1991 FORD F-250 — Problems, Recalls & Safety Data

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N/A

Safety Rating

145

Owner Complaints

5 Crashes 9 Fires

7

Recalls

ACTIVE RECALL

0

Service Bulletins

0

Investigations

Overview of the 1991 FORD F-250

The 1991 FORD F-250 has received a total of 145 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There have been 7 recall campaigns affecting this vehicle, covering issues with FUEL SYSTEM, GASOLINE, TIRES:TREAD/BELT, ELECTRICAL SYSTEM:IGNITION. The most commonly reported problems involve the Electrical Systemignitionswitch (10 complaints), Tires (9 complaints), and Fuel System Gasolinestoragetank Assembly (8 complaints).

Recalls for the 1991 FORD F-250

NHTSA has recorded 7 recalls for the 1991 FORD F-250, potentially affecting up to 24,146,410 vehicles.

Recall 01I008000 — FUEL SYSTEM, GASOLINE

| 1,556,221 vehicles affected

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...

Consequence: SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.

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...

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Recall 01X001000 — TIRES:TREAD/BELT

| 13,000,000 vehicles affected

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...

Consequence: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

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.

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Recall 96V071000 — ELECTRICAL SYSTEM:IGNITION

| 7,900,000 vehicles affected

Defect: THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

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Recall 94V040000 — FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

| 89,770 vehicles affected

Defect: 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.

Consequence: ABRASION OF THE STEEL TUBE WALL THAT EVENTUALLY CAUSES A FUEL LEAK MAY RESULT IN A FIRE, IF A SOURCE OF IGNITION IS PRESENT.

Remedy: FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.

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Recall 93V125000 — FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

| 1,131,000 vehicles affected

Defect: 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.

Consequence: SPILLED FUEL CAN RESULT IN A FIRE WHEN EXPOSED TO ASOURCE OF IGNITION.

Remedy: REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.

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Recall 93V066000 — STEERING: STEERING WHEEL/HANDLE BAR

| 2,419 vehicles affected

Defect: 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.

Consequence: THE LODGED KEYS CAN CAUSE LOSS OF STEERING CONTROL, WHICHCAN RESULT IN AN ACCIDENT WHEN THE VEHICLE IS BEING USED ON THE HIGHWAY.

Remedy: A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN PLACE BY THE STEERING LOCK BAND.

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Recall 92V026000 — SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

| 467,000 vehicles affected

Defect: 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.

Consequence: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.

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.

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Owner Complaints for the 1991 FORD F-250

145 complaints have been filed with NHTSA for the 1991 FORD F-250. Below is a breakdown by vehicle component.

Electrical Systemignitionswitch
Complaints: 10 4 Fires
Tires
Complaints: 9
Fuel System Gasolinestoragetank Assembly
Complaints: 8 1 Fire
Service Brakes Hydraulicfoundation Components
Complaints: 7 2 Injuries
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slip
Complaints: 6 2 Crashes 1 Injury
Fuel System Gasolinedeliveryfuel Pump
Complaints: 5
Fuel System Gasolinestorageauxillary Tankselector Devices
Complaints: 5
Engine And Engine Coolingenginegasoline
Complaints: 4 1 Fire
Fuelpropulsion System
Complaints: 4
Power Trainautomatic Transmission
Complaints: 4 1 Crash 1 Injury
Service Brakes Hydraulicfoundation Componentsdisccaliper
Complaints: 4
Tirestreadbelt
Complaints: 4 1 Crash
Electrical Systemalternatorgeneratorregulator
Complaints: 3
Fuel System Gasoline
Complaints: 3
Power Trainaxle Assemblyaxle Shaftseal
Complaints: 3
Service Brakes Hydraulicfoundation Componentsdisc
Complaints: 3 1 Fire
Service Brakes Hydraulicfoundation Componentsdrum
Complaints: 3
Vehicle Speed Control
Complaints: 3
Electrical System
Complaints: 2
Engine And Engine Coolingenginegasolinebelts And Associated Pulleys
Complaints: 2
Exterior Lightingheadlightsswitch
Complaints: 2
Fuel System Gasolinedeliveryhoses Linespiping And Fittings
Complaints: 2
Fuel System Gasolinestorageauxillary Tank
Complaints: 2
Fuel System Gasolinestoragetank Assemblyfiller Pipe And Cap
Complaints: 2
Seat Belts
Complaints: 2
Seatsfront Assemblyrecliner
Complaints: 2
Service Brakes Airdisccaliper
Complaints: 2
Service Brakes Hydraulic
Complaints: 2
Service Brakes Hydraulicfoundation Componentsdiscpads
Complaints: 2
Service Brakes Hydraulicfoundation Componentsdiscrotor
Complaints: 2
Steering Steering Wheelhandle Bar
Complaints: 2 1 Fire
Structurebody
Complaints: 2
Structureframe And Members
Complaints: 2
Electrical Systemignitionmodule
Complaints: 1
Electrical Systemwiring
Complaints: 1
Engine And Engine Coolingcooling System
Complaints: 1
Engine And Engine Coolingengine
Complaints: 1
Exterior Lightingheadlights
Complaints: 1
Exterior Lightingheadlightshighlow Beam Dimmer Switch
Complaints: 1
Fuel System Gasolinedelivery
Complaints: 1
Power Train
Complaints: 1
Power Trainautomatic Transmissioncooling Unit And Lines
Complaints: 1 1 Fire
Power Trainclutch Assembly
Complaints: 1
Power Traindrivelineuniversal Joint
Complaints: 1
Power Trainmanual Transmission
Complaints: 1
Seat Beltsfrontanchorage
Complaints: 1
Seat Beltsfrontbuckle Assembly
Complaints: 1
Seat Beltsfrontretractor
Complaints: 1
Seats
Complaints: 1
Service Brakes
Complaints: 1
Service Brakes Hydraulicfoundation Componentshoses Linespiping And Fittings
Complaints: 1
Service Brakes Hydraulicfoundation Componentsmaster Cylinder
Complaints: 1 1 Crash
Steeringgear Box Other Than Rack And Pinion
Complaints: 1
Structurebodyhood
Complaints: 1
Suspension
Complaints: 1
Suspensionfront
Complaints: 1
Suspensionrear
Complaints: 1
Unknown Or Other
Complaints: 1
Visibilitywindshield Wiperwasher
Complaints: 1
Visibilitywindshield Wiperwashermotor
Complaints: 1

Most Recent Complaints

#11292463 | FUEL/PROPULSION SYSTEM | | N/A miles
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.
#10717803 | ELECTRICAL SYSTEM | | 137,000 miles
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.
#10706349 | FUEL/PROPULSION SYSTEM | | 161,000 miles
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
#10689779 | SERVICE BRAKES | | 55,000 miles
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
#10689779 | VEHICLE SPEED CONTROL | | 55,000 miles
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

View all Electrical Systemignitionswitch complaints →

Safety Rating for the 1991 FORD F-250

NHTSA has not yet tested the 1991 FORD F-250 in its New Car Assessment Program.

Technical Service Bulletins for the 1991 FORD F-250

No technical service bulletins have been reported for this vehicle.

NHTSA Investigations for the 1991 FORD F-250

There are no NHTSA defect investigations on record for this vehicle.

Other Model Years of the FORD F-250

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Other FORD Models

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