FUEL SYSTEM, GASOLINE
1991 Ford F-250
Recalls, owner-reported complaints, investigations and safety data
Data refreshed
Overview
Our database contains 107 NHTSA owner-reported complaints for the 1991 Ford F-250, most frequently naming the fuel system, brakes and electrical categories. 7 safety recalls have been issued covering this model year; 11 NHTSA investigations name it; and 52 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.
Complaint activity over time
When owners filed reports about this model year
View as table
| Month | Complaints filed | Cumulative |
|---|---|---|
| Oct 1995 | 1 | 12 |
| Nov 1995 | 1 | 13 |
| Feb 1996 | 2 | 15 |
| Mar 1996 | 1 | 16 |
| Apr 1996 | 4 | 20 |
| May 1996 | 3 | 23 |
| Jun 1996 | 3 | 26 |
| Jul 1996 | 5 | 31 |
| Aug 1996 | 1 | 32 |
| Sep 1996 | 1 | 33 |
| Oct 1996 | 3 | 36 |
| Nov 1996 | 2 | 38 |
| Dec 1996 | 3 | 41 |
| Jan 1997 | 1 | 42 |
| Feb 1997 | 3 | 45 |
| Mar 1997 | 1 | 46 |
| May 1997 | 1 | 47 |
| Jul 1997 | 1 | 48 |
| Oct 1997 | 1 | 49 |
| Feb 1998 | 1 | 50 |
| Mar 1998 | 4 | 54 |
| May 1998 | 2 | 56 |
| Aug 1998 | 1 | 57 |
| Nov 1998 | 1 | 58 |
| May 1999 | 1 | 59 |
| Jun 1999 | 2 | 61 |
| Jul 1999 | 1 | 62 |
| Jan 2000 | 1 | 63 |
| Feb 2000 | 1 | 64 |
| Mar 2000 | 2 | 66 |
| Apr 2000 | 1 | 67 |
| May 2000 | 1 | 68 |
| Oct 2000 | 6 | 74 |
| Nov 2000 | 2 | 76 |
| Jan 2001 | 3 | 79 |
| Feb 2001 | 3 | 82 |
| Mar 2001 | 1 | 83 |
| May 2001 | 1 | 84 |
| Jun 2001 | 2 | 86 |
| Aug 2001 | 1 | 87 |
| Oct 2001 | 1 | 88 |
| Apr 2002 | 1 | 89 |
| May 2002 | 1 | 90 |
| Jun 2002 | 1 | 91 |
| Jul 2003 | 1 | 92 |
| Dec 2003 | 1 | 93 |
| May 2004 | 1 | 94 |
| Feb 2005 | 1 | 95 |
| Dec 2005 | 1 | 96 |
| Nov 2007 | 1 | 97 |
| May 2009 | 1 | 98 |
| Oct 2010 | 1 | 99 |
| Nov 2010 | 1 | 100 |
| Aug 2011 | 1 | 101 |
| May 2012 | 1 | 102 |
| Apr 2013 | 1 | 103 |
| Feb 2015 | 1 | 104 |
| Apr 2015 | 1 | 105 |
| May 2015 | 1 | 106 |
| Jan 2020 | 1 | 107 |
What owners report
Complaints grouped by the component NHTSA recorded
- Fuel system3124.0%
- Brakes2720.9%
- Electrical1511.6%
- Tires & wheels107.8%
- Engine86.2%
- Transmission75.4%
- Body & structure53.9%
- Seat belts43.1%
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
7 campaigns cover this model year
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.govTIRES:TREAD/BELT
ELECTRICAL SYSTEM:IGNITION
Safety investigations
NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.
DUAL FUEL TANK CROSSFLOW/LEAKAGE
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.
FORD F-SERIES DUAL FUEL TANK LEAKAGE
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.
IDLE AIR SPD CTRL VLV MALF
There is no summary currently available
ALTERNATOR BELT FAILURE
There is no summary currently available
Recent owner complaints
Reports submitted to NHTSA, shown in the owner's own words
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.
- NHTSA ID
- 11292463
- Incident
- Oct 7, 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.
- NHTSA ID
- 10717803
- Incident
- May 18, 2015
- Mileage
- 137,000 mi
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
- NHTSA ID
- 10706349
- Incident
- Apr 17, 2015
- Mileage
- 161,000 mi
I HAD JUST BEEN JUMPED BY AAA BECAUSE MY TRUCK WASN'T STARTING; THE AAA AGENT ALSO CLEANED THE BATTERY TERMINALS. I INTENDED TO HAVE IT TOWED TO THE FORD DEALER BECAUSE I DIDN'T THINK IT WOULD START. SINCE THE AAA AGENT WAS ABLE TO GET TO START, I DECIDED TO STILL TAKE IT TO THE DEALER TO FIND OUT WHY THE BATTERY WAS DEAD (GIVEN THEY HAD THE CAR FOR A MONTH AND HAD PUT IN A NEW BATTERY AND STARTER, AMONG OTHER REPAIRS). DRIVING THE 7 MILES TO THE DEALERSHIP THE CAR SEEMED TO BE ACCELERATING ON ITS OWN, THE ENTIRE WAY, I ONLY STEPPED ON THE GAS ONCE; IT WAS GOING 35 MILES/HOUR BY ITSELF (PER THE SPEEDOMETER). I DIDN'T KNOW WHY THIS WAS HAPPENING AND WHEN I TRIED TO SLOW DOWN USING THE BRAKES, THE TRUCK WAS VERY DIFFICULT TO STOP, SUCH THAT I NEARLY REAR-ENDED MULTIPLE CARS. IT WAS ALL I COULD DO TO PUSH THE BRAKE DOWN AND TWICE HUGE AMOUNTS OF SMOKE CAME FROM UNDER THE VEHICLE (PROBABLY THE BRAKES WERE NOW OVERHEATING?). WHEN I WAS 500 FEET FROM THE DEALERSHIP I TOOK A QUICK LEFT TURN AND HONESTLY COULD NOT STOP THE TRUCK, I THREW IT INTO PARK AND SHUT IT OFF JUST IN TIME TO MISS PLOWING INTO PARKED VEHICLES. SMOKE BILLOWED OUT FROM BELOW THE HOOD. I HAVE NEVER BEEN SO FRIGHTENED IN MY LIFE-I WAS SURE I WAS EITHER GOING TO SMASH INTO SOMEONE SINCE I COULDN'T STOP OR THE TRUCK WAS GOING TO IMPLODE IN FIRE, OR SOMETHING AND I WOULD BE DEAD. I WAS NOT ABLE TO SUCCESSFULLY STOP IT USING THE BRAKES. THE PARKING BRAKE WAS ALSO NOT WORKING (WHICH IS ALSO WHY I WAS RETURNING IT TO THE DEALER). WHEN I ASKED THE SERVICE PERSON AT THE FORD DEALERSHIP IF HE'D SEEN A STUCK THROTTLE LIKE THIS BEFORE, HE SAID, "YES, SOMETIMES WHEN VEHICLES SIT FOR A WHILE". THIS IS A SATURDAY, SO THEY ARE GOING TO EVALUATE THE PROBLEM ON MONDAY. THE SERVICE REP ALSO SAID SOMETIMES CLEANING THE TERMINALS MIGHT CONTRIBUTE TO EXTRA CONDUCTION, WHICH MIGHT HAVE CAUSED THE ACCELERATION ISSUE. *TR
- NHTSA ID
- 10689779
- Incident
- Feb 21, 2015
- Mileage
- 55,000 mi
THE VEHICLE IS A 1990 AND THE SITE DOES NOT PROVIDE A SPACE CHOICE FOR THE 1990, ONLY '91 AND UP. THE TRUCK HAS THE EXACT SAME PROBLEM AS THE OTHER MANY FORD TRUCKS. WHILE IDLING, OR UNDERWAY, THE VEHICLE SPEWS GASOLINE FROM THE FRONT TANK, OUT ONTO THE ROAD, OR ANY DRIVEWAY, IF IDLING. IT'S CLEAR THAT ONCE YOU FILL THE REAR TANK AND THEN TRAVEL, THE FUEL, WHICH SHOULD RETURN TO THE REAR TANK IN A CYCLE, DOES NOT. IT SIMPLY RETURNS TO THE FRONT TANK, UNTIL IT FILLS THE FRONT TANK AND FLOODS OUT. THE PUMP IN THE REAR TANK APPEARS TO JUST CONTINUE TO RUN, FOR EXAMPLE,,,, YOU HAVE A FULL REAR TANK. YOU HAVE HALF A TANK OF FUEL IN THE FRONT TANK. YOU DRIVE. THE REAR TANK PUMP, PUMPS ALL OF THE FULL REAR TANK INTO THE FRONT TANK. SO, HALF A TANK OF GAS FLOWS OUT OF THE FRONT TANK, ONTO THE GROUND. OBVIOUSLY, THE CYCLE, WHERE THE FUEL SHOULD GO FROM REAR, TO ENGINE AND BACK, ISN'T HAPPENING. INSTEAD, THE FUEL ROLLS BY THE ENGINE AND RETURNS TO A FULL FRONT TANK, RATHER THAN THE REAR TANK, SO, ONTO THE GROUND GOES THE FUEL. ON AN OLDER RECALL REPORT, THE REPAIR IS DESCRIBED, WHERE THE 'JUMPER' MUST BE REPLACED, DESPITE THE FACT THERE'S NO SUCH THING, THERE'S A FUEL PUMP AND PROBABLY SOME SORT OF 'BI-VALVE' THAT SOMEONE'S POOR ENGINEERING FAILED ON THE WHOLE, AT THE TIME OF DESIGN. I THINK I'LL JUST PULL INTO THE LOCAL FORD LOT AND IDLE OUT A FEW GALLONS NOW AND THEN. BUT SINCE THE 90 ISN'T ON THE RECALL, DESPITE THE OBVIOUS EXACT PROBLEM AS THE 91'S AND UP, THERE'S NO USE. IT WOULD SEEM COMMON SENSE, THAT DEALERS COULD SIMPLY BE NOTIFIED THAT THE 1990 F 250'S ARE DOING THE EXACT THING AS MANY OTHER MAKES AND THE LEAST THE DEALER COULD DO, IS BE A LITTLE MORE SPECIFIC ABOUT THE REPAIR. BUT NOT IF THEIR CORPORATE ENGINEERS AND REPAIR CENTERS KEEP THE MECHANICAL INFORMATION SECRET, OR WRITTEN IN SOME MANUFACTURER 'CODE LANGUAGE'. *TR
- NHTSA ID
- 10508195
- Incident
- Apr 14, 2013
- Mileage
- 150,000 mi
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
- NHTSA ID
- 10460199
- Incident
- Oct 11, 2011
- Mileage
- 102,000 mi
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.
- NHTSA ID
- 10418150
- Incident
- Aug 9, 2011
- Mileage
- 150,000 mi
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.
- NHTSA ID
- 10366402
- Incident
- Sep 16, 2010
- Mileage
- 38,525 mi
Manufacturer communications
A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.
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
POWER TRAIN:AUTOMATIC TRANSMISSION
TRANSMISSION- E40D/4R100-1989-99-MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART. YD
POWER TRAIN:AUTOMATIC TRANSMISSION
TRANSMISSION-E40D-NO 2-3 UPSHIFT. SOME VEHICLES MAY EXHIBIT A NO 2-3 UPSHIFT CONDITION. *AK
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
POWER TRAIN:AUTOMATIC TRANSMISSION
INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS
ELECTRICAL SYSTEM:WIRING
SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT
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
| Year | Complaints | Recalls | Investigations | Issue Index |
|---|---|---|---|---|
| 2019 | 0 | 0 | 1 | — |
| 2018 | 0 | 0 | 1 | — |
| 2017 | 0 | 0 | 1 | — |
| 2015 | 0 | 0 | 1 | — |
| 2014 | 142 | 0 | 1 | 41.3 |
| 2013 | 95 | 0 | 1 | 42.7 |
| 2012 | 266 | 1 | 1 | 44.1 |
| 2011 | 248 | 2 | 1 | 49.2 |
| 2010 | 73 | 0 | 0 | 37.4 |
| 2009 | 54 | 1 | 0 | 35.9 |
| 2008 | 195 | 8 | 1 | 57.1 |
| 2007 | 60 | 7 | 2 | 53.9 |
| 2006 | 221 | 7 | 2 | 56.5 |
| 2005 | 144 | 5 | 2 | 54.1 |
| 2004 | 153 | 7 | 2 | 57.0 |
| 2003 | 116 | 7 | 2 | 61.8 |
| 2002 | 156 | 7 | 2 | 60.8 |
| 2001 | 220 | 9 | 4 | 65.4 |
| 2000 | 326 | 10 | 3 | 65.6 |
| 1999 | 581 | 19 | 4 | 63.9 |
| 1998 | 56 | 9 | 2 | 54.4 |
| 1997 | 304 | 14 | 3 | 63.2 |
| 1996 | 176 | 5 | 2 | 62.9 |
| 1995 | 184 | 4 | 2 | 60.9 |
| 1994 | 123 | 10 | 5 | 66.9 |
| 1993 | 130 | 9 | 3 | 59.0 |
| 1992 | 119 | 7 | 9 | 62.4 |
| 1991Viewing | 107 | 7 | 11 | 65.4 |
| 1990 | 111 | 7 | 11 | 67.5 |
| 1989 | 112 | 6 | 5 | 65.3 |
| 1988 | 62 | 3 | 6 | 65.0 |
| 1987 | 38 | 2 | 5 | 69.2 |
| 1986 | 38 | 2 | 4 | 70.8 |
| 1985 | 21 | 2 | 3 | 69.7 |
| 1984 | 10 | 3 | 3 | 71.8 |
| 1983 | 1 | 6 | 3 | — |
| 1982 | 0 | 3 | 0 | — |
| 1981 | 1 | 5 | 0 | — |
| 1980 | 0 | 3 | 0 | — |
| 1979 | 2 | 9 | 0 | — |
| 1978 | 2 | 10 | 0 | — |
| 1977 | 2 | 6 | 0 | — |
| 1976 | 0 | 3 | 0 | — |
| 1975 | 0 | 6 | 0 | — |
| 1974 | 2 | 2 | 0 | — |
| 1973 | 0 | 5 | 0 | — |
| 1972 | 0 | 3 | 0 | — |
| 1970 | 1 | 0 | 0 | — |
| 1969 | 0 | 1 | 0 | — |
| 1968 | 1 | 1 | 0 | — |
| 1967 | 0 | 3 | 0 | — |
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.