1991 Ford F-150: problems, recalls and reliability
6 recalls and 304 owner complaints on record; the weakest area is fuel system, gasoline (48% of complaints).
Data updated weekly · latest recall Jul 2001
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 304 owner complaints filed with NHTSA for this exact model year.
“The truck wont crank. When the key is turned off and removed some electrical systems still work and cause smoking. I have had to disconnect the battery in fear the truck will burn down. Ford was contacted about the issue and said they cant do anything because their records for recalls only go 10 years. Even though the truck has less than 84000 miles on it.”Owner report · Electrical System · Mar 2021
“Fuel spilling out around neck while parked at work, also rear fuel tank pumping gas into front gas tank while driving.... *tr”Owner report · Fuel/Propulsion System · Sep 2015
“Tl* the contact owns a 1991 ford f-150. The contact stated that a portion of the unused fuel from one tank was being returned to the second tank, causing a fuel spillage. The contact also stated that the fuel pressure was low. The contact was not diagnosed. The manufacture was made aware of the failure and stated the vehicle was serviced under recall NHTSA campaign number: 01i008000(fuel system, gasoline) however the failure persisted. The vehicle was not repaired. The failure mileage was 77,000.”Owner report · Fuel/Propulsion System · Apr 2014
Show 7 more owner reports
“Tl* the contact owns a 1991 ford f-150. The contact stated that one of the tanks in the vehicle would not work and caused the vehicle to stall. The vehicle was taken to an independent mechanic, but could not be repaired. The details of the diagnostic test could not be provided. The VIN was not included in NHTSA campaign number: 01l008000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 123,000. Updated 01/05/17*lj”Owner report · Fuel System, Gasoline · Oct 2013
“Tl* the contact owns a 1991 ford f-150. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer who stated the fuel pump failed. The vehicle was repaired but the failure recurred. The manufacturer was contacted about the failure. The failure mileage was 145,000. The consumer stated the battery failed and the seal around the speedometer went bad.”Owner report · Electrical System · May 2013
“Tl* the contact owns a 1991 ford f-150. The contact stated that the fuel pump assembly caused a portion of the unused fuel from one tank to be returned to the second tank. When the failure occurred, the capacity of the second tank was exceeded and would cause fuel spillage. The contact believed that the vehicle was exhibiting the exact same failure indicated in NHTSA campaign number: 93v125000. (fuel system, gasoline). The manufacturer was made aware of the failure. The contact was informed that the vehicle was not included in the recall campaign. The failure and current mileage was 96,000.”Owner report · Fuel System, Gasoline · May 2013
“Tl* the contact owns a 1991 ford f-150. The contact stated that a portion of the unused fuel from one tank was being returned to the second tank, causing fuel spillage. The vehicle was taken to the dealer where it was diagnosed that the fuel pressure regulator and installation of redundant check valves needed to be replaced. The manufacturer was made aware of the failure and stated that the vehicle was not included in NHTSA campaign number: 93v125000 (fuel system, gasoline). The vehicle was not repaired. The approximate failure mileage was 130,000 and the current mileage was 132,000. *tr”Owner report · Fuel System, Gasoline · May 2012
“Tl*the contact owns a 1991 ford f-150. The contact stated that while driving less than 1 mph, there was a strong fuel odor. The contact pulled over and noticed that fuel leaking from the gas cap. The contact called the dealer who stated that they could not check the VIN because the system was outdated. The vehicle had not been repaired. The failure mileage was 89,429 and the current mileage was 89,430.”Owner report · Fuel System, Gasoline · Nov 2010
“Tl*the contact owns a 1991 ford f-150. While driving at an unknown speed, the contact noticed that fuel was leaking. The failure occurred intermittently. The contact was informed by the manufacturer that the vehicle was not included in recall 01i008000 (fuel system, gasoline). The vehicle had not been repaired. The failure mileage was approximately 95,000 and the current mileage was approximately 130,000.”Owner report · Fuel System, Gasoline · Nov 2009
“Tl* the contact owns a 1991 ford f-150. The vehicle was equipped with a dual fuel tank. The contact observed fuel leakage in the second fuel tank spilling fuel into the first fuel tank and causing an excessive overflow. There were two recalls under NHTSA campaign id numbers 01i008000 (fuel system, gasoline) and 93v125000 (fuel system, gasoline: storage: tank assembly). The VIN was excluded from the safety recall. The vehicle had not been repaired. The contact had concern of the potential safety hazard. The failure mileage was 170,000. The current mileage was 182,000.”Owner report · Fuel System, Gasoline · Mar 2009
When filing, owners marked a crash in 12 of these complaints and injuries in 8 - self-reported to NHTSA, not verified accident statistics.
Recalls - 6 campaigns
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.
Remedy: 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.
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1990-1993 FORD F-SERIES VEHICLES EQUIPPED WITH DUAL FUEL TANKS AND 4.9, 5.0,5.8, OR 7.5 LITER GASOLINE FUELED ENGINES. SOME VEHICLES CAN EXPERIENCE A CROSS TANK FUEL FLOW CONDITION DUE TO A DAMAGED CHECK VALVE IN THE FUEL PUMP/SENDER ASSEMBLY. FUEL MAY BE SUPPLIED FROM ONE TANK AND SOME OR ALL OF THE UNUSED FUEL MAY BE RETURNED TO THE OTHER TANK.
Remedy: FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150,000 MILES FROM THE VEHICLE'S WARRANTY START DATE, WHICHEVER OCCURS FIRST. THIS COVER WILL AUTOMATICALLY TRANSFER TO SUBSEQUENT OWNERS AT NO CHARGE. IF A VEHICLE ALREADY HAS MORE THAN 150,000 MILES, THIS OVERAGE WILL LAST UNTIL DECEMBER 31, 2001. IF THE VEHICLE IS EXPERIENCING A FUEL CROSS-FLOW CONDITION, DEALERS WILL REPAIR THE CONDITION FREE OF CHARGE.
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.
Remedy: 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.
A MALFUNCTIONING CHECK VALVE WITHIN THE FUEL PUMP ASSEMBLY CAUSES A PORTION OF THE UNUSED FUEL FROM ONE TANK TO BE RETURNED TO THE SECOND TANK. WHEN THIS OCCURS, THE CAPACITY OF THE SECOND TANK CAN BE EXCEEDED, CAUSING FUEL SPILLAGE.
Remedy: REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.
KEYS ATTACHED TO THE KEY RING OF AN IGNITION KEY WHILE IT IS IN THE VEHICLE IGNITION CAN BECOME LODGED IN THE STEERING LOCK RECEIVER AS THE STEERING WHEEL IS BEING TURNED.
Remedy: A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN PLACE BY THE STEERING LOCK BAND.
How other years compare
Check your exact F-150 by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 1991 Ford F-150 reliable?
NHTSA has 304 owner complaints and 6 recall campaigns on record for the 1991 Ford F-150. The most complained-about area is fuel system, gasoline (48% of complaints).
At what mileage do 1991 Ford F-150 problems usually appear?
Half of the complaints that mention mileage were filed at 107,000 miles or less.
Does the 1991 Ford F-150 have open recalls?
6 recall campaigns have been issued, the latest concerning tires:tread/belt. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.