Ford Explorer 1991–1994 problems by year and mileage
1st generation · UN46
NHTSA data through 18 October 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
Recall areas Structure — body · Service brakes, hydraulic — power assist · Seat belts — front
Check the VIN at NHTSA
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
Recall areas Structure — body · Visibility — rearview mirrors/devices · Service brakes, hydraulic — power assist
Check the VIN at NHTSA
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
Recall areas Structure — body · Visibility — rearview mirrors/devices · Service brakes, hydraulic — power assist
Check the VIN at NHTSA
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
Recall areas Structure — body · Visibility — rearview mirrors/devices · Service brakes, hydraulic — power assist
Check the VIN at NHTSA
Tiles: each year’s median failure mileage. Latest: the 1991; earliest: the 1994, and the 1991 is 3 years older (part of the gap is age).
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 — complaints, not a failure rate.
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?
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 (why that is not a lifespan).
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
20,000-mile bins, 0 to 200,000 miles, linear scale; tallest bar 27 complaints
- Rest of the range
- Median
- 200,000+ — 15 complaints (8.6%), plotted separately
- 10%
- 43,000
- 25%
- 79,000
- 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.
Common Explorer problems, and when they happen
Figure 2 · Ford Explorer 1991–1994
When each system fails
Bar: middle half of reports · notch: median · proportional (log) scale (how to read it)
- Tyres803 reportsmedian 97,000middle half 69,000–140,000
- Engine and its cooling system245 reportsmedian 97,000middle half 86,000–171,000
- Transmission and driveline304 reportsmedian 100,000middle half 30,000–154,000
- Hydraulic brake circuit675 reportsmedian 100,000middle half 68,000–150,000
- Electrical system216 reportsmedian 110,000middle half 89,000–141,000
- Throttle and speed control133 reportsmedian 110,000middle half 80,000–195,000
- Body structure337 reportsmedian 153,000middle half 88,000–198,000
- Your odometer, once entered below
Ordered by median mileage, earliest first.
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% | — | — |
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.
- Run the VIN at nhtsa.gov/recalls. 12 campaigns cover this generation.
- Check Suspension/Tires on 1991–1994 cars. What it looks like: Known problems.
- End with a pre-purchase inspection of this car.
Explorer problems by mileage: where your car sits
Type your odometer, or read the table.
| 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
Steps at bin edges (how to read it)
- 60,000 mi — 11% of reports below
- 120,000 mi — 55% of reports below
- 200,000 mi — 91% of reports below
- Median (the 50% line)
- Your odometer, once entered
Linear axis, same as Figure 1.
1991–1994 Ford Explorer recalls (12)
NHTSA records 12 recall campaigns covering vehicles in this generation (what a recall is).
The campaigns cluster around body structure (4), visibility equipment (2), the fuel system (2) (why one area can repeat).
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
Out of 3,385 complaints against this generation, owners also reported:
- Crashes
- 299 (8.8%)
- Fires
- 258
- Injury reports
- 241
- Fatality reports
- 24
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 2026-10-20 · 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 7,911 reports with mileage, most about the steering
- Explorer 2020–2025 622 reports with mileage, most about the transmission and driveline