Ford Explorer 1991–1994
1st generation · UN46
NHTSA data through 12 August 20264,294 complaints, 224 with mileageMethod
On this generation, 56% of failures occur beyond 100,000 miles — a wear pattern.
- Rest of the range
- Median
- 200,000+ — 20 complaints (8.9%), plotted separately
- 10%
- 43,000
- 25%
- 79,600
- Median
- 101,000
- 75%
- 145,000
- 90%
- 197,000
Show the numbers
| Mileage | Complaints | Share |
|---|---|---|
| 0–20,000 | 14 | 6.2% |
| 20,000–40,000 | 7 | 3.1% |
| 40,000–60,000 | 5 | 2.2% |
| 60,000–80,000 | 31 | 13.8% |
| 80,000–100,000 | 42 | 18.8% |
| 100,000–120,000 | 35 | 15.6% |
| 120,000–140,000 | 28 | 12.5% |
| 140,000–160,000 | 18 | 8.0% |
| 160,000–180,000 | 15 | 6.7% |
| 180,000–200,000 | 9 | 4.0% |
| 200,000+ | 20 | 8.9% |
What this can and cannot tell you: these are complaints owners chose to file, not a failure rate. Popular models accumulate more of them simply by being common. How this is built.
Owners filed 4,294 complaints with NHTSA about the 1991–1994 Ford Explorer, and 224 of them record the mileage at which the failure happened. That is enough to show not just what fails, but when.
56% of failures occur beyond 100,000 miles — a wear pattern. The car generally reaches substantial mileage before trouble starts.
The most-reported areas are the tyres (21.2% of complaints, typically around 97,000 miles), the hydraulic brake circuit (18.9% of complaints, typically around 100,000 miles), body structure (8.3% of complaints, typically around 153,000 miles).
What fails, and when
- Tyres97,000median 97,100 miles, middle half 69,000 to 140,000
- Hydraulic brake circuit100,000median 100,000 miles, middle half 88,000 to 135,000
- Body structure153,000median 153,000 miles, middle half 88,000 to 198,000
- Transmission and driveline100,000median 99,999 miles, middle half 30,000 to 154,000
- Engine and its cooling system91,000median 91,250 miles, middle half 86,000 to 124,000
- Electrical system114,000median 114,000 miles, middle half 89,000 to 138,000
- Visibility equipment94,000median 93,500 miles, middle half 75,000 to 101,000
| System | Complaints | Share | Median | 25–75% |
|---|---|---|---|---|
| Tyres | 912 | 21.2% | 97,000 | 69,000–140,000 |
| Hydraulic brake circuit | 810 | 18.9% | 100,000 | 88,000–135,000 |
| Body structure | 357 | 8.3% | 153,000 | 88,000–198,000 |
| Transmission and driveline | 335 | 7.8% | 100,000 | 30,000–154,000 |
| Engine and its cooling system | 303 | 7.1% | 91,000 | 86,000–124,000 |
| Electrical system | 250 | 5.8% | 114,000 | 89,000–138,000 |
| Suspension | 239 | 5.6% | — | — |
| Visibility equipment | 212 | 4.9% | 94,000 | 75,000–101,000 |
| Throttle and speed control | 140 | 3.3% | 106,000 | 80,000–195,000 |
| Equipment | 114 | 2.7% | — | — |
Which systems, and when
Complaints about this generation are not spread evenly across the vehicle, and the systems that generate the most of them do not all fail at the same point in a car's life. The median failure across all systems here is 101,000 miles; the figures below show which parts of the car run ahead of that and which run behind.
The tyres account for 21.2% of complaints (912 reports, 24 of them with a mileage figure), with a median of 97,100 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 68,940 and 140,000 miles.
The hydraulic brake circuit accounts for 18.9% of complaints (810 reports, 21 of them with a mileage figure), with a median of 100,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 88,500 and 135,000 miles.
Body structure accounts for 8.3% of complaints (357 reports, 10 of them with a mileage figure), and it fails late — a median of 153,000 miles, considerably beyond the vehicle's overall median. That pattern is consistent with normal service life rather than a defect, though it matters for anyone buying an example already near that mileage. The middle half of these reports falls between 88,000 and 198,000 miles.
The transmission and driveline accounts for 7.8% of complaints (335 reports, 15 of them with a mileage figure), with a median of 99,999 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 30,000 and 154,233 miles.
The engine and its cooling system accounts for 7.1% of complaints (303 reports, 17 of them with a mileage figure), with a median of 91,250 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 86,000 and 124,000 miles.
The electrical system accounts for 5.8% of complaints (250 reports, 42 of them with a mileage figure), with a median of 114,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 89,000 and 138,000 miles.
Differences between model years
Within this generation, complaint volume is not constant across model years. The 1994 model year drew the most — 1,531 complaints — while 1991 drew the fewest at 764. The median year sits at 999.
Recalls and what they cover
No recall campaigns covering this generation appear in NHTSA's post-2010 recall file. That is not the same as an absence of problems — recalls address safety defects specifically, and many of the complaints above concern faults that are expensive or annoying without meeting that threshold.
Reported severity
Of the 4,294 complaints filed against this generation, 346 reported a crash; 303 reported a fire; 484 reported an injury; 35 reported a fatality. Crash-involved reports represent 8.1% of the total.
These are owner-reported outcomes, not verified investigations, and they are not adjusted for how many of these vehicles are on the road. They are included because the distinction between a fault that strands a car and a fault that causes a collision is the one that matters most, and it is not visible in a complaint count alone.
What this means if you are buying one
For a buyer, a late-failure pattern shifts the question from whether to when. 56% of reported failures occur beyond 100,000 miles, so an example approaching that figure is approaching the range where other owners started reporting problems. The middle half of all failures falls between 79,600 and 145,000 miles.
On inspection, the tyres and the hydraulic brake circuit are where this generation's reports concentrate, so those are the areas worth a specific look. The tyres in particular shows a median failure mileage of 97,100, which gives a concrete number to compare against the odometer of any car you are considering.
None of this is a substitute for a pre-purchase inspection on the individual car. Aggregate patterns describe a population; the example in front of you has its own history.
Documented problems
Suspension/Tires 1991–1994
Early expression of the rollover/tire-separation pattern that later became the Firestone crisis; low recommended tire pressure (26 psi) combined with a high center of gravity.
By model year
| Year | Complaints | With mileage |
|---|---|---|
| 1991 | 764 | 37 |
| 1992 | 848 | 37 |
| 1993 | 1,151 | 46 |
| 1994 | 1,531 | 104 |
What owners reported
Uniroyal tire side wall cracks lt 235 75r15 - no failure - just crack. All 4 of my tires had a side wall crack the entire diameter of the tire about 3 inches down on the side wall . I noticed the crack on the inside as well so it appears the tires had some issue. I had never applied tire foam cleaner(armor all…
1991 · 2,000 miles · Tyres
On june 4th my daughter and i were driving east bound on 62nd and over-hill in los angeles ca. Shortly after 12:00pm. When suddenly the Ford Explorer was engulfed in flames. My daughter and i were ordered to exit the vehicle. I was never notified of a recall. Due to investigation on my own i have received a recall…
1991 · 15,000 miles · Fuel and propulsion system
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…
1991 · 74,000 miles · Engine and its cooling system
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 wheel drive to see…
1991 · 75,000 miles · Transmission and driveline
Built from 224 NHTSA complaints with mileage · snapshot 2026-08-12 · open data · reproduce this page