RoadVitals

1991 Ford F-150

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
304
Latest Apr 8, 2025
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
6
Latest Jul 19, 2001
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
12
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
54
8 injuries, 0 deaths reported

Overview

Our database contains 304 NHTSA owner-reported complaints for the 1991 Ford F-150, most frequently naming the fuel system, electrical and brakes categories. 6 safety recalls have been issued covering this model year; 12 NHTSA investigations name it; and 45 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

6 campaigns cover this model year

View all 6

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
01I008000

FUEL SYSTEM, GASOLINE

Jul 19, 2001
1,556,221 units potentially affected
The defect: 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.
The risk: SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.
The 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.
FORD MOTOR COMPANYView on NHTSA.gov
01X001000

TIRES:TREAD/BELT

May 22, 2001
13,000,000 units potentially affected
The defect: 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.
The risk: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.
The 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.
FORD MOTOR COMPANYManufacturer number 01B77View on NHTSA.gov
00T005000

TIRES:TREAD/BELT

Aug 21, 2000
14,400,000 units potentially affected
The defect: 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.
The risk: IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.
The 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.
BRIDGESTONE/FIRESTONE, INC.View on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

EA99032ClosedEngineering Analysis

DUAL FUEL TANK CROSSFLOW/LEAKAGE

Opened Nov 4, 1999
Closed Dec 6, 2001

ON JULY 14, 1993 FORD FILED A DEFECT INFORMATION REPORT CONCERNING FUEL TANK CROSS FLOW LEAKAGE ON F-SERIES LIGHT TRUCKS AND CAB CHASSIS BUILT FROM JULY 22, 1989 THROUGH DECEMBER 17, 1992.THE REMEDY WAS TO REPLACE THE FUEL PRESSURE REGULATOR AND INSTALL A CHECK VALVE BETWEEN EACH FUEL SUPPLY LINE AND FUEL TANK (2) TO REPAIR THE SUPPLY SIDE FUEL CROSS FLOW PROBLEM (RECALL 93V-125).ODI OPENED RQ98-008 ON MAY 29, 1998 BECAUSE OF THE LARGE NUMBER OF ALLEGED REMEDY FAILURES AND REPORTS OF FUEL CROSS FLOW ON VEHICLES OUTSIDE OF THE RECALL POPULATION.BASED ONTHE INFORMATION RECEIVED FROM FORD ON AUGUST 11, SEPTEMBER 30, AND DECEMBER 15, 1998, AND THE INCREASING TREND OF REMEDY FAILURES AND OUT OF SCOPE CROSSFLOW REPORTS, ODI OPENED EA99-032 ON NOVEMBER 4, 1999.THE ATTACHED ENGINEERING ANALYSIS CLOSING REPORT FULLY DESCRIBES THE RESULTS OF THIS INVESTIGATION AND REASON FOR CLOSING.THE SUBJECT VEHICLES CAN EXPERIENCE FUEL TRANSFER FROM ONE TANK TO THE OTHER DUE TO MALFUNCTIONS IN THE FUEL SYSTEM.WHEN FUEL IS PUMPED OR RETURNED TO THE NON-OPERATING TANK (CROSS FLOW), THE CAPACITY OF THE NON-OPERATING TANK CAN BE EXCEEDED, CAUSING FUEL TO OVERFLOW PAST THE FILLER CAP, CREATING A FIRE POTENTIAL.

VEHICLE SPEED CONTROL:LINKAGESLed to recall 00V424000
RQ98008ClosedRecall Query

FORD F-SERIES DUAL FUEL TANK LEAKAGE

Opened May 29, 1998
Closed Nov 4, 1999

THESE VEHICLES CAN EXPERIENCE FUEL TRANSFER FROM ONE TANK TO THE OTHER DUE TO A MALFUNCTIONING FUEL PUMP.FROM THE INFORMATION GATHERED TO DATE, IT APPEARS THAT THERE CAN BE MULTIPLE CAUSES AND/OR A COMBINATION OF CAUSES FOR FUEL CROSS FLOW AND THAT THE RECALL REMEDY MAY BE INADEQUATE.FURTHER INVESTIGATION IS NEEDED.THIS INVESTIGATION IS UPGRADED TO EA99-032.CLICK ON DOCUMENT SEARCH BUTTON FOR ADDITIONAL INFORMATION.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLYLed to recall 93V125000
EA93022ClosedEngineering Analysis

IDLE AIR SPD CTRL VLV MALF

Opened Jul 30, 1993
Closed Aug 31, 1994

There is no summary currently available

ENGINE AND ENGINE COOLING
PE93010ClosedPreliminary Evaluation

IDLE AIR SPD CTRL VLV MALF

Opened Mar 2, 1993
Closed Jul 30, 1993

There is no summary currently available

ENGINE AND ENGINE COOLING

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 304
Fuel system
Filed Apr 8, 2025

The contact owns a 1991 Ford F-150. The contact stated that while driving at an undisclosed speed, the rear fuel tank gauge began indicating that the rear tank was losing fuel abnormally fast. After a visual inspection, the contact observed that fuel was flowing from the rear fuel tank into the front fuel tank. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the fuel pump assembly check valve; however, the dealer declined to attempt to repair the vehicle due to the age of the vehicle. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 93V125000 (Fuel System, Gasoline), but was unaware if the VIN was ever included in the recall. The manufacturer was notified of the failure, a case was opened, and the contact was later informed that the VIN was included in the recall and had been repaired already. The failure mileage was 112,000.

NHTSA ID
11653547
Incident
Apr 7, 2025
Mileage
112,000 mi
Electrical
Filed Mar 29, 2021

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.

NHTSA ID
11405365
Incident
Mar 18, 2021
Mileage
83,100 mi
Fuel system
Filed Jan 6, 2017

FUEL SPILLING OUT AROUND NECK WHILE PARKED AT WORK, ALSO REAR FUEL TANK PUMPING GAS INTO FRONT GAS TANK WHILE DRIVING.... *TR

NHTSA ID
10940174
Incident
Sep 15, 2015
Fuel system
Filed Oct 18, 2016

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

NHTSA ID
10916762
Incident
Oct 4, 2013
Mileage
123,000 mi
Fuel system
Filed Apr 6, 2016

WHILE THE ENGINE IS RUNNING, THE DUAL TANKS CROSS-FLOW INTO ONE ANOTHER. ONE TANK HAS OVER-FILLED THE OTHER TANK AND VISA VERSA TO INCLUDE SPILLAGE. I HAVE CONTACTED THE LOCAL DEALER AND FORD ABOUT IT BUT THEY SAY THEY CAN'T DO ANYTHING FOR ME AS FAR AS A RECALL IS CONCERNED EVEN THOUGH THIS ISSUE WAS A SAFETY RECALL ISSUE IN THE PAST. I DO NOT KNOW IF THE PREVIOUS OWNER ADDRESSED THE RECALL BUT IT IS A PROBLEM RIGHT NOW. WHEN I PURCHASED THE TRUCK, I DIDN'T KNOW IT HAD A CROSS-FLOW PROBLEM UNTIL SOMEONE TOLD ME SOMETHING WAS LEAKING FROM UNDER MY TRUCK. SINCE THEN, I HAVE NOTICED THAT THE FUEL GAUGE GOES DOWN QUICKER THAN IT SHOULD AND WHEN I SWITCH TANKS, THE OTHER TANK HAS MORE FUEL THAN IT DID. THIS ISSUE HAPPENS REGARDLESS IF IN MOTION OR STANDING STILL. IF THE TRACK WAS FIXED VIA A RECALL, THEY OBVIOUSLY DIDN'T DO IT RIGHT OR THE "FIX" DIDN'T FIX THE PROBLEM. I CAN NOT AFFORD TO FIX THIS ISSUE EVEN THOUGH IT SHOULD HAVE BEEN FIXED THROUGH THE RECALL ALREADY.

NHTSA ID
10853825
Incident
Nov 30, 2014
Mileage
46,300 mi
Fuel system
Filed May 12, 2014

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.

NHTSA ID
10587770
Incident
May 16, 2013
Mileage
96,000 mi
Fuel system
Filed Apr 7, 2014

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.

NHTSA ID
10578051
Incident
Apr 2, 2014
Mileage
77,000 mi
Driver assistanceElectricalFuel system
Filed Jul 16, 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.

NHTSA ID
10525094
Incident
May 28, 2013
Mileage
145,000 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

01156

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

01157

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

002310

POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

98167

POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION-E40D-NO 2-3 UPSHIFT. SOME VEHICLES MAY EXHIBIT A NO 2-3 UPSHIFT CONDITION. *AK

98168

POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION- E40D/4R100-1989-99-MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART. YD

0038

POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

VEHICLES MAY EXPERIENCE SOLID PARTICLE CONTAMINANTS FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR, MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM IS NOT PROPERLY FLUSHED, FLUID IN-LINE FILTER KIT. *MJS

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Ford F-150 by model year
YearComplaintsRecallsInvestigationsIssue Index
2026410—
202510012062.6
202418310068.1
202339612060.7
202257423268.2
202197429163.2
202070911164.2
20191,3029164.0
20182,26519266.3
20171,40118370.1
20162,01014467.5
20151,67114568.3
20141,5158262.6
20132,9703361.0
20121,7764458.8
20112,1846458.8
20108421042.6
20093242050.5
20083681151.0
20074887159.4
200658514263.9
20051,11214362.1
20042,02816460.6
200342211366.8
200282110366.2
20011,23619670.9
20001,07417474.6
19991,04418565.6
19981,381181165.5
19972,758261866.9
19963247267.6
19956267164.4
199467613266.4
199358613260.0
19924709867.2
1991Viewing30461268.8
199027551168.3
19892244567.8
19881392670.4
1987913271.1
1986611461.0
1985281260.8
1984151255.9
1983101159.8
1982500—
1981230—
1980340—
19792100—
19784100—
1977360—
1976020—
1975140—
1973010—
1968100—
1966100—
1955100—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.