FaultScore

1991 Ford Explorer engine problems

66 of the 764 complaints about the 1991 Ford Explorer are about the engine — 9% of everything reported for this model year. Half of the failures with a mileage on record happened before 74,096 miles.

F

66

Complaints

0

Crashes

17

Fires

2

Injuries

Exactly what failed

Gasoline 25 37.9%
Engine 18 27.3%
FAN 10 15.2%
Radiator Assembly 4 6.1%
Cooling System 4 6.1%
Engine AND Engine Cooling 2 3.0%
Exhaust System 1 1.5%
Manifold/Header/Muffler/Tail Pipe 1 1.5%
Emission Control 1 1.5%

Engine & Cooling across every Ford Explorer year

1991 66 1.6%
1992 84 2.0%
1993 68 1.6%
1994 89 2.1%
1995 55 1.3%
1996 96 2.3%
1997 227 5.4%
1998 212 5.1%
1999 112 2.7%
2000 102 2.4%
2001 47 1.1%
2002 214 5.1%
2003 91 2.2%
2004 116 2.8%
2005 47 1.1%
2006 227 5.4%
2007 38 0.9%
2008 25 0.6%
2010 17 0.4%
2011 104 2.5%
2012 93 2.2%
2013 292 7.0%
2014 264 6.3%
2015 294 7.1%
2016 495 11.9%
2017 313 7.5%
2018 123 3.0%
2019 24 0.6%
2020 136 3.3%
2021 58 1.4%
2022 29 0.7%
2023 11 0.3%

What owners said

Filed with NHTSA, in their own words.

Greenup, KY Fire 1 injured

ENGINE AND ENGINE COOLING

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 AND MASSIVE FLAMES ERUPTED FROM THE ENGINE COMPARTMENT. THE FIRE DEPARTMENT WAS CALLED TO THE SCENE. THE VEHICLE WAS COMPLETELY DESTROYED AND HAS NOT BEEN TOWED AWAY FROM THE SCENE. THE CONTACT SUSTAINED MINOR INJURIES TO HER HANDS. THE INSURANCE COMPANY WAS NOTIFIED OF THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE UNAVAILABLE.

NHTSA complaint #10267328 — an unverified report by a vehicle owner.

at 74,096 miles LOS Angeles, CA

ENGINE AND ENGINE COOLING:ENGINE

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 DISCOVERED THAT NO LUGS; BOLTS WERE PUT BACK ON THE FRONT WHEEL. THE CONSUMER WAS HAVING ENGINE WORK DONE TO THE VEHICLE. WHY WOULD THEY TAKE THE WHEELS OFF TO SERVICE THE ENGINE, AND THEN NOT PUT THE BOLTS BACK ON. *AK THE CONSUMER FELT THAT THIS WAS AN ACT OF VANDALISM. *SC

NHTSA complaint #10099632 — an unverified report by a vehicle owner.

at 91,250 miles Hazard, KY

ENGINE AND ENGINE COOLING:ENGINE

I HAVE A 1991 FORD EXPLORER AND AT 91026.8 MILES IT BLEW THE HEAD GASKETS . I HAVE SINCE LEARNED THAT THIS TRUCK IS BAD FOR DOING THIS . IT HAS A 4.0 - V6I DON'T KNOW WHY FORD IS NOT HELD ACCOUNTABLE FOR THIS . *NLM

NHTSA complaint #10014376 — an unverified report by a vehicle owner.

at 60,000 miles Winchester, VA

ENGINE AND ENGINE COOLING

TRUCK LEAKING ANTIFREEZE AND REQUIRED REPLACEMENT OF HEAD GASKET AND MANIFOLD GASKET. *NLM

NHTSA complaint #10014297 — an unverified report by a vehicle owner.

Wyoming, MI Fire

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

WHILE CONSUMER WAS PAYING A TOLL AT THE TOLL BOOTH, VEHICLE CAUGHT ON FIRE IN THE ENGINE COMPARTMENT, THERE WAS DAMAGE TO THE TOLL BOOTH AND THE VEHICLE WAS COMPLETELY CONSUMED BY THE FIRE, OHIO TRAFFIC CRASH REPORT. *SLC

NHTSA complaint #566987 — an unverified report by a vehicle owner.

SAN Antonio, TX Fire

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

VEHICLE EXPERIENCED A FIRE IN THE ENGINE AREA/RUNNING GEAR/WHEEL AREA.*JG (FIRE INCIDENT REPORT)

NHTSA complaint #567003 — an unverified report by a vehicle owner.

Wilmette, IL

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

CONSUMER STATES VEHICLE HAS AN OIL LEAK.

NHTSA complaint #785769 — an unverified report by a vehicle owner.

Stockton, CA Fire

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

WHILE CONSUMER'S DAUGTHER WAS DRIVING ABOUT 25 MPH ENGINE SUDDENLY STALLED. THEN, DRIVER RESTARTED ENGINE WHEN SHE SAW FIRE COMING FROM DRIVER'S SIDE. JUMPED OUT, AND VEHICLE BURNED DOWN. FIRE DEPARTMENT COULD NOT DETERMINE WHERE FIRE HAD STARTED. PLEASE PROVIDE MORE INFORMATION.

NHTSA complaint #8004615 — an unverified report by a vehicle owner.

Chipley, FL

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

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.

Chipley, FL

ENGINE AND ENGINE COOLING:COOLING SYSTEM

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.

Wilmette, IL

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

CONSUMER STATES VEHICLE HAS AN OIL LEAK.

NHTSA complaint #785769 — an unverified report by a vehicle owner.

Delta, PA

ENGINE AND ENGINE COOLING:ENGINE

BLACK GOO OOZES OUT FROM AROUND THE LACING OF STEERING WHEEL. CONSTANTLY HAVE THE WIPE WHEEL & HANDS. DRIVER'S SEAT BROKE AND WENT BACKWARDS WHILE DRIVING. I ONLY WEIGHT 185 LBS. SO WEIGHT SHOULD NOT BE A PROBLEM. THERE HAD BEEN NO REAR-END COLLISION EITHER. FRONT WHEEL HUBS FAILED DUE TO ENGINEERING DEFECT. DEALER TRIED TO MAKE ME PAY THE FIRST $55. I REFUSED AND WON. THE TRANSMISSION PROBLEM WAS A SHAFT THAT SNAPPED. VALVE GASKETS ARE INFERIOR MATERIAL. HAVE BEEN TIGHTENED, BUT STILL LEAK.

NHTSA complaint #752295 — an unverified report by a vehicle owner.

Solvay, NY

ENGINE AND ENGINE COOLING:ENGINE

THE FAULTY ALUMINIUM HEADS CRACKED CAUSING THE VEHICLE TO OVERHEAT RESULTING IN THE NUMBER ONE PISTON MELTING AND DAMAGE TO THE CYLINDERS.

NHTSA complaint #561444 — an unverified report by a vehicle owner.

Sarasota, FL Fire

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

THE THERMOSTAT FAILED CAUSING THE VEHICLE TO OVERHEAT. NLM

NHTSA complaint #560209 — an unverified report by a vehicle owner.

Ronkonkoma, NY

ENGINE AND ENGINE COOLING:ENGINE

VEHICLE HAS EXPERIENCED SOME ENGINE PROBLEMS, ENGINE WAS REPLACED ON 8-5-98, ON 1-7-99 MORE ENGINE PROBLEMS CAME ABOUT AND IT WAS DISCOVERED THAT THE FLYWHEEL HAD BROKEN WHEN THE TRANSMISSION WAS REPLACED, HOWEVER THE FLYWHEEL HAS NOW BEEN REPLACED 4 TIMES AND ON THE LAST TIME THE FLYWHEEL COMPLETELY BROKE, CONSUMER ALSO STATES THAT THE MOTOR CHEWS UP THE DIPSTICK AND THIS PART HAS BEEN REPLACED 3 TIMES. *SLC

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

Ronkonkoma, NY

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

VEHICLE HAS EXPERIENCED SOME ENGINE PROBLEMS, ENGINE WAS REPLACED ON 8-5-98, ON 1-7-99 MORE ENGINE PROBLEMS CAME ABOUT AND IT WAS DISCOVERED THAT THE FLYWHEEL HAD BROKEN WHEN THE TRANSMISSION WAS REPLACED, HOWEVER THE FLYWHEEL HAS NOW BEEN REPLACED 4 TIMES AND ON THE LAST TIME THE FLYWHEEL COMPLETELY BROKE, CONSUMER ALSO STATES THAT THE MOTOR CHEWS UP THE DIPSTICK AND THIS PART HAS BEEN REPLACED 3 TIMES. *SLC

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

Chester, PA

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

KNOCKS WHEN PRESS BRAKES, NO HEAT.

NHTSA complaint #741681 — an unverified report by a vehicle owner.

Gadsden, AL

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

WHILE DRIVING, THE ENGINE SHUT OFF, CAUSING THE WHEEL AND BRAKES TO LOCK UP, THE VEHICLE HIT A HILL AND ROLLED ONTO THE DRIVER'S SIDE. *SLC

NHTSA complaint #556826 — an unverified report by a vehicle owner.

Gadsden, AL

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

WHILE DRIVING, THE ENGINE SHUT OFF, CAUSING THE WHEEL AND BRAKES TO LOCK UP, THE VEHICLE HIT A HILL AND ROLLED ONTO THE DRIVER'S SIDE. *SLC

NHTSA complaint #556826 — an unverified report by a vehicle owner.

West Hollywood, CA

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

WHILE DRIVING ENGINE WOULD SUDDENLY STALL OUT. WOULD HAVE NO WARNING. WOULD HAPPEN AT ANY SPEED. ENGINE LIGHT WOULD FLASH ON/OFF. TOOK VEHICLE TO DEALERSHIP & WAS INFORMED BY MECHANIC IT WAS MASS AIR FLOW WAS CAUSING A SHORT IN ENGINE LIGHT. PROBLEM WAS INTERMITTENT.

NHTSA complaint #875372 — an unverified report by a vehicle owner.

ST. John, AZ

ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

FAN THAT COOLS ENGINE IS MADE OF NYLON, IF IT FAILS IT COULD COME THROUGH FAN BLADES AND THROUGH RADIATOR. CONSUMER FEELS ITS A MANUFACTURER'S DEFECT.*AK FAILURE OF NYLON FAN COULD CAUSE SEVERE DAMAGE TO RADIATOR, HOSES AND THE HOOD.

NHTSA complaint #874620 — an unverified report by a vehicle owner.

Sedalia, MO

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

ENGINE FAILED. *SLC

NHTSA complaint #554720 — an unverified report by a vehicle owner.

Sedalia, MO

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

ENGINE FAILED. *SLC

NHTSA complaint #554720 — an unverified report by a vehicle owner.

Running Spring, CA

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

WHILE DRIVING ON HIGHWAY ENGINE COMPLETELY SHUTS DOWN WITHOUT WARNING CAUSING LOSS OF VEHICLE CONTROL. *AK THE BRAKES AND THE POWER STEERING FAILED WHEN THE VEHICLE STALLED. MAF SENSOR FAILED. THROTTLE BODY AND GASKET FAILED. RADIATOR IS LEAKING. THERMOSTAT FAILED.

NHTSA complaint #871873 — an unverified report by a vehicle owner.

Running Spring, CA

ENGINE AND ENGINE COOLING:ENGINE

WHILE DRIVING ON HIGHWAY ENGINE COMPLETELY SHUTS DOWN WITHOUT WARNING CAUSING LOSS OF VEHICLE CONTROL. *AK THE BRAKES AND THE POWER STEERING FAILED WHEN THE VEHICLE STALLED. MAF SENSOR FAILED. THROTTLE BODY AND GASKET FAILED. RADIATOR IS LEAKING. THERMOSTAT FAILED.

NHTSA complaint #871873 — an unverified report by a vehicle owner.

Running Spring, CA

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

WHILE DRIVING ON HIGHWAY ENGINE COMPLETELY SHUTS DOWN WITHOUT WARNING CAUSING LOSS OF VEHICLE CONTROL. *AK THE BRAKES AND THE POWER STEERING FAILED WHEN THE VEHICLE STALLED. MAF SENSOR FAILED. THROTTLE BODY AND GASKET FAILED. RADIATOR IS LEAKING. THERMOSTAT FAILED.

NHTSA complaint #871873 — an unverified report by a vehicle owner.

Pearl City, HI

ENGINE AND ENGINE COOLING:COOLING SYSTEM

1991 FORD EXPLORER COOLING SYSTEM WAS INADEQUATE TO COOL THE 4.0L V-6 ENGINE ADAPTED FROM THE FORD F100 SERIES TRUCK. I HAVE TALKED TO NUMEROUS OWNERS WHO EXPERIENCED THE SAME PROBLEM. THE ENGINE COOKS THERMOSTATS ABOUT EVERY 2 YEARS OR 30000 MILES. A AM A MARINE AND WHILE I WAS DEPLOYED OVERSEAS FOR 6 MONTHS, MY WIFE NOTICED THAT THE TEMPERATURE GAUGE WAS FLUCTUATING SIGNIFICANTLY. SHE REPORTED THIS TO SANDERS FORD IN JACKSONVILLE, NC AND WAS TOLD IT WAS NORMAL. SHE EXPLAINED THAT THE TEMP GAUGE HAD NEVER MOVED BEFORE BUT THEY INSISTED THAT IT NORMALLY FLUCTUATES. ABOUT 2 WKS LATER, MY WIFE NOTICED THAT IT WAS LOOSING COOLANT CONSTANTLY. SHE TOOK THE TRUCK BACK TO SANDER FORD, IN JACKSONVILLE, NC AND AFTER FORFEITING $1478.32 AND 2 DAYS LOSS OF THE VEHICLE, HER SUSPICION WAS CONFIRMED THAT THE CYLINDER HEAD HAD WARPED. THIS COMMON PROBLEM TO THE EARLY MODEL FORD EXPLORERS HAS NEVER BEEN RECALLED BY FORD. MORE ALARMING IS THE PROPENSITY OF FORD DEALERSHIPS TO BE DISHONEST AND MONOPOLIZING IN OVERPRICING PARTS AND SERVICE. WE HAVE OBSERVED THIS IN CA, VA, NC, AND HI. FORD MOTOR CO APPEARS UNABLE TO CONTROL QUALITY OF SERVICE IN ITS FRANCHISE DEALERSHIPS.

NHTSA complaint #725151 — an unverified report by a vehicle owner.

Sarasota, FL Fire

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

ENGINE FIRE. MJS

NHTSA complaint #549194 — an unverified report by a vehicle owner.

Sarasota, FL

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

THERMOSTAT STUCK, ENGINE BLEW UP DUE TO OVERHEATING AND CRACKED HEAD GASKET. MJS

NHTSA complaint #549194 — an unverified report by a vehicle owner.

Salida, CA Fire 3 injured

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

POSSIBLE ENGINE FAILURE RESULTED IN VEHICLE FIRE, ON TWO OCCASIONS. NLM

NHTSA complaint #548068 — an unverified report by a vehicle owner.

Other 1991 Ford Explorer problems

← Full 1991 Ford Explorer report