Ford Explorer 1992 - Structure - car safety information, failing parts, recalls, bulletins, complaints

Ford Explorer 1992

Recalls
Technical Service Bulletins
Defect investigations
Consumer Complaints

Recalls

Campaign	Manufacturer	Manufacturing date	Type	# of units affected	Date Owner notified Mfg	Recall Initiated by	Manufacturers of recalled vehicles/products	Report Recieved Date	Record Creation Date
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
95V164001	FORD MOTOR COMPANY	from 01/01/1992 to 03/01/1993	V (Vehicle)	364784	08/30/1995	ODI	FORD MOTOR COMPANY	08/25/1995	08/31/1995
Defect Summary	The hydraulic lift cylinders are attached to brackets that are welded to the liftgate. the bracket welds can fracture.
Consequence Summary	With a broken bracket weld, there is a potential for the liftgate bracket to gradually bend inward allowing the lift cylinderball stud to disengage.
Corrective Summary	Dealers will install reinforcement brackets.
Notes	System: structure; hatchback hydraulic cylinder.vehicle description: multi-purpose passenger vehicles.note: owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy 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.
95I007000	FORD MOTOR COMPANY	from 02/01/1990 to 02/01/1995	I	1029380	10/25/1995	ODI	FORD MOTOR COMPANY	01/31/1996	02/09/1996
Defect Summary	Vehicle 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 Summary	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 assist cylinder would not hold the liftgate in an open position. personal injury could occur.
Corrective Summary	Ford dealers will reinforce the bracket attachments.
Notes	Ford 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
97V235001	FORD MOTOR COMPANY	from 01/05/1990 to 01/15/1993	V (Vehicle)	185000	03/02/1998	ODI	FORD MOTOR COMPANY	12/18/1997	02/25/1998
Defect Summary	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 glass panel.
Consequence Summary	Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
Corrective Summary	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 warning label for attachment to the sunroof's latch knob will also be provided to the owners.
Notes	Owner 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

Bulletin	Bulletin date	Item no.	Summary	Added
STRUCTURE
9747	02/17/1997	51689	Frame- rivet replacement with bolts- service tips. *jd	06/27/1997
STRUCTURE - BODY
95161	08/01/1995	45947	Sheet metal-roof panel and drip rail replacement- seam sealer application procedure.*sd	04/25/1996
STRUCTURE - BODY - DOOR
94229	10/01/1994	37751	Inside door handle breaks when opening. *tw	01/06/1995
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
BC0001950906	09/01/1995	45787	Advance notification to dealers of recall on hydraulic lift tubes and a change in normal procedures due to media coverage. *tw	04/25/1996
STRUCTURE - FRAME AND MEMBERS
97210	01/20/1997	51393	Body - rust perforation - quarter panel - service tips. *tw	06/27/1997

Investigations

NHTSA ID	Manufacturer	Date open	Date close	Subject	Recall campaign
STRUCTURE
PE99072	FORD MOTOR COMPANY	11/30/1999	04/14/2000	SPARE 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.
EA97011	FORD MOTOR COMPANY	05/23/1997	01/20/1998	SUNROOF SHATTERING AND SEPARATION	97V235002
	Sunroof (air roof) shattering and separation
EA00012	FORD MOTOR COMPANY	04/14/2000	10/20/2000	SPARE 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.
RQ99016	FORD MOTOR COMPANY	07/29/1999		LIFTGATE SUPPORT BRACKET FAILURE	99V310002
	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.
DP98001	FORD MOTOR COMPANY	01/06/1998	02/04/1998	HEAVY 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.
EA97011	FORD MOTOR COMPANY	05/23/1997	01/20/1998	SUNROOF SHATTERING AND SEPARATION	97V235001
	Sunroof (air roof) shattering and separation
PE96074	FORD MOTOR COMPANY	12/17/1996	05/23/1997	SUNROOF (AIR ROOF) SHATTER
	The sunroof shattered or was blown off.in all but one case this occurred while driving.
RQ99016	FORD MOTOR COMPANY	07/29/1999		LIFTGATE SUPPORT BRACKET FAILURE	99V310001
	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.
EA97011	FORD MOTOR COMPANY	05/23/1997	01/20/1998	SUNROOF SHATTERING AND SEPARATION	97V235000
	Sunroof (air roof) shattering and separation

Consumer Complaints

Fail date	miles	occurences	Purchase date
STRUCTURE
05/12/2008	250000
	Tl*the contact owns a 1992 ford explorer. the contact stated that the right hydraulic lift bracket detached from the vehicle. as a result, the lift gate fell on the contacts head. the contact sustained bruises to the back of the head. there is a recall for the structure: body: hatchback/liftgate: support device (nhtsa campaign id #95i007000) however, the dealer stated that his vin was not included. the contact felt that his vehicle should have been included. the failure mileage was 250,000 and current mileage was 255,000.
04/19/2002		1	04/01/1995
	Consumer stated the vehicle rolled over several times during an accident caused by hitting a deer, consumer is not sure if it was the brand new continential tires, p235/75r15, that were purchased 3 weeks prior or just the design of the vehicle.*jb
		1
	Vehicle had firestone wilderness at tires (p235/75r15) and experienced a rollover, the consumer did not say the tires were the cause of the accident. *slc
10/10/1995		2	06/15/1992
	Lift gate brackets connected to cylinders failed, repaired under recall, however problem continues.
STRUCTURE - BODY
01/10/2012	145000
	Tl-the contact owns a 1992 ford explorer. the contact stated there were numerous cracks near the rear windshield, next to the manufacturing emblem.the vehicle had not been inspected or repaired. the manufacturer was not notified of the defect. the approximate failure mileage was 145,000. kmj
01/10/2012	145000
	Tl-the contact owns a 1992 ford explorer. the contact stated there were numerous cracks beside the ford emblem which was located near the rear windshield. the vehicle had not been inspected or repaired. the manufacturer was not notified of the defect. the approximate failure mileage was 145,000. js
02/01/1998			04/14/1992
	Driver's side interior door handle malfunctioned. also,center console padded arm restmount failed.
			01/17/1992
	The paint on the roof of vehicle began fading three years after purchase.
STRUCTURE - BODY - DOOR

	Driver's side door inside handle breaks upon opening door. has to use window to open door from outside to exit vehicle. please provide any further information, and vehicle identification number. *ak
06/01/2000			06/01/2000
	Paint is coming off in areas and it is only 8 y/o, and also every inside door handle has broken off in the same manner atleast a year or two ago, so says the previous owner. both problems were obvious when vehicle was purchased and the previous owner took very well care of it, i honestly believe the door handles were a bad make in the first place it is obvious they would break with time or the first pull of the handle. the paint should not be doing what it is doing at this point in time, thank you for any help you may give. suzanne brantley, cepa
12/01/1996		4	08/01/1996
	Ihave been looking for interior door panels for about 2 yrs.the problem is with the portion of the interior door panel where you are supposed to grab the door to close it.all the salvage yards say the same thingidont have to look that up, i know we dont have any, there all broken. my children have scratched their arms on the broken plastic that is left behind after the door pull/armrest breaks off.since i have been unsucssful in tring to locate a replacement i can only conclude that this is a big problem. it makes shutting the front doors difficult as there is no place to grab the door to close it. this is a real hassle when parked on a hill or it is windy, as the only thing to grab is the door handle half the time the door dosent latch fully making in nessessary to open the window and grab the top of the window to shut the door fully, creating a second hazard by opening up the possibilities of breaking the window. my children as i mentioned have been scratched badly enough to draw blood on several occasions,and my wife has ruined a couple of sweaters by getting them snagged on the jagged plastic. ford wants over 100.00 per door to replace them(i need all four) and frankly icant afford it and dont think i should have to. thank you. *ak
05/15/2000
	Both of the backside doors cannot be opened from the inside as if both doors had the child safety lock on. but neither door had the child safety lock on. effect can cause consumer and passengers to be stuck inside vehicle from the backseats. *ak
		1
	All four door handles cracked due to defective plastic used in manufacturing. yh
12/14/1998		2	07/01/1997
	The door grip on the drivers side of the explorer cracked off first. one month later the door grip on the passengers side cracked off. the door grip is the only way of securely closing the doors. the grip cracked off as it is one molded piece. the only means of repair is to replace the entire door panel at a cost of $415.00 per door plus labor. this grip has since been redesigned to eliminate this problem
02/01/1998			04/14/1992
	Driver's side interior door handle malfunctioned. also,center console padded arm restmount failed.
11/29/1997			11/01/1997
	Rear door opened during crash.
		1	11/01/1995
	Arm rest pivot assembly failed.
		1	11/01/1995
	Exterior door handle has excessive wear. the handles are loose and vibrate while driving.
		1	11/01/1995
	Rocker panels (rear door) rusted through.
01/01/1995		4	11/14/1992
	All four door handles are broken.
05/01/1996		1	05/01/1992
	Interior door handles cracked.
05/01/1996		1	07/01/1992
	Plastic arm rest bracket cracked.
09/13/1995		1
	Door panel cracked.
11/16/1995		6
	Rear passenger automatic door lock will not disengage. *dsh
06/15/1995
	While closing driver/passenger side doors, door handles broke off; very difficult closing doors properly; have to open/close doors from outside of windows. tt
STRUCTURE - BODY - DOOR - HINGE AND ATTACHMENTS
		1	11/01/1995
	Front door hinge has failed causing door to sag and not close properly.
STRUCTURE - BODY - HATCHBACK/LIFTGATE
02/23/1998		1	12/01/1995
	Handle on the inside of the rear door is a safety hazard, consumer was injured in the head trying to close door.
11/13/1995
	Consumer took vehicle in to get the recall repaired parts not in. tt
08/04/1995
	The rear door was warped out of shape so the door would not close properly. please describe. tt
STRUCTURE - BODY - HATCHBACK/LIFTGATE - HINGE AND ATTACHMENTS
01/01/1999		2	01/01/1992
	The entire rear door was recalled back in 1993. the door was replaced by ford. i'm curious to know if i can be reimbursed for the hydraulic lift which i just purchased. it fell off during normal use. *ak
10/10/1995
	The welds on hinges that hold rear gate are breaking, difficulty closing door. tt
05/24/1995
	Left hinge that hold tailgate up broke off, resulting in falling down. tt
11/03/1994
	Right hinge that holds tailgate up broke. tt
12/01/1994		1
	The rivots that hold the right rear hinge to the frame broke on closing the hatch. tt
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
		1
	Brackets that are welded to liftgate have fractured. vehicle has been repaired under recall campaign # 95 v 164 001.*ak
		1
	Brackets that are welded to liftgate have fractured. a recall has been issued on vehicle's make and model; however, this vehicle was not included due to vin.*ak
10/16/2000		1	03/09/1992
	The support bracket that supports liftgate broke. there has already been a recall, but this vehicle was not included.*ak
08/27/1999			01/01/1995
	Right strut/piston on rear tailgate broke. previous recall on this by ford. it expired in january 1999. consumer's strut broke in august 1999. ford has refused to fix this, even though they recalled it. consumer took the matter to ford's dispute settlement board, but they refused, saying this did not full under their jurisdiction. *ak
		1
	The gas assist cylinders failed. recall repairs refused due to vehicle exceeding mileage limitations.
07/09/1997
	Vehicle experiences severe vibration. dealer attempted to fix it several times, but problem continues. also, brackets that connect the hydraulic cylinders to rear liftgate to pulled away from inside of the liftgate prior to recall (95v-164-001) *ak
06/12/1995		2
	Rear door lift rod broke loose/had to be rewelded. *ak
11/18/1995		1	02/01/1992
	The dealership will not honor the recall and claims the part is on back order. tt consumer made arrangements on nov 13, 1995 part was to be on hand (was ordered previously) vehicle to be repaired in 3 days, on the 4th day consumer called dealerand was told nothing had been done, part was not pre-ordered as stated by body shop foreman and vehicle was left 4 days with no attempt to let consumer know about problem, consumer has made several calls to dealer and is still being told that part is on back order, consumer was injuried when orignal part failed.*jb
10/01/1995
	The rear hatchback rod was not available when the recall letter was presented to the dealership. please describe. tt
10/17/1995		1	07/01/1993
	Went to the dealership to have her hydraulic strut replaced and they said they did the work and did not. tt recall was for liftgate brackets, after supposed repair consumer went home and inspected vehicle to find repairs were not done, the only thing dealership did was scrape paint off passenger side bracket in one spot! *slc

	The rear hatch fell. please describe. tt
08/25/1995		1
	Medal plate that support the rear lift gate detached, support arm does not work. tt
08/19/1995
	The rear that holds up the door has come out and the rear door is very heavy and it slammed down onto the owners head. please describe. tt
12/15/1994
	Right rear support broke from its mount; now, left mount has broken off; results in very limited use of hatch door. tt
06/18/1995		1
	Rear liftgate mount bracket broke, resulting in collapsing gate. *ak

	Customer sts rear door support bracket snapped on closing the door. tt
04/01/1995
	Opened rear door hydraulic rod broke and got struck. tt
06/14/1995
	The bracket holding the hydraulic cylinders comes off the welding of the car causing the rear door to fall on a persons head. tt
06/04/1995		1
	Closed liftgate door; heard bang; opened door; liftgate piston popped out of rivets; door would not stay up. tt
10/15/1993
	Design: liftgate support rod suffers from fatigue; causes liftgate door to fall down while in use. tt
STRUCTURE - BODY - HOOD
		1
	Resistor failed in heater which caught fire from leaves, leaves fall under the hood and onto the heating system and catch fire.
STRUCTURE - BODY - ROOF AND PILLARS
01/20/2002		0
	I am the owner of a 1992 ford explorer and have noticed that the factory installed roof rack is very unstable and wobbly. i am concerned that if i secure my property to the rack, that i run the risk of losing it on the road and possibly creating hazardous conditions for other drivers. i have inspected the racks of several other similar vehicles and they all seem to have the same problem.
STRUCTURE - BODY - TAILGATE
06/01/1998		1
	Tailgate brace broke despite recall repair.
10/01/1995			02/29/1992
	Mounting bracket for liftgate piston failed.
04/09/1996
	Dealer doesn't carry the parts, recall #95s21 or 96s35.
STRUCTURE - BODY - TAILGATE - HINGE AND ATTACHMENTS
05/18/1999
	Recall 95i007000; recall repairs were done 4 years ago. but repairs done for reinforcement brackets only applied to the bottom part of the cylinder, not the top part, which in this case broke off from the frame, causing liftgate to fall and almost resulting in injuries. please provide further information. *ak
05/04/1998		1	01/01/1992
	Lift gate (rear cargo door) support bracket tore
10/01/1995		1	06/01/1992
	Tailgate support strut broke, recall repairs not done due to a lack of parts.
STRUCTURE - FRAME AND MEMBERS
		1	11/01/1991
	Every 1992 for explorer that i have seen has had both rear rocker panels rusted away. origonal body rust was guarenteed for 4 year or 60, 000 mi. my rust began much prior to 60,000 mi. but i was told at my ford dealer that the rust would have to have gone all the way through. my was well taken care of and did not rust as much as most. ford does not even offer or make any parts to repair this. ask any dealer in a 4 season state and they can tell you this is true. i feel this is way too widespread and should be addressed by ford to it's customers. i filed a complaint with ford some time ago. they said my complaint was noted and i never received any response. thank you.

	Frame bracket has cracked at where raduis arm and bracket meet on two occasions, causing safety hazard. dealer cannot determine cause. *ak
			12/27/1996
	External body paint has begun peelin goff from the factory primer on the roof sides doors. *ak
06/01/1996
	The truck has a really bad shimmy when going over 50mph because of the motor mounts,and sway bars. please describe. *ak
10/07/1995
	When shutting the rear hatch latch the glass cracked the power steering pump went on the car . tt
01/16/1992		6
	Vehicle design does not accommodate high performance/all season tires. *aw