Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
STRUCTURE - BODY - BUMPERS
91V026000FORD MOTOR COMPANYfrom 02/01/1990 to 01/01/1991V (Vehicle)22000003/26/1991MFRFORD MOTOR COMPANY02/12/199102/21/1991
Defect SummaryRear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
Consequence SummaryUnder extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
Corrective SummaryInstall two brackets to reinforce the bumper.
NotesSystem: rear bumper reinforcement.vehicle description: multi-purpose passenger vehicle.note: bumper mounted trailer hitch ball assembly should not be used until repairprocedure is completed.
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
95I007000FORD MOTOR COMPANYfrom 02/01/1990 to 02/01/1995I102938010/25/1995ODIFORD MOTOR COMPANY01/31/199602/09/1996
Defect SummaryVehicle description: multi-purpose passenger vehicles. this is not a safety recall in accordance with federal regulation 573. however, it is deemed a safety improvement campaign by the agency. the campaign will reinforce the bracket attachments of the rear liftgate gas assist cylinders which could pull away from the inside of the liftgate.
Consequence SummaryIf a bracket and gas assist cylinder were to detach completely from the liftgate and no longer bear against the liftgate as intended, the remaining assist cylinder would not hold the liftgate in an open position. personal injury could occur.
Corrective SummaryFord dealers will reinforce the bracket attachments.
NotesFord has decided to conduct a safety improvement service campaign to reinforce the bracket attachments without charge. owners can contact ford at 1-800-392-3673.
STRUCTURE - BODY - ROOF AND PILLARS
97V235001FORD MOTOR COMPANYfrom 01/05/1990 to 01/15/1993V (Vehicle)18500003/02/1998ODIFORD MOTOR COMPANY12/18/199702/25/1998
Defect SummaryVehicle 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 glass panel.
Consequence SummaryUnexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
Corrective SummaryOwners 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 warning label for attachment to the sunroof's latch knob will also be provided to the owners.
NotesOwner notification began march 2, 1998. owners who do not receive the instruction booklet and warning label within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
STRUCTURE
974702/17/199751689Frame- rivet replacement with bolts- service tips. *jd06/27/1997
STRUCTURE - BODY
9516108/01/199545947Sheet metal-roof panel and drip rail replacement- seam sealer application procedure.*sd04/25/1996
STRUCTURE - BODY - DOOR
9422910/01/199437751Inside door handle breaks when opening. *tw01/06/1995
STRUCTURE - FRAME AND MEMBERS
9721001/20/199751393Body - rust perforation - quarter panel - service tips. *tw06/27/1997

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
STRUCTURE
PE99072FORD MOTOR COMPANY11/30/199904/14/2000SPARE TIRE WINCH CABLE
 Odi received 18 complaint alleging that the winch cable, that lifts and retains the spare tire under the rear of the vehicle, fails while the vehicle is underway.this results in the spare wheel dropping onto the roadway.
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235001
 Sunroof (air roof) shattering and separation
RQ99016FORD MOTOR COMPANY07/29/1999LIFTGATE SUPPORT BRACKET FAILURE99V310001
 Summary:on august 22, 1995, ford conducted safety recall, 95v-164, on 1992 and 1993 model year explorer due to liftgate failures.the rear liftgate hydraulic cylinder bracket can become unattached allowing the liftgate to suddenly drop.the recall remedy was to install reinforcements on the brackets.ford also initiated a safety improvement campaign in october 1995, for 1991-1995 model year explorer vehicles which were not included in the recall, to install reinforcements on those bracket that were found to be loose or detached.this campaign ended in october 1996. since november 1996, odi has received 51 consumer complaints alleging liftgate failures caused by the bracket separation, of which 19 reported the liftgate struck the occupant causing 12 injuries.one complaint was on 1992 model year vehicle, three complaints were on 1993 model year vehicles, and 47 complaints were on 1994 model year vehicles. this rq is to determine the extent of the problem experience and the scope of safety recall 95v-164.
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235000
 Sunroof (air roof) shattering and separation
EA00012FORD MOTOR COMPANY04/14/200010/20/2000SPARE TIRE WINCH CABLE
 From the beginning of the 1991 model year production until the middle of the 1994 model year production, ford used a galvanized steel cable to lift, and hold in stored position, the explorer spare tire.on may 19, 1994, based on the results of ford durability testing, ford changed to a 4.00mm stainless steel cable.there have been over 100 incidents in which the original galvanized steel cable failedallowing the spare tire to drop from its rear storage well.one of these incidents caused a following vehicle to be involved in a collision and on six other occasions the wheel made contact with following vehicles, resulting in property damage.
RQ99016FORD MOTOR COMPANY07/29/1999LIFTGATE SUPPORT BRACKET FAILURE99V310002
 Summary:on august 22, 1995, ford conducted safety recall, 95v-164, on 1992 and 1993 model year explorer due to liftgate failures.the rear liftgate hydraulic cylinder bracket can become unattached allowing the liftgate to suddenly drop.the recall remedy was to install reinforcements on the brackets.ford also initiated a safety improvement campaign in october 1995, for 1991-1995 model year explorer vehicles which were not included in the recall, to install reinforcements on those bracket that were found to be loose or detached.this campaign ended in october 1996. since november 1996, odi has received 51 consumer complaints alleging liftgate failures caused by the bracket separation, of which 19 reported the liftgate struck the occupant causing 12 injuries.one complaint was on 1992 model year vehicle, three complaints were on 1993 model year vehicles, and 47 complaints were on 1994 model year vehicles. this rq is to determine the extent of the problem experience and the scope of safety recall 95v-164.
DP98001FORD MOTOR COMPANY01/06/199802/04/1998HEAVY LATERAL VIBRATION
 The petition alleges that early model ford explores sport utility vehicles develop heavy lateral vibrations at speeds above 55 mph and when encountering bumps at low speeds.the petition further alleges that these vibrations could possibly cause loss of vehicle control.
EA97011FORD MOTOR COMPANY05/23/199701/20/1998SUNROOF SHATTERING AND SEPARATION97V235002
 Sunroof (air roof) shattering and separation

Consumer Complaints

Fail datemilesoccurencesPurchase date
STRUCTURE
1
 Vehicle structure experienced rust. *slc
STRUCTURE - BODY
08/10/2003004/14/2003
 Mva, damage to rearend & drivetrain; driverseat & seatbelt poss. compromised. *ak
01/01/1992
 Sheet metal roof is rusting badly at the point of three of five screws which hold luggage rack to vehicle.
 Paint is peeling from vehicle and ford officially claims to have no knowledge of the problem of of tsb 91-18-1.
09/01/199403/30/1991
 Arm rest support failed to work properly. *ak
12/21/19911
 Cowl design allowed leaves to enter vehicle onto heater coil, causing heater to catch fire. *tw
STRUCTURE - BODY - BUMPERS
08/10/2003004/14/2003
 Mva, damage to rearend & drivetrain; driverseat & seatbelt poss. compromised. *ak
08/11/199801/01/1991
 No summary
STRUCTURE - BODY - DOOR
11/15/2002204/01/2000
 Both rear door latchs failed. causing the rear door to open while driving. does not shut properly when closed. dt
06/01/1996
 The questionnaire does not fit my complaint. the door handle on the front left and rear right have broken. this makes it nearly impossible to close the doors tightly. i have looked into several other ford explorers with the same inside door panels and they also have at least one of the handles broken. i feel this must be a defect in design since it seems to have occured in several vehicles. i have not looked into one like mine yet and not found at least one handle broken. i e-mailed to ford inquiring into rather there had been an recall on the inside door panels and have not received any reply. also the front right pannel has a crack in it. *ak
07/01/1994
 Doors will not open from inside. child safety locks are not on. the problem became increasingly worse over time, one door and then the other. the entire handle eventually broke from having to be pulled on so hard.
07/27/1999
 Driver's and the passenger's side doors did not shut all the way. owner had truck checked by an auto body shop. mechanic stated that truck was most likely in a crash. please provide any further information. *ak
08/11/199801/01/1991
 No summary
103/01/1991
 Panel on rear side doors rusted.
 The rear door will not open, took to dealer, can't find problem; this happened a year ago . please describe . *ak
07/01/19954
 Right/rear inside door handles cracked at attactachment to door, unable to close door. *ak
04/27/1995
 Vehicle door handle has come off for the third(3rd) time. tt
 Vehicle rear passenger doors are extremely hard to open due to design. dealer is aware of problem. tt
STRUCTURE - BODY - DOOR - HINGE AND ATTACHMENTS
09/01/2001
 Driver's side and passenger side doors are coming off the hinges. dealer has been contatced. please provide further details.*ak
STRUCTURE - BODY - HATCHBACK/LIFTGATE
10/15/19955
 Rear hatch handle inoperative. *sd
STRUCTURE - BODY - HATCHBACK/LIFTGATE - HINGE AND ATTACHMENTS
03/17/2005150001
 The rear liftgate was in the up position and it dropped while the consumer was unloading groceries. the right side hinge broke. this vehicle was not included in liftgate recall campaign 04v442000. *ak *sc *jb
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
11/22/2006161000111/09/1996
 Copy of letter to fmc: i own a 1991 ford explorer 4wd xlt (vin 1fmdu34x0mua29345). i purchased this vehicle on 11/9/96, from crown dodge, ventura, california. the selling dealer assured me at the time that no recalls were outstanding on this vehicle. on november 11/22/06, as i closed the hatch on this vehicle, the bracket that attaches the right-side liftgate gas assist cylinder to the hatch tore away from the hatch. i have just learned that a safety improvement campaign (number 95i007000) was issued in october 1995 to reinforce this bracket. the campaign stated that if a bracket and gas assist cylinder were to detach completely from the liftgate and no longer bear against the liftgate as intended, the remaining cylinder would not hold the liftgate in an open position. personal injury could occur. the corrective action was for ford dealers to reinforce the bracket attachments. my local ford dealer service representative stated today they could not honor this safety improvement campaign. rebecca (#6048) at the ford customer service call center told me the campaign had expired, and couldn't offer assistance. your company's response to date is not acceptable. the bracket was attached to the hatch by only two small spot welds, as is the left-side bracket. the failure still has the potential for causing serious injury, especially if the left-side bracket were to fail. the vehicle was apparently not repaired under this safety improvement campaign. i was not notified of the campaign nor offered an opportunity to have this defect repaired. since the safety hazard that this safety improvement campaign sought to resolve still exists on my vehicle, i request that the broken bracket be repaired and the remaining bracket reinforced at no charge to me, per the intent of the safety improvement campaign. thank you for your assistance. jay ellis. *nm
01/01/2001198000109/07/1990
 In 2001 the right side bracket attachment of the rear liftgate gas assist cylinder came off from the inside of the liftgate of my 1991 ford explorer. the remaining assist cylinder does not hold the liftgate in an open position. as i understand from nhtsa campaign id no 95i007000 over a million vehicles had the brackets reinforced, but my explorer wasn't included although in my opinion it clearly should have been. i haven't priced the repairs.*ak
07/01/1996111/18/1995
 Lift gate open the hydrolic lift bracket snapped off causing the liftgate to fall on my sons head. bracket was poorly welded. they claim that there was a recall aroung the time the car, but it is no longer in effect. the recall was to be reenforce the brackets. this is still a safety issue.
03/01/1995102/01/1993
 The rear hatch fell. tt when hatch was opening the spot welds holding the upper left gas strut mount to the hatch broke. this allowed the hatch to fall striking me on the shoulder. the gas strut also extended suddenly stricking and scratching the body of the vehicle.
03/04/19951
 Rod that holds up right rear tail lift gate up broke, resulting in a hit on the heat by the gate, replace shocks in lift gate. tt
STRUCTURE - BODY - HOOD
07/26/1999107/01/1995
 I was driving on a freeway transition when the hood flew open and hit the windshield. the hood did not detach from the vehicle. the hood, windshield, wipers and plate between the windshied and hood require replacement.
STRUCTURE - FRAME AND MEMBERS
08/10/2003004/14/2003
 Mva, damage to rearend & drivetrain; driverseat & seatbelt poss. compromised. *ak
04/11/2001110/01/2000
 Cracks developing in crossmember frame around radius arm bushings on both sides. bushings have been replaced before so the excuse of worn bushings is bull.*ak
206/01/1998
 The left and right rear rocker panels are rusted through. this is a common problem amoungst ford explorer's (1991-1994). many auto body shops have confimed that this cronic problem is a a result of poor design of not adding drain holes in the rear proportion of the rocker panels. though this matter is not a saftey factor it is very costly to repair. *ak
05/15/1999112/01/1998
 There are huge corrosion holes under both rear doors. i noticed the same corrosion problem on all 1991-1993 ford explorers driven around.
04/01/1991
 Excessive paint peeling from top and hood. *ak
06/15/1994
 Paint on the roof is coming off.
08/05/1997
 Vehicle's structural component is rusted. *ak

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