1991 FORD EXPLORER Recalls (11)

Campaign:
90V098000 on 05/30/1990
Component:
Visibility:sun roof assembly
Manufactured:
01/31/1989 - 04/30/1990
Affected:
2,500
Defect:
If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
Consequence:
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.
Correction:
Install revised sunroof hinges that will adequately retain sunroof assembly.
Notes:
System: sunroof hinges.vehicle description: multi-purpose passenger 4-door vehicles with sunroofs.
Campaign:
91V026000 on 02/20/1991
Component:
Structure:body:bumpers
Manufactured:
01/31/1990 - 12/31/1990
Affected:
220,000
Defect:
Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
Consequence:
Under extreme conditions, bumper could separate from thevehicle when using a bumper mounted trailer hitch ball.
Correction:
Install two brackets to reinforce the bumper.
Notes:
System: rear bumper reinforcement.vehicle description: multi-purpose passenger vehicle.note: bumper mounted trailer hitch ball assembly should not be used until repairprocedure is completed.
Campaign:
91V024000 on 02/27/1991
Component:
Fuel system, gasoline:storage:tank assembly
Manufactured:
01/31/1990 - 10/31/1990
Affected:
25,000
Defect:
The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
Consequence:
This penetration of the fuel tank causes vapors to escapeand possibly fuel to spill, which could catch fire in the presence of anignition source.
Correction:
Relocate the heat shield; inspect and replace damaged fuel fuel tanks.
Notes:
System: fuel tank and heat shield.vehicle description : multi-purpose passenger vehicle.
Campaign:
91V025000 on 02/27/1991
Component:
Fuel system, gasoline:storage:tank assembly
Manufactured:
06/30/1990 - 07/31/1990
Affected:
18,000
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.
Consequence:
The escaped vapor or leaked fuel could cause a fire inthe presence of a source of ignition.
Correction:
Fuel tank will be removed and inspected for weld integrity. fuel tanks with inadequate welds will be replaced.
Notes:
System: vapor vent valve carrier weld to plastic fuel tank.vehicle description: multi-purpose passenger vehicles.
Campaign:
91V189000 on 11/05/1991
Component:
Power train:automatic transmission
Manufactured:
06/30/1989 - 07/31/1991
Affected:
792,000
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.
Consequence:
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 surface, andinadvertent motion when the vehicle is started. all of these conditions canresult in a vehicle accident.
Correction:
Repair the transmission with a new park pawl.
Notes:
System: transmission.vehicle description: pickup trucks, vans, and multi-purpose vehicles equippedwith a4ld automatic transmissions.
Campaign:
92V113000 on 08/23/1992
Component:
Seat belts:front:buckle assembly
Manufactured:
02/28/1989 - 07/31/1990
Affected:
565,000
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 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 sufficiently to provide occupant protection.
Consequence:
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 allow theoccupant to get out of the vehicle in an emergency situation.
Correction:
Ford will replace the rigid mounted safety belt buckles with end release safety belt buckles designed to prevent latch problems.
Notes:
System: safety belt buckle.vehicle description: passenger cars and utility vehicles.note: only the end release buckles on "rigid" mountings are susceptible to thismalfunction, the web-mounted front center end release buckles and theweb-mounted rear facing third seat end release buckles in taurus or sablevehicles will not be replaced. also, the web-mounted front center buckles inexplorer vehicles will not be replaced.
Campaign:
95I007000 on 02/08/1996
Component:
Structure:body:hatchback/liftgate:support device
Manufactured:
01/31/1990 - 01/31/1995
Affected:
1,029,380
Defect:
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:
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.
Correction:
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.
Campaign:
96V024001 on 02/28/1996
Component:
Service brakes, hydraulic:power assist:hydraulic
Manufactured:
02/28/1991 - 10/31/1993
Affected:
108,000
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.
Consequence:
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 activating increasing the risk of a vehicle accident.
Correction:
Dealers will replace the power brake vacuum booster assembly.
Notes:
System: brakes; power assist; primary; booster. vehicle description: multi-purpose vehicles and light duty trucks originally sold or currently registered in the southern california counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern.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.
Campaign:
97V235001 on 02/24/1998
Component:
Structure:body:roof and pillars
Manufactured:
01/04/1990 - 01/14/1993
Affected:
185,000
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 glass panel.
Consequence:
Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
Correction:
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.
Campaign:
00T005000 on 08/09/2000
Component:
Tires:tread/belt
Affected:
14,400,000
Defect:
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.
Consequence:
If the tread separates from the tire, the driver can lose control of the vehicle, possibly resulting in a crash causing injury or death.
Correction:
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.
Campaign:
01X001000 on 05/21/2001
Component:
Tires:tread/belt
Affected:
13,000,000
Defect:
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. ford is replacing these tires to prevent possible premature tire failure. vehicle description: the vehicles listed below may have been originally equipped with firestone wilderness at tires or may have had wilderness at tires installed during the firestone recall launched in august 2000. certain 1991 throught 2002 ford explorer certain 2001 throught 2002 explorer sport, and sport trac certain 1997 through 2002 mercury mountaineer certain 1991 through 2001 ranger certain 1999 through 2001 expedition certain 1991 through 1994, and 1997 model year f-series certain 1991 through 1994 bronco note: both original equipment and replacement tires are affected.
Consequence:
Should the tread separate at highway speeds, a vehicle crash could occur, possibly resulting in personal injury or death.
Correction:
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.

1991 FORD EXPLORER TSBs (63)

Bulletin:
94229
Component:
162300 structure:body:door
Summary:
inside door handle breaks when opening. *tw
Bulletin:
942211
Component:
353600 equipment:air conditioner
Summary:
insufficient air flow through condenser. *tw
Bulletin:
FD94M85
Component:
061000 engine and engine cooling:engine
Summary:
announcement letter for recall 94m85. *tw
Bulletin:
95102
Component:
116000 electrical system:ignition
Summary:
vehicles may have a disconnect of the ignition control module (icm) connector or moisture buildup within the connector. *tw
Bulletin:
BC1350950906
Component:
103000 power train:automatic transmission
Summary:
high altitude transmission available. *tw
Bulletin:
95153
Component:
062100 engine and engine cooling:cooling system:radiator assembly
Summary:
temperature gauge - fluctuating and /or inaccurate high readings. *sd
Bulletin:
95161
Component:
162000 structure:body
Summary:
sheet metal-roof panel and drip rail replacement- seam sealer application procedure.*sd
Bulletin:
BC0131960102
Component:
106000 power train:axle assembly
Summary:
4x4 front axles must use hypoid 4x4 gear oil p/n f1tz-19580-a & high temp 4x4 front axle & wheel bearing grease when servicing. it is not recommended to use heavier weight lubes in these front axles.
Bulletin:
95212
Component:
036000 service brakes, hydraulic:antilock
Summary:
the use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. if petroleum-based grease is used to lubricate any par
Bulletin:
BC5225961001
Component:
105300 power train:driveline:driveshaft
Summary:
Vehicles may experience a vibration during wide open throttle acceleration or while cruising at highway speeds. revised front driveshaft. *tt
Bulletin:
BC0328961129
Component:
034420 service brakes, hydraulic:foundation components:drum:shoes/linings
Summary:
Concerns with rear brake grab during the first few brake applications when the brakes are cold or in the morning after an overnight rain. *tw
Bulletin:
96246
Component:
114000 electrical system:wiring
Summary:
Wiring - electrical diode identification and service replacements. *tw
Bulletin:
96249
Component:
103700 power train:automatic transmission:torque converter
Summary:
Torque converter - leak test procedure - service tip. *tw
Bulletin:
962417
Component:
105000 power train:driveline
Summary:
Noise - pinging or creaking from driveline when vehicle is put into gear. *tw
Bulletin:
96221
Component:
131000 visibility:windshield
Summary:
Windshield and interior glass - fog/film. *tw
Bulletin:
962612
Component:
103700 power train:automatic transmission:torque converter
Summary:
Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw
Bulletin:
97210
Component:
161000 structure:frame and members
Summary:
Body - rust perforation - quarter panel - service tips. *tw
Bulletin:
BC3485972301
Component:
062300 engine and engine cooling:cooling system:hose
Summary:
4.0l equipped vehicles may experience temperature gauge fluctuation that may be accompanied with a thumping noise or feel in the coolant hose with the engine at normal operating temperature. *jd
Bulletin:
BC1019997230
Component:
062300 engine and engine cooling:cooling system:hose
Summary:
4.0l equipped vehicles may experience temperature gauge fluctuation that may be accompnied with a thumping noise or feel in the coolant hoses with the engine at normal operating temperature. *jd
Bulletin:
9747
Component:
160000 structure
Summary:
Frame- rivet replacement with bolts- service tips. *jd
Bulletin:
97511
Component:
103000 power train:automatic transmission
Summary:
Fluid- transmission fluid usage charts. *jd
Bulletin:
9768
Component:
980000 unknown or other
Summary:
Fuel economy- customer expectations versus vehicle usage. *jd
Bulletin:
BC2361970501
Component:
980000 unknown or other
Summary:
Authorized warranty part replacement of brake pads to correct excessive brake noise. *tw
Bulletin:
971110972312
Component:
105000 power train:driveline
Summary:
Concerns with "pinging" or "creaking" being heard from the driveline when shifting from park to drive or reverse, between drive and reverse, or when engaging the clutch. *yc
Bulletin:
985A13
Component:
034500 service brakes, hydraulic:foundation components:disc
Summary:
The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc
Bulletin:
985A22
Component:
036000 service brakes, hydraulic:antilock
Summary:
A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. *yc
Bulletin:
985A36
Component:
034000 service brakes, hydraulic:foundation components
Summary:
A grabbing and/or sticking condition during the first few brake applications when the brakes are cold or in the morning after an overnight rain may occur on some vehicles. *yc
Bulletin:
9888
Component:
103000 power train:automatic transmission
Summary:
Information on a new transmission fluid usage chart. *yc
Bulletin:
9848
Component:
353600 equipment:air conditioner
Summary:
Announcing the ford oem air conditioning retrofit kit availability. *yc
Bulletin:
9852
Component:
190000 tires
Summary:
Information on tire company telephone numbers for customer assistance. *yc
Bulletin:
9864
Component:
063000 engine and engine cooling:exhaust system
Summary:
Information on a buzzing or rattle noise from the exhaust system. *tt
Bulletin:
9873
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio. *tt
Bulletin:
982310
Component:
063100 engine and engine cooling:exhaust system:emission control
Summary:
Mass air flow (maf)- sensor contamination- service tip. *ak
Bulletin:
98246
Component:
110000 electrical system
Summary:
Ford motor company has released a new electrical grease ( f8az - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals. *yc
Bulletin:
98112
Component:
103000 power train:automatic transmission
Summary:
Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt
Bulletin:
98116
Component:
020000 suspension
Summary:
Information regarding comprehensive pull and drift diagnostic procedure developed to assist technicians with vehicle service. *tt
Bulletin:
986001
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Customer complaint of engine miss under load while going up steep hills. *tt
Bulletin:
99816
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt
Bulletin:
99129
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump. *tt
Bulletin:
12905
Component:
106000 power train:axle assembly
Summary:
Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making cornering maneuvers on vehicles equipped with a four wheel drive hi or low range mode. *tt
Bulletin:
995157
Component:
190000 tires
Summary:
Information on maintaining tire pressure. *tt
Bulletin:
983074
Component:
106000 power train:axle assembly
Summary:
Concerns with axle wind-up and / or clunking, popping, ratcheting type noises when making cornering maneuvers. *tt
Bulletin:
99156
Component:
353600 equipment:air conditioner
Summary:
Some vehicles may exhibit a burning odor or smoke, and / or rustling noise occuring when the blower motor is running if leaves or foreign material enters the blower case. *tt
Bulletin:
99206
Component:
353600 equipment:air conditioner
Summary:
Concerns with burning odor or smoke, and / or rustling noise while blower motor is on. *tt
Bulletin:
99222
Component:
114000 electrical system:wiring
Summary:
Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
Bulletin:
99196
Component:
353600 equipment:air conditioner
Summary:
Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
Bulletin:
6603
Component:
105000 power train:driveline
Summary:
Some vehicles may exhibit an audible pinging or creaking noise that may be heard from the driveline when engine torque is initially applied to the driveline. *tt
Bulletin:
7366
Component:
102000 power train:manual transmission
Summary:
Some vehicles equipped with manual transmission may exhibit neutral gear rollover noise (a light metallic rattling sound from the transmission) which occurs at idle with transmission in neutral clutch engaged (clutch pedal up). *tt
Bulletin:
0015
Component:
103000 power train:automatic transmission
Summary:
Information regarding the new transmission cooler flusher- service tip. *mjs
Bulletin:
12115
Component:
190000 tires
Summary:
Information regarding the tire inflation pressure for all models during predelivery process and during maintenance intervals. *mjs
Bulletin:
985157
Component:
190000 tires
Summary:
Information on setting the tire inflation pressure for 1991 through 1999 model year vehicles in the pre-delivery process and during maintenance intervals. *tt
Bulletin:
985A12
Component:
354600 equipment:mechanical:wrecker and wheel lift devices
Summary:
Recommended guidelines for towing behind recreational vehicles. *tt
Bulletin:
6896
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt
Bulletin:
13118
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt
Bulletin:
99152
Component:
103000 power train:automatic transmission
Summary:
Information on the new flush and fill tool available through rotunda. *tt
Bulletin:
00243
Component:
181000 vehicle speed control:accelerator pedal
Summary:
On some vehicles, the accelerator pedal bracket may become loose or separated from the dash panel. this may be caused by repeated excessive force on the accelerator pedal, resulting in cracking of the dash panel sheet metal at the acceler
Bulletin:
00L09
Component:
355100 equipment:other:labels
Summary:
Subject pertaining to supplemental tire inflation label. *jb
Bulletin:
01156
Component:
138120 visibility:defroster/defogger system:windshield:heater core
Summary:
Some vehicles may exhibit heater core leaks. *slc
Bulletin:
01157
Component:
980000 unknown or other
Summary:
Information regarding transmission fluid usage charts. *slc
Bulletin:
01197
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles equipped with the 4.0l ohv engine may exhibit an engine noise which may be perceived by the customer as a piston / onnecting rod bearing knock. *tt
Bulletin:
01B77
Component:
190000 tires
Summary:
Owner notification program supplement 7 revised information - regarding replacement of wilderness at tires. *tt
Bulletin:
02142
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles equipped with an automatic transmission and a 4.0l ohv engine may exhibit a noise / vibration, no drive, unusual noise during cranking or a no crank condition. *tt
Bulletin:
16735
Component:
022000 suspension:rear
Summary:
Various noise issues from the rear leaf springs while driving. *tt

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