1991 Ford Explorer

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 TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS…

Fix: 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 ASSISTANCE.

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 PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE TIRE TREAD.

Fix: 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 ASSISTANCE.

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.

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 WARNING LABEL FOR ATTACHMENT TO THE SUNROOF'S LATCH KNOB WILL ALSO BE PROVIDED TO THE OWNERS.

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.

Fix: DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

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.

Fix: FORD DEALERS WILL REINFORCE THE BRACKET ATTACHMENTS.

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 SECOND DEFECT IS THE SAFETY BELT BUCKLE MAY NOT LATCH. THE THIRD POSSIBLE DEFECT IS THAT THE TONGUE MAY BE RETAINED BY THE BUCKLE, BUT IT MAY NOT BE LATCHED SUFF…

Fix: FORD WILL REPLACE THE RIGID MOUNTED SAFETY BELT BUCKLES WITH END RELEASE SAFETY BELT BUCKLES DESIGNED TO PREVENT LATCH PROBLEMS.

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

REAR BUMPER REINFORCEMENT MAY BE SUBJECT TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED TRAILER HITCH BALL.

Fix: INSTALL TWO BRACKETS TO REINFORCE THE BUMPER.

THE FRONT HEAT SHIELD MAY CONTACT THE FRONT OF THE PLASTIC FUEL TANK, CAUSING CUTS OR OTHER DAMAGE TO THE EXTENT OF PENETRATION.

Fix: RELOCATE THE HEAT SHIELD; INSPECT AND REPLACE DAMAGED FUEL FUEL TANKS.

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.

Fix: FUEL TANK WILL BE REMOVED AND INSPECTED FOR WELD INTEGRITY. FUEL TANKS WITH INADEQUATE WELDS WILL BE REPLACED.

IF SUNROOF GLASS IS REMOVED AND REINSTALLED BY VEHICLE OPERATOR, HINGE ASSEMBLIES CAN BE ACCIDENTALLY IMPROPERLY MATED.

Fix: INSTALL REVISED SUNROOF HINGES THAT WILL ADEQUATELY RETAIN SUNROOF ASSEMBLY.

SPARE TIRE WINCH CABLE Closed

SPARE TIRE WINCH CABLE Closed

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 FAILED ALLOWING THE SPA…

LIFTGATE SUPPORT BRACKET FAILURE Closed

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 W…

HEAVY LATERAL VIBRATION Closed

NHTSA WAS PETITIONED TO COMMENCE A DEFECT INVESTIGATION OF THE SUBJECT VEHICLES ON JANUARY 6, 1998. THE PETITION ALLEGES THAT EARLY MODEL FORD EXPLORER 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. THE ANALYSIS OF THE PETITION IS PRESENTED IN THE…

PARKING PAWL Closed

WHEN THE AUTOMATIC SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARKING PAWL DOES NOT ALWAYS ENGAGE THE PARK GEAR. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OF GEAR UNINTENTIONALLY AND CAUSE THE VEHICLE TO START ROLLING INADVERTENTLY

SUNROOF SHATTERING AND SEPARATION Closed

SEPARATION OF MASTER CYLINDER Closed

FORD CONTINUES TO SUDY THE PROBLEM ATTEMPTING TO DETERMINE WHY STUD FRACTURES ARE NOT FREQUENTLY OCCURRING IN OTHER PARTS OF THE COUNTRY. LIKEWISE, ODI CONTINUES GATHERING INFORMATION TO ASCERTAIN WHETHER THE RECALL SCOPE SHOULD INCLUDE OTHER GEOGRAPHICAL AREAS. IF EVIDENCE INDICATES THE SCOPE SHOULD BE EXPANDED, ODI WILL REOPEN THE INVESTIGATION AS WARRANTED.

BRAKE MASTER CYLINDER/BOOSTER SEPARATION Closed

ENGINE COOLING FAN CRACKS Closed

THROTTLE STICKING Closed

FRONT SEAT TRACK FAILURE Closed

WHL SEPARATION/TORQUE LOSS Closed

Other

Certain vehicles, from Ontario to Newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicle is being driven, the spare tire could drop down, potentially creating a roadway obstacle. Correction: Owners are to inspect the cable, and if corrosion or broken wire strands are present the vehicle is to be taken to a…

Structure

NOTE: VEHICLES EQUIPPED WITH FACTORY INSTALLED SUNROOFS WITH REMOVABLE GLASS PANELS. IF MISINSTALLED BY THE OPERATOR, THE SUNROOF'S REMOVABLE GLASS PANEL MAY SEPARATE FROM THE VEHICLE WHILE IT IS BEING DRIVEN. THE SEPARATED GLASS PANEL MAY POTENTIALLY STRIKE OTHER VEHICULAR TRAFFIC OR FORCE OTHER MOTORISTS TO TAKE EVASIVE ACTION. CORRECTION: OWNER'S OF AFFECTED VEHICLES WILL BE…

Seats And Restraints

SEAT BELT BUCKLES ON THESE VEHICLES MAY EXPERIENCE CONDITIONS WHEREBY THE BUCKLE MAY NOT UNLATCH WHEN THE RELEASE BUTTON IS DEPRESSED OR MAY NOT LATCH, OR IN SOME CASES, MAY LATCH PARTIALLY BUT NOT SUFFICIENTLY TO PROVIDE OCCUPANT RESTRAINT IN THE EVENT OF A COLLISION. NOTE: ONLY END-RELEASE BUCKLES ON "RIGID" MOUNTINGS ARE SUSCEPTIBLE TO THIS MALFUNCTION. CORRECTION: FACTORY I…

Lights And Instruments

NOTE: ALSO INCLUDES SOME MEDIUM AND HEAVY TRUCKS. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 108 - LIGHTING. DAYTIME RUNNING LIGHT MODULE MAY MALFUNCTION WHICH CAN RESULT IN DAYTIME RUNNING LIGHTS THAT DIM, FLICKER OR GO OFF OR IN SOME INSTANCES MAY REMAIN ON AFTER THE IGNITION IS TURNED OFF. CORRECTION: DAYTIME RUNNING LIGHT MODULE WILL BE REPLACED ON AFFECTED VEHICLES.

Powertrain

THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHICLE MAY ROLL AS IF IN NEUTRAL IF THE PARKING BRAKE IS NOT SET. THIS COULD RESULT IN A VEHICLE ACCIDENT OR PERSONAL INJURY. CORRECTION: OWNERS WILL BE NOTIFIED OF CONDITION AND ADVISED TO SET THE PARKING BRAKE EACH TIME T…

Fuel System

THE CORNER OF THE FRONT HEAT SHIELD MAY CONTACT THE UPPER FRONT CORNER OF THE PLASTIC FUEL TANK. THIS COULD DAMAGE THE TANK AND ALLOW FUEL OR FUEL VAPOUR TO ESCAPE. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR. CORRECTION: HEAT SHIELD WILL BE RELOCATED AND FUEL TANK WILL BE INSPECTED. FUEL TANKS DAMAGED BY HEAT SHIELD WILL BE REPLACED.