THE ACCIDENT INVOLVED MY VEHICLE HITTING A VEHICLE IN FRONT OF ME (I WAS TRAVELLING AT ABOUT 35-45 MPH AND REACHED AN INTERSECTION WHERE TRAFFIC WAS STOPPED FOR THE LIGHT. I HIT THE BRAKES AND THOUGHT I HAD ENOUGH TIME TO STOP THE VEHICLE, BUT I ENDED UP REAR-ENDING A TRUCK (AT THE POINT OF IMPACT THE CAR WAS PROBABLY TRAVELLING 5-10 MPH)). ANYHOW WHEN I RECEIVED MY CAR FROM THE REPAIR SHOP IT RODE EXTREMELY ROUGHLY. AFTER TAKING IT TO A FIRESTONE DEALER THEY INFORMED ME THAT MY TREAD HAD 'SEPARATED' AND TOLD ME THE ONLY SOLUTION WAS TO BUY NEW TIRES. THIS IS ALL VERY CIRCUMSTANCIAL EVIDENCE (I REALIZE), BUT AFTER READING ABOUT OTHER SIMILAR INCIDENTS REGARDING THE SAME EQUIPMENT, I FELT COMPELLED TO REPORT THIS ACCIDENT AS WELL IN CASE THE TIRE TOO WERE RESPONSIBLE. THE FAULTY TIRES (2 OF 4) HAVE SINCE BEEN DISCARDED. I WOULD APPRECIATE KNOWING WHETHER THE TIRE SEPARATION COULD HAVE BEEN RELATED TO THE ACCIDENT AS I KNOW THINK IT MAY HAVE (THE TIRE'S TREAD WAS NOT SEPARATED PRIOR TO THE ACCIDENT AND THE OTHER TIRES WHICH HAD BEEN PURCHASED AT THE SAME TIME ARE STILL ROADWORTHY). *AK( DOT NUMBER: TIRE SIZE: P235/75R15 )

NHTSA complaint #726753 — an unverified report by a vehicle owner.

Sarasota, FL

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

CONFIRMATION INFO...COLUMES DOESN'T MY INFO....BUT TO ADD TRANSMISSION WAS REPLACE, WAS INFORMED VEHICLE WAS REPAINTED BY AAA, BRAKES WENT OUT, REPLACED CABLE WIRES TO BATTRERY- WIRED COAT HANGER PIECES IN WITH CABLE WIRES...

NHTSA complaint #724839 — an unverified report by a vehicle owner.

Ocean Springs, MS Crash 1 injured

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

MY ABS LIGHT CAME ON WHILE I WAS DRIVING AT APPROX. 5 P.M. ON 4/28/2000. I CONTINUED WITH MY DAILY ACTIVITIES AND MADE A MENTAL NOTE TO GET THIS CHECKED OUT. AT APPROX. 6P.M. I WAS TRAVELING AT AROUND 45 MPH WHEN A CAR CUT IN FRONT OF ME. I HIT THE BRAKES, THE REAR TIRES LOCKED UP, AND THE VEHICLE WENT IMMEDIATELY INTO A 90+ DEGREE SLIDE, THE VEHICLE ROLLED 1 FULL TIME AND LANDED UPRIGHT FACING THE LANE I WAS JUST IN. I'VE DRIVEN 3 CARS WITHOUT ABS AND I'VE NEVER HAD THE REAR TIRES LOCK UP SO EASILY.

NHTSA complaint #722389 — an unverified report by a vehicle owner.

Ocean Springs, MS Crash

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM

I ALREADY ENTERED A COMPLAINT (#722389) THEN I READ THE CONSUMER COMPLAINTS AND REALIZED THAT 2 THINGS THAT I THOUGHT WERE NORMAL MIGHT NOT BE. THE FRIST ONE BEING THAT A I HEARD THE SQUISHY NOISE COMING FROM MY MASTER CYLINDER/ VACUUM BOOSTER THE PEDAL WAS ALWAYS SOFT BUT I NEVER ENCOUNTERED ANY DIFFICULY STOPPING THAT I CAN REMEMBER. THE OTHER PROBLEM IS THAT AFTER MY EXPLORER ROLLED AND CAME TO REST, THE DRIVER'S SEAT WAS COMPLETELY LAID BACK.

NHTSA complaint #722390 — an unverified report by a vehicle owner.

Ocean Springs, MS Crash

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

I ALREADY ENTERED A COMPLAINT (#722389) THEN I READ THE CONSUMER COMPLAINTS AND REALIZED THAT 2 THINGS THAT I THOUGHT WERE NORMAL MIGHT NOT BE. THE FRIST ONE BEING THAT A I HEARD THE SQUISHY NOISE COMING FROM MY MASTER CYLINDER/ VACUUM BOOSTER THE PEDAL WAS ALWAYS SOFT BUT I NEVER ENCOUNTERED ANY DIFFICULY STOPPING THAT I CAN REMEMBER. THE OTHER PROBLEM IS THAT AFTER MY EXPLORER ROLLED AND CAME TO REST, THE DRIVER'S SEAT WAS COMPLETELY LAID BACK.

NHTSA complaint #722390 — an unverified report by a vehicle owner.

Lake Wood, CO

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

WHILE PULLING OUT OF PARK POSITION BRAKES WOULD LOCK UP. CAUSING CONSUMER TO PULL WHEEL OFF TO RETURN TO NORMAL WHILE TRAVELING. PLEASE PROVIDE FURTHER INFORMATION.

NHTSA complaint #860654 — an unverified report by a vehicle owner.

Taft, CA

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

BRAKE ROTORS CRACKED.

NHTSA complaint #534006 — an unverified report by a vehicle owner.

Taft, CA

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

ROTORS CRACKING

NHTSA complaint #534006 — an unverified report by a vehicle owner.

Taft, CA

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:PADS

BRAKE PADS CRACKED.

NHTSA complaint #534006 — an unverified report by a vehicle owner.

Other 1991 Ford Explorer problems

← Full 1991 Ford Explorer report