Ford Explorer 1991–1994 problems by year and mileage
1st generation · UN46
NHTSA data through 24 September 20263,385 complaints, 175 with mileageMethod
Which year is yours? Tap it to see what breaks on it.
The 1991 Ford Explorer
Close- Median failure report
- 122,000 mi
- Complaints filed
- 609
- Recalls naming this year
- 8
Most reported on the 1991
- Hydraulic brake circuit118 reports
- Tyres102 reports
- Transmission and driveline69 reports
8 recall campaigns name the 1991: Structure — body; Service brakes, hydraulic — power assist; Seat belts — front. Not every car in a campaign is affected — check the VIN at NHTSA. Recall repairs are free.
The 1992 Ford Explorer
Close- Median failure report
- 111,000 mi
- Complaints filed
- 633
- Recalls naming this year
- 4
Most reported on the 1992
- Tyres128 reports
- Hydraulic brake circuit97 reports
- Transmission and driveline77 reports
4 recall campaigns name the 1992: Structure — body; Visibility — rearview mirrors/devices; Service brakes, hydraulic — power assist. Not every car in a campaign is affected — check the VIN at NHTSA. Recall repairs are free.
The 1993 Ford Explorer
Close- Median failure report
- 117,000 mi
- Complaints filed
- 939
- Recalls naming this year
- 6
Most reported on the 1993
- Tyres243 reports
- Hydraulic brake circuit222 reports
- Body structure86 reports
6 recall campaigns name the 1993: Structure — body; Visibility — rearview mirrors/devices; Service brakes, hydraulic — power assist. Not every car in a campaign is affected — check the VIN at NHTSA. Recall repairs are free.
The 1994 Ford Explorer
Close- Median failure report
- 99,000 mi
- Complaints filed
- 1,207
- Recalls naming this year
- 4
Most reported on the 1994
- Tyres331 reports
- Hydraulic brake circuit238 reports
- Body structure158 reports
4 recall campaigns name the 1994: Structure — body; Visibility — rearview mirrors/devices; Service brakes, hydraulic — power assist. Not every car in a campaign is affected — check the VIN at NHTSA. Recall repairs are free.
Each tile shows the median mileage at which that model year’s failures were reported. The 1991 reports latest and the 1994 earliest, but part of that gap is age: the 1991 has had 3 more years on the road to accumulate mileage.
The short answer
“Is the 1991–1994 Ford Explorer reliable?”
- Median of reported failures
- 104,000 mi
- 90% of reports came by
- 197,000 mi
- Reports with mileage
- 175
- Recalls
- 12
Most reported
- Tyres23.7% of complaints · median 97,000 mi
- Hydraulic brake circuit19.9% of complaints · median 100,000 mi
- Body structure10.0% of complaints · median 153,000 mi
Owners filed 3,385 complaints with NHTSA about the 1991–1994 Ford Explorer; the tyres leads with 23.7% of them, and half of the 175 that record an odometer reading came by 104,000 miles. A count like this can’t rate reliability on its own: NHTSA records what owners chose to report, not how many of each car were sold.
59% of failures occur beyond 100,000 miles — a wear pattern. The car generally reaches substantial mileage before trouble starts.
Before-you-buy checklist ↓At your mileage ↓Check this VIN — NHTSA ↗
How many miles does a 1991–1994 Ford Explorer last?
Complaint records can’t measure how long a car lasts; they show when reported failures happened. On the 1991–1994 Ford Explorer, half of the 175 complaints that record an odometer reading were filed by 104,000 miles and 90% by 197,000 miles.
47 reports came in past 150,000 miles and 15 past 200,000 — each one proof that an Explorer reached that mileage, not that it failed there.
Figure 1 · Ford Explorer 1991–1994 · 175 reports with mileage
Mileage at failure
Complaints per 20,000-mile bin, 0 to 200,000 miles, equal bins on a linear scale. Tallest bar = 27 complaints.
- Rest of the range
- Median
- 200,000+ — 15 complaints (8.6%), plotted separately
- 10%
- 43,000
- 25%
- 79,300
- Median
- 104,000
- 75%
- 150,000
- 90%
- 197,000
Show the numbers
| Mileage | Complaints | Share |
|---|---|---|
| 0–20,000 | 10 | 5.7% |
| 20,000–40,000 | 6 | 3.4% |
| 40,000–60,000 | 4 | 2.3% |
| 60,000–80,000 | 25 | 14.3% |
| 80,000–100,000 | 27 | 15.4% |
| 100,000–120,000 | 25 | 14.3% |
| 120,000–140,000 | 22 | 12.6% |
| 140,000–160,000 | 18 | 10.3% |
| 160,000–180,000 | 14 | 8.0% |
| 180,000–200,000 | 9 | 5.1% |
| 200,000+ | 15 | 8.6% |
Source: NHTSA Office of Defects Investigation, public domain. Complaint counts reflect what owners reported and are not a measure of failure rate per vehicle sold.
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.
Common Explorer problems, and when they happen
Figure 2 · Ford Explorer 1991–1994
When each system fails
Bar spans the middle half of reports; the notch inside each bar is the median. Miles at failure on a proportional scale — equal distances are equal ratios, not equal miles.
- Tyres803 reports97,00069,000–140,000Tyres: 803 reports, median 97,000 miles, middle half 69,000 to 140,000 miles.
- Engine and its cooling system245 reports97,00086,000–171,000Engine and its cooling system: 245 reports, median 97,000 miles, middle half 86,000 to 171,000 miles.
- Transmission and driveline304 reports100,00030,000–154,000Transmission and driveline: 304 reports, median 100,000 miles, middle half 30,000 to 154,000 miles.
- Hydraulic brake circuit675 reports100,00068,000–150,000Hydraulic brake circuit: 675 reports, median 100,000 miles, middle half 68,000 to 150,000 miles.
- Electrical system216 reports110,00089,000–141,000Electrical system: 216 reports, median 110,000 miles, middle half 89,000 to 141,000 miles.
- Throttle and speed control133 reports110,00080,000–195,000Throttle and speed control: 133 reports, median 110,000 miles, middle half 80,000 to 195,000 miles.
- Body structure337 reports153,00088,000–198,000Body structure: 337 reports, median 153,000 miles, middle half 88,000 to 198,000 miles.
- Your odometer — appears after you enter it in “Where your car sits”
Ordered by median mileage, earliest first. The first 12,000 miles are shaded: that is the boundary this site uses between a manufacturing defect and ordinary wear, not a property of the world.
Source: NHTSA Office of Defects Investigation, public domain.
All systems in a table
| System | Complaints | Share | Median | 25–75% |
|---|---|---|---|---|
| Tyres | 803 | 23.7% | 97,000 | 69,000–140,000 |
| Hydraulic brake circuit | 675 | 19.9% | 100,000 | 68,000–150,000 |
| Body structure | 337 | 10.0% | 153,000 | 88,000–198,000 |
| Transmission and driveline | 304 | 9.0% | 100,000 | 30,000–154,000 |
| Engine and its cooling system | 245 | 7.2% | 97,000 | 86,000–171,000 |
| Suspension | 217 | 6.4% | — | — |
| Electrical system | 216 | 6.4% | 110,000 | 89,000–141,000 |
| Visibility equipment | 205 | 6.1% | — | — |
| Throttle and speed control | 133 | 3.9% | 110,000 | 80,000–195,000 |
| Equipment | 111 | 3.3% | — | — |
System by system, in words
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 104,000 miles; the figures below show which parts of the car run ahead of that and which run behind.
The tyres account for 23.7% of complaints (803 reports, 24 of them with a mileage figure), with a median of 97,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 69,000 and 140,000 miles.
The hydraulic brake circuit accounts for 19.9% of complaints (675 reports, 15 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 68,000 and 150,000 miles.
Body structure accounts for 10.0% of complaints (337 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 9.0% of complaints (304 reports, 15 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 30,000 and 154,000 miles.
The engine and its cooling system accounts for 7.2% of complaints (245 reports, 16 of them with a mileage figure), with a median of 97,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 86,000 and 171,000 miles.
The electrical system accounts for 6.4% of complaints (216 reports, 38 of them with a mileage figure), with a median of 110,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 89,000 and 141,000 miles.
Known problems with the 1991–1994 Explorer
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.
Before you buy a 1991–1994 Explorer: the 3-minute check
Generated from 175 mileage-tagged complaints, 12 recall campaigns, 1 documented problem area. Print this page — the checklist survives print.
- Run the VIN at nhtsa.gov/recalls. 12 campaigns cover this generation; an open recall is a free repair you can make the seller's problem.
- Check suspension/tires on 1991–1994 cars. 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.
- End with a pre-purchase inspection of this car. Aggregate data describes the population; the example in front of you has its own history.
For a buyer, a late-failure pattern shifts the question from whether to when. 59% 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 79,000 and 150,000 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 97,000, 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.
Explorer problems by mileage: where your car sits
Type your odometer reading, or read the common mileages in the table. Your marker lands on the timing chart above and on the curve below.
| System | Middle half of reports, mi | At 60k mi11% below | At 90k mi31% below | At 120k mi55% below | At 150k mi73% below | At 200k mi91% below |
|---|---|---|---|---|---|---|
| Tyres | 69,000–140,000 | later | in window | in window | earlier | earlier |
| Hydraulic brake circuit | 68,000–150,000 | later | in window | in window | earlier | earlier |
| Body structure | 88,000–198,000 | later | in window | in window | in window | earlier |
| Transmission and driveline | 30,000–154,000 | in window | in window | in window | in window | earlier |
| Engine and its cooling system | 86,000–171,000 | later | in window | in window | in window | earlier |
| Electrical system | 89,000–141,000 | later | in window | in window | earlier | earlier |
| Throttle and speed control | 80,000–195,000 | later | in window | in window | in window | earlier |
Figure 3 · Ford Explorer 1991–1994 · 175 reports with mileage
Share of reports below each mileage
Share of mileage-tagged reports filed at or below each odometer reading. Steps rise only at bin edges, by exact counted shares.
- 60,000 mi — 11% of reports below
- 120,000 mi — 55% of reports below
- 200,000 mi — 91% of reports below
- Median — the staircase crosses the 50% line here
- Your odometer — appears after you enter it above
The staircase tops out at 91%: the remaining 8.6% of reports (15) came above 200,000 miles.
Nothing is smoothed or interpolated. Linear axis, same as Figure 1.
Source: NHTSA Office of Defects Investigation, public domain.
1991–1994 Ford Explorer recalls (12)
NHTSA records 12 recall campaigns covering vehicles in this generation. A recall means the manufacturer or the regulator concluded there was a safety defect or a standard was not met, and that a free remedy is owed to owners — including second and later owners.
The campaigns cluster around body structure (4), visibility equipment (2), the fuel system (2). Several campaigns against one area can mean a remedy that did not hold, or separate defects in parts filed under the same heading; the summaries below name each defect.
Recall status is specific to the individual vehicle, not the model. Checking a VIN against NHTSA's lookup is free and takes under a minute, and it is the only way to know whether a particular car has had the work done.
Nov 1999 · 1993–1994 · StructureWith a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing…
The defect. Vehicle description: on certain sport utility vehicles, the hydraulic lift cylinder bracket welds could fracture.
What can happen. With a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinder ball stud to disengage, unexpectedly allowing the liftgate to fall from…
The free fix. Dealers will install liftgate reinforcement brackets. Depending upon the condition of the liftgate sheet metal in the area of the bracket, dealers may also install a larger reinforcement.
Dec 1997 · 1991–1993 · StructureUnexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a…
The defect. 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…
What can happen. Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
The free fix. 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…
May 1997 · 1992–1994 · VisibilityThe current can overheat the printed circuit board and other plastic and elastomeric components of the switch…
The defect. A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad.
What can happen. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire.
The free fix. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly.
Feb 1996 · 1991–1994 · Service Brakes, HydraulicIf a crack occurs, it could result in one or both studs fracturing.
The defect. 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.
What can happen. 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…
The free fix. Dealers will replace the power brake vacuum booster assembly.
Aug 1995 · 1992–1993 · StructureWith a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing…
The defect. The hydraulic lift cylinders are attached to brackets that are welded to the liftgate. The bracket welds can fracture.
What can happen. With a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinderball stud to disengage.
The free fix. Dealers will install reinforcement brackets.
Sep 1994 · 1993–1994 · Parking BrakeWhen the above occurs, it can result in parking brake system ineffectiveness.
The defect. The parking brake control self-adjust pawl does not line up properly with the self-adjust rachet causing the pawl to slip over one or more teeth in the rachet.
What can happen. When the above occurs, it can result in parking brake system ineffectiveness. The parking brake will not hold the vehicle, causing the vehicle to roll freely, if the transmission is not left in gear.
The free fix. A wedge will be installed which will serve to lock the parking brake self-adjust mechanism pawl into engagement with the rachet. Also, owners will be advised to release and reapply the parking brake…
Aug 1992 · 1991 · Seat BeltsAn insufficiently latched or unlatched safety beltincreases the risk of injury to seat occupants in the event…
The defect. 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…
What can happen. 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…
The free fix. Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.
Nov 1991 · 1991 · Power TrainDriver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged.
The defect. When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
What can happen. 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…
The free fix. Repair the transmission with a new park pawl.
Feb 1991 · 1991 · StructureUnder extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch…
The defect. Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
What can happen. Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
The free fix. Install two brackets to reinforce the bumper.
Feb 1991 · 1991 · Fuel System, GasolineThe escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.
The defect. 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.
What can happen. The escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.
The free fix. Fuel tank will be removed and inspected for weld integrity. Fuel tanks with inadequate welds will be replaced.
Feb 1991 · 1991 · Fuel System, GasolineThis penetration of the fuel tank causes vapors to escapeand possibly fuel to spill, which could catch fire…
The defect. The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
What can happen. This penetration of the fuel tank causes vapors to escapeand possibly fuel to spill, which could catch fire in the presence of anignition source.
The free fix. Relocate the heat shield; inspect and replace damaged fuel fuel tanks.
May 1990 · 1991 · VisibilitySunroof could detach from the vehicle while being driven,creating a risk to following vehicles or people in…
The defect. If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
What can happen. 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.
The free fix. Install revised sunroof hinges that will adequately retain sunroof assembly.
Crashes, fires and injuries owners reported
What owners reported alongside the failure itself, out of 3,385 complaints against this generation:
- Crashes
- 299 (8.8%)
- Fires
- 258
- Injury reports
- 241
- Fatality reports
- 24
These flags are self-reported by complainants and unverified by NHTSA; one report can carry several flags, so the counts overlap and do not sum to a total. They are not adjusted for how many of these vehicles are on the road. No chart is drawn here on purpose: overlapping counts spanning very different magnitudes cannot be honestly encoded as lengths.
Explorer problems by model year
The 1994 drew the most complaints of this generation, 1,207, most of them about the tyres, and the 1991 the fewest, 609. A typical year drew about 786.
| Year | Complaints | With mileage | Median miles | Most reported | Recalls |
|---|---|---|---|---|---|
| 1991 | 609 | 34 | 122,000 | Hydraulic brake circuit (118) | 8 |
| 1992 | 633 | 33 | 111,000 | Tyres (128) | 4 |
| 1993 | 939 | 40 | 117,000 | Tyres (243) | 6 |
| 1994 | 1,207 | 68 | 99,000 | Tyres (331) | 4 |
What Explorer owners reported
the contact owns a 1993 Ford Explorer. The contact stated that while driving approximately 20 MPH, the brake pedal was depressed and went to the floorboard without warning. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the ABS module failed and needed to be replaced.…
1993 · 68,000 miles · Brakes
Purchased vehicle transmission out,came with rebuilt transmission,installed,lasted about 1 year.Kept blowing front seals.Always heated up going uphill.Next transmission,same story.Serviced regular,with filter change.Current transmission in trans. Shop,burnt up,new clutches,bands,seals,you name it.It still will not…
1994 · 180,000 miles · Transmission and driveline
the contact owns a 1992 Ford Explorer. While reversing, the vehicle lost power. In addition, the contact stated that the vehicle caught fire. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 444,980. Updated 5/18/15*cn the repair shop replaced the…
1992 · 445,000 miles · Engine
the contact owns a 1994 Ford Explorer. The contact stated that while driving approximately 50 MPH, an odor of gasoline fumes emitted inside of the vehicle and the engine warning light illuminated. In addition, there was smoke coming from under the hood. The contact experienced bronchial health issues that required…
1994 · 190,000 miles · Fuel system
Built from 175 NHTSA complaints with mileage · snapshot 2026-09-26 · open data · how it is built
Other Explorer generations
- Explorer 1995–2001 1,534 reports with mileage, most about the tyres
- Explorer 2002–2005 4,953 reports with mileage, most about the transmission and driveline
- Explorer 2006–2010 980 reports with mileage, most about the transmission and driveline
- Explorer 2011–2019 7,896 reports with mileage, most about the steering
- Explorer 2020–2025 611 reports with mileage, most about the transmission and driveline