VehicleVerdict

1991 Ford Explorer brakes problems

The 1991 Ford Explorer has 151 brakes complaints filed with NHTSA — 20% of the year's total, and up sharply from the prior model year.

151

Brakes complaints

20%

Share of year

19

Crash-involved

1

Related recalls

Brakes complaints by year

Explorer brakes complaints by model year310 complaints1986: 1 complaints1987: 1 complaints1988: 1 complaints1990: 2 complaints1991: 151 complaints1992: 142 complaints1993: 276 complaints1994: 310 complaints1995: 94 complaints1996: 149 complaints1997: 106 complaints1998: 102 complaints1999: 89 complaints2000: 72 complaints2001: 37 complaints2002: 136 complaints2003: 49 complaints2004: 54 complaints2005: 18 complaints2006: 41 complaints2007: 12 complaints2008: 8 complaints2009: 2 complaints2010: 15 complaints2011: 29 complaints2012: 20 complaints2013: 40 complaints2014: 27 complaints2015: 32 complaints2016: 19 complaints2017: 22 complaints2018: 10 complaints2019: 5 complaints2020: 83 complaints2021: 22 complaints2022: 14 complaints2023: 6 complaints2025: 13 complaints2026: 1 complaints
Explorer brakes complaints by model year. Red bars are years to avoid.

Related recalls

96V024001BrakesFebruary 5, 1996 · 108,000 units

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.

Remedy

DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

What owners report

“CONSUMER WAS TRAVELING ABOUT 35MPH ON A SIDE STREET AND HEARD A JINGLE NOISE. HE PULLED OVER TO SHOULDER, AND LOOKED ALL OVER THE VEHICLE. WHEN HE APPLIED BRAKES PEDAL WENT ALL THE WAY TO THE FLOOR, AND VEHICLE SWERVED/ HIT A TREE STUMP, AND ROLLED OVER. VEHICLE WAS TOTALED. MANUFACTURER WAS…”

Complaint filed with NHTSA · Brakes · November 15, 2001 · crash

Common questions

How many brakes complaints does the 1991 Ford Explorer have?

NHTSA has 151 complaints about the 1991 Ford Explorer brakes — 20% of all complaints filed for that model year.

Are there recalls for the 1991 Ford Explorer brakes?

Yes — 1 NHTSA recall campaign for this model year is tied to the brakes: 96V024001.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.