FordExplorer1991Overview/ford/explorer/1991/base/

1991 Ford Explorer

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1991 Explorer.

Body SUVTransmission Automatic 4-spd

The 1991 Ford Explorer is an SUV paired with an automatic 4-speed transmission and an engine requiring 5.0 quarts of 5W-30 API oil, returning an EPA-estimated 15 city and 20 highway mpg for a 16 combined. Beyond these mechanical parameters, the vehicle's ownership record is marked by 699 total owner complaints, 11 recalls, and a dominant vulnerability in hydraulic service brakes. Within the model's broader 1990-2025 complaint history, 1991 registers well above the lowest year of 1990 (12 complaints) but far below the 2002 peak of 3,620, positioning this model year as an early but already problematic indicator of the reliability issues that would come to define the Explorer's trajectory.

Model year202620252024202320212020201920181991

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-30 APIOEM · verified
EPA fuel economy15/20/16 mpgEPA · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length174.4 in
Overall width68.5 in
Overall height70.1 in
Wheelbase102 in
Curb weight3688 lb

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 20 / 16 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Explorer of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

10.8–11.7 sec0–60 mph (tested)quickest 10.80 sec — 1991 Eddie Bauer
YearTrim / engine0–60¼ mileHPDrivetrain
1991Eddie Bauer 4.0L V610.80 sec17.90 sec155 hp4x4
1991Eddie Bauer 4.0L V611.70 sec18.20 sec155 hp4x4
1992Eddie Bauer 4.0L V610.50 sec17.80 sec155 hp4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-30 API engine oil, 80W-90 · GL-5 in the differential, DOT 3 brake fluid.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity7 Pints ( Rear)
Engine Oil5W-30 · API
Engine Oil Capacity5.0 qt
Power Steering FluidATF
Transfer Case FluidATF
Transfer Case Fluid Capacity2.5 pt

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 miTire & Wheel Assembly (rotate)
Every 7,500 miCV Joint Boot (inspect) · Clutch Master Cylinder (inspect fluid level) · Driveshaft Slip Yoke (lubricate) · Driveshaft U-Joint (lubricate) · Engine Oil (drain & refill) · Engine Oil Filter (replace)
Every 15,000 miBrake System (inspect) · Disc Brake Caliper Guide Pin (lubricate) · Tire & Wheel Assembly (rotate)
Every 30,000 miBrake Hydraulic System (inspect fluid level) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Locking Hub (inspect) · Parking Brake System (inspect) · Throttle Body Lever Stud (lubricate)
Every 60,000 miAccessory Drive Belt (inspect) · Exhaust System (Complete) (inspect) · Idle Air Bypass Solenoid (inspect) · PCV Valve (replace) · Spark Plug Wires (replace) · Spark Plugs (replace)
Every 100,000 miDrive Axle Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Compared to 1990’s negligible federal activity of 12 complaints, 0 recalls, and 2 investigations, the 1991 Ford Explorer registers 699 complaints, 11 recalls, and 18 investigations, representing an abrupt inflection and the first high-volume year in this record. The subsequent trend shows complaints climbing steadily from 699 to 1,421 by 1994 and remaining elevated for years, while recalls persist in the high single digits to low double digits, placing 1991 at the start of a prolonged escalation in reported problems. For 1991 specifically, the leading complaint categories are Service Brakes, Hydraulic (122) and Tires (110), followed by Power Train (68) and Engine & Engine Cooling (58), with 73 fire and 57 crash complaints also logged; the data does not specify root causes. Although 1991’s complaint count is lower than the immediately following years, its 11 recalls and 18 investigations mark the highest regulatory response of that early phase. Because it initiates a multiyear arc of intensifying complaints and carries substantial reported problems in brakes, tires, and fire complaints, 1991 is a risky used purchase and not a recommended year to buy.

11
Open recalls
NHTSA campaigns
67
Service bulletins
Manufacturer communications
18
ODI investigations
Office of Defects Investigation
699
Owner complaints
57 involved a crash · 73 a fire

Owner complaints filed with NHTSA, by component

All 699 complaints on record, top 8 components.

Service Brakes, Hydraulic122
Tires110
Power Train68
Engine & Engine Cooling58
Electrical System55
Structure29
Visibility29
Suspension29

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 11 campaigns on record for this vehicle.

01X001000Tires:Tread/BeltReported 22/05/2001

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH… Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE…

00T005000Tires:Tread/BeltReported 21/08/2000

TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION… Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE…

Technical service bulletins NHTSA · verified

Showing 5 of 67 bulletins on record with NHTSA.

BulletinDateComponentSummary
167352003-04-01SuspensionVARIOUS NOISE ISSUES FROM THE REAR LEAF SPRINGS WHILE DRIVING. *TT
167142003-03-01Engine And Engine CoolingFOR ALL OBDI VEHICLES THAT USE THE .5V DPFE SENSOR, A 1.0V SENSOR IS CURRENTLY THE ONLY…
021422002-07-22Engine And Engine CoolingSOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A…
011972001-10-01Engine And Engine CoolingSOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE…
01B772001-10-01TiresOWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Explorer. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 1991 Explorer take?

5.0 qt of 5W-30 API, per the factory manual.

Does the 1991 Explorer have open recalls?

NHTSA lists 11 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Explorer get?

EPA figures are 15 city / 20 highway / 16 combined mpg.