1991–2001 Ford Explorer Carpet Replacement – Buyer's Guide
July 13, 2025
The 1991–2001 Ford Explorer helped define the modern SUV era. As one of Ford’s most popular utility vehicles, the 4-door Explorer became a staple for families, outdoor enthusiasts, and commuters alike. After decades of use, it’s common for these vehicles to show wear inside—especially in the carpet and cargo areas. Fortunately, replacing the interior carpet is a cost-effective way to refresh your SUV and extend its comfort and value.
This guide outlines all available carpet replacement options for the 4-door Explorer, including full interior kits, rear passenger-only sections, and cargo-area liners. Whether you’re restoring a well-used Explorer or updating a daily driver, Factory Interiors offers tailored solutions to bring your interior back to life.
Original Material: Cutpile Carpet
All replacement kits listed here are made from Cutpile, the original material used by Ford during this generation. Cutpile provides a soft texture with excellent durability and sound insulation—ideal for both comfort and daily utility. It’s the preferred choice for original-style restorations and functional upgrades alike.
Construction Types: Molded vs. Die-Cut
- Molded Carpet: The complete and passenger-area kits are molded to the exact contours of the Explorer’s floor pan, ensuring a precise fit with minimal trimming.
- Die-Cut Carpet: The cargo-area carpet is flat-trimmed (die cut) and designed to drop into the rear cargo space of 4-door models.
Padding & Optional Upgrades
- Jute Padding: Included on all molded kits for thermal and acoustic insulation.
- Vinyl Heel Pad: Factory-style reinforcement installed under the driver’s feet for extra durability.
- Mass Backing: Optional upgrade available on molded kits for enhanced heat resistance and noise control. Learn more about mass backing.
Available Products
| Product | Material | Construction | Logo | Image |
|---|---|---|---|---|
| Complete Carpet – Cutpile | Fits: 4DR | Cutpile | Molded | — |  |
| Passenger Area Carpet – Cutpile | Fits: 4DR | Cutpile | Molded | — |  |
| Cargo Area Carpet – Cutpile | Fits: 4DR | Cutpile | Die Cut | — |  |
Why Replace Your Explorer’s Carpet?
Over time, the Explorer’s carpet can accumulate stains, moisture damage, and wear—especially in high-traffic zones and the cargo area. Common reasons for replacement include:
- Heavy staining or lingering odors from spills or pets
- Fading and wear in the driver/passenger footwells
- Mildew from leaks or wet cargo
- Desire to clean up a used vehicle or prep for resale
Replacing the carpet restores the cabin's freshness, improves insulation, and helps maintain vehicle value.
Installation Tips
- Remove all seats and trim: Including the center console and door sill plates, to access all mounting points.
- Let the carpet relax: Allow molded kits to warm in the sun or indoors before installation to reduce wrinkles.
- Use a drill in reverse: When making holes for seat bolts or shifter trim, reverse drilling prevents fraying.
- Inspect the floor pan: Address any rust or leaks before installing your new kit.
- Vacuum thoroughly: Remove all old debris and padding before laying in new carpet or sound deadening.
DIY or Professional Installation?
Explorer carpet replacement is doable for most DIYers with a few hours and basic tools. Expect 4–6 hours for a complete install. However, professional installation is recommended for:
- Rust remediation or water-damaged floors
- Show-quality finishes
- Convenience if time is limited
Local auto upholstery shops, detailers, body shops, or trusted mechanics can complete the job efficiently with professional results.
Benefits of New Carpet
- Cleaner, odor-free interior
- Improved comfort and sound deadening
- Better resale value and presentation
- Increased pride of ownership
Why Factory Interiors?
All Ford Explorer carpet kits listed here are manufactured in the USA by Auto Custom Carpets (ACC), the #1 manufacturer of replacement automotive carpet in the world. With decades of experience, ACC ensures vehicle-specific fitment and OEM-style materials.
Factory Interiors is a leading distributor of ACC products and a trusted source for expert support, fast shipping, and premium carpet solutions for your SUV. Whether you're restoring your Explorer or improving its durability for daily use, our team ensures a precise, high-quality result every time.