1991 Ford F-250: problems, recalls and reliability
7 recalls and 107 owner complaints on record; the weakest area is fuel system, gasoline (22% 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 107 owner complaints filed with NHTSA for this exact model year.
“Fuel leaked from heater wire in fuel filter. The fuel followed the wire up the copper core until it reached a crack in the insulation any time there was fuel pressure, ie engine running or even with boost pump pressure with engine off.”Owner report · Fuel/Propulsion System · Oct 2019
“Tl* the contact owns a 1991 ford f-250. After the vehicle was parked, the contact noticed a strong fuel odor from the side of the vehicle. The contact noticed fuel pouring out of the opening of the tank that spilled onto the street and underneath another vehicle. The dealer stated that the fuel check valve in the pump unit was damaged, which caused the fuel to travel from one tank to the other and overflow. The vehicle was not repaired. The manufacturer was not informed of the failure. The approximate failure mileage was 137,000.”Owner report · Electrical System · May 2015
“Tl* the contact owns a 1991 ford f-250. After refueling the vehicle, fuel started leaking from the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The contact was aware of NHTSA campaign number: 01i008000 (fuel system, gasoline) but the VIN was not included. The failure mileage was 161,000. ..updated 05/20/15 *bf the consumer has experienced the fuel switch over issue and would like to be added to the recall. Updated 7/6/2015 *js”Owner report · Fuel/Propulsion System · Apr 2015
Show 7 more owner reports
“Tl* the contact owns a 1991 ford f250. The contact stated that gasoline fuel was leaking from the vehicle and onto the driveway. The vehicle was not taken to the dealer for inspection or repairs. The manufacturer was contacted and they advised the contact that the vehicle was not included in the recall and provided no further assistance. The failure mileage was 102,311 and the current mileage was 102,622. ..updated 09/07/12 *bf updated 09/17/2012 *js”Owner report · Fuel/Propulsion System · Oct 2011
“Tl* the contact owns a 1991 ford f-250. The contact stated that after refueling the vehicle, gasoline would overflow from the rear fuel tank into the front fuel tank, causing spillage. The contact believed that the fuel pump was defective. The vehicle was taken to the dealer who advised that the vehicle was not included in NHTSA campaign id number: 93v125000 (fuel system, gasoline: storage: tank assembly). The dealer advised that the entire fuel tank would need replacing. The manufacturer was not made aware of the failure. The vehicle was not repaired and the VIN was unavailable. The failure mileage was 150,000.”Owner report · Fuel System, Gasoline · Aug 2011
“Tl*the contact owns a 1991 ford f250. The contact stated while driving approximately 45 mph, he noticed gasoline spilling out of the tank. Prior to the spill, he smelled a gasoline odor for about 6 months. The vehicle was inspected by pepboys who informed the contact that the fuel tank selector needed to be replaced. The VIN was unknown. The vehicle was repaired. The failure mileage was 38,525.”Owner report · Fuel System, Gasoline · Sep 2010
“Discoverer a/t tires size lt265/75r16 catastrophically failed while driving at highway speed. Tread completely peeled off. Had only been driving for 30 minutes and outside temperature was 70 degrees f. Tires had about 23,000 miles on them. 1-2 years previously, the same type tire on opposite wheel developed a bulge in the sidewall and had to be replaced. *tr”Owner report · Tires · May 2009
“Dad: the contact states there is NHTSA recall campaign 93v125000 concerning the fuel system: tank assembly. This vehicle has the same problems as indicated in the recall, but ii is not included in the recall due to VIN. The contact repaired the vehicle at his own expense. *ak the dealer charged the consumer 500.00 to replace the fuel pump which was different from the recall. Updated 01/11/06. *jb”Owner report · Fuel System, Gasoline · Nov 2005
“There was an acrid odor in the cabin on several occasions. The radio light began functioning intermittently. The dash lights failed to work twice. The head lights failed to work twice, on separate occasions from the dash lights. I went to replace the headlamp switch, and found the connector charred and melted, and the b2 terminal on the switch was loose and discolored. The switch was charred around the b2 terminal.. I am going to replace the connector also. *jb”Owner report · Electrical System · Feb 2005
“The gasoline was not transferring between the fuel tanks, causing vehicle to stall due to low gasoline. The dealer replaced the fuel tank sender and the fuel pump. *ak there were four attempts to remedy the transferring of fuel from the rear tank to the front tank throughout the filler cap and caused leakage. The consumer requested that ford cover the charges. *sc *jb”Owner report · Fuel System, Gasoline · Feb 2003
When filing, owners marked a crash in 5 of these complaints and injuries in 4 - self-reported to NHTSA, not verified accident statistics.
Recalls - 7 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.
A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.
Remedy: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.
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.
THE STEEL FUEL RETURN TUBES THAT CONNECT THE FRAME FUEL RETURN LINES WITH THE ENGINE FUEL RAIL CAN CONTACT THE PINCH WELD FLANGE CONNECTING THE DASH PANEL TO THE FLOOR PAN. CONTINUED CONTACT LEADS TO ABRASION OF THE STEEL FUEL RETURN TUBE AND EVENTUALLY RESULTS IN A FUEL LEAK.
Remedy: FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.
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-250 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-250 reliable?
NHTSA has 107 owner complaints and 7 recall campaigns on record for the 1991 Ford F-250. The most complained-about area is fuel system, gasoline (22% of complaints).
At what mileage do 1991 Ford F-250 problems usually appear?
Half of the complaints that mention mileage were filed at 102,000 miles or less.
Does the 1991 Ford F-250 have open recalls?
7 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.