Blown head gasket in 1995.
Replaced muffler 2 times and resonator/tail pipe assembly 3 times during 8 years.
Required 93 octane fuel (supposed to run on 87).
Engine cut out under acceleration (dealer could not fix).
Transmission needed rebuilding at 117000 miles.
Two trips to dealer to fix the radio when new, radio quit working in 1996.
Rear wiper motor quit in 1996.
Early 1991 model Ford Explorer, Ford did not have all the bugs worked out at the time it was built.
I feel you really nailed it when you stated that Ford had not worked the bugs out. As a owner of one my comment would have to match yours to a tee. Very expensive and frequent mechanical work. I like to refer to mine as the "exploder".