IllustrationFUEL 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.
1991 Ford F-250
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 1991 Ford F-250 do not stand out strongly from the model-year median of 119.
About this comparison →How this year compares
Owner complaints by model year
Compare all F-250 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 15 of 107 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Fuel System, Gasoline. Review the 26 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 24 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 15 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
5 crash reports9 fire reports3 injury reports
Fuel/propulsion System complaints
4 reportsTL* 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 MIL…
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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
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 T…
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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
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 AS…
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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
Official recalls
596V071000 · Electrical System:ignition
Apr 25, 1996
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Consequence & remedy
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.
94V040000 · Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Feb 23, 1994
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 & remedy
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.
93V125000 · Fuel System, Gasoline:storage:tank Assembly
Aug 2, 1993
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 & remedy
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.
93V066000 · Steering: Steering Wheel/handle Bar
Apr 27, 1993
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 & remedy
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.
92V026000 · Service Brakes, Hydraulic:foundation Components:drum:shoes/linings
Mar 3, 1992
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 & remedy
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.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
11EA99032 · Dual Fuel Tank Crossflow/leakage
Opened Nov 4, 1999 · Closed Dec 6, 2001
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
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.
Additional source detail variants (2)
Vehicle Speed Control:linkages
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:linkages
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.
RQ98008 · Ford F-SERIES Dual Fuel Tank Leakage
Opened May 29, 1998 · Closed Nov 4, 1999
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly
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.
EA93022 · Idle Air Spd Ctrl Vlv Malf
Opened Jul 30, 1993 · Closed Aug 31, 1994
Status: closed (inferred from source dates) · Engine And Engine Cooling
There is no summary currently available
EA93014 · Alternator Belt Failure
Opened Jun 4, 1993 · Closed Jul 29, 1994
Status: closed (inferred from source dates) · Electrical System
There is no summary currently available
PE93010 · Idle Air Spd Ctrl Vlv Malf
Opened Mar 2, 1993 · Closed Jul 30, 1993
Status: closed (inferred from source dates) · Engine And Engine Cooling
There is no summary currently available
EA93001 · Fuel Expulsion
Opened Jan 7, 1993 · Closed Aug 20, 1993
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
PE92077 · Fuel Expulsion
Opened Sep 9, 1992 · Closed Jan 7, 1993
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
EA91044 · Loss Of Brake Effectivenes
Opened Oct 30, 1991 · Closed Oct 30, 1992
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
===
EA91031 · Fuel Expulsion
Opened Jun 26, 1991 · Closed Nov 1, 1991
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
PE91077 · Loss Of Brake Effectivenes
Opened May 23, 1991 · Closed Oct 31, 1991
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
PE91064 · Transmission Fluid Fires
Opened Apr 9, 1991 · Closed Jul 5, 1991
Status: closed (inferred from source dates) · Power Train
There is no summary currently available