IllustrationHEADLIGHT SWITCH IS FAULTY CAUSING THE LIGHTS TO FAIL WHILE DRIVING. NLM
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
What owners actually said
107 reportsRECALL 96 V 071 00/ELECTRICAL SYSTEM IGNITION: VEHICLE EXPERIENCING PROBLEM WITH IGNITION SWITCH FAILING TO OPERATE/ WILL NOT TURN ON. HAD TO DISCONNECT SWITCH AND HOT WIRE TO GET VEHICLE TO START. MANUFACTURER NOTIFIED, AND INFORMED CONSUMER THAT THEY COULD NOT LOCATE VIN SYSTEM. ASKING NHTSA TO HELP IN THIS MATTER. FEEL …
Read full complaint
RECALL 96 V 071 00/ELECTRICAL SYSTEM IGNITION: VEHICLE EXPERIENCING PROBLEM WITH IGNITION SWITCH FAILING TO OPERATE/ WILL NOT TURN ON. HAD TO DISCONNECT SWITCH AND HOT WIRE TO GET VEHICLE TO START. MANUFACTURER NOTIFIED, AND INFORMED CONSUMER THAT THEY COULD NOT LOCATE VIN SYSTEM. ASKING NHTSA TO HELP IN THIS MATTER. FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS PROBLEM. *AK
TREAD STARTED COMING OFF TIRE. REMOVED BEFORE BLOWOUT. LOCAL DEALER CONTACTED BUT "NO RECALL PROGRAM ON THAT SIZE". SEEMS TO BE SAME PROBLEM AS WITH 235/75/R15'S. *AK (TIRESIZE: 235/85/R16)( DOT NUMBER: TIRE SIZE: 235/85/R16 )
CONSUMER WAS TRAVELING 58-59MPH AND PASSENGER'S REAR TIRE TREAD SEPARATED. ONLY WARNING WAS THAT VEHICLE SWAYED FORM SIDE TO SIDE. TREAD WAS HITTING REAR OF WHEEL WELL AND RUNNING WELL. VEHICLE HAD OVER $2407.00 WORTH OF DAMAGE. TIRE SIZE P265/75R16, APRROXIMATELY 3500, AFTERMARKET TIRES.*AK *JB
CONSUMER WENT TO START VEHICLE , SMOKE STARTED TO COME OUT OF ENGINE COMPARTMENT , FILLED TRUCK WITH BAD BURNING SMELL, SHUT OFF ENGINE AND NOTICED INSULATION HAS COMPLETELY MELTED ,WIRES OFF ENGINE,A MAJOR CONNECTOR WAS ALSO BURNED, BUT NO FUSES WERE BLOWN. CONSUMER HAS ALREADY FILED COMPLAINT EVOQ#861040 BUT SAME DEFECT RECOO…
Read full complaint
CONSUMER WENT TO START VEHICLE , SMOKE STARTED TO COME OUT OF ENGINE COMPARTMENT , FILLED TRUCK WITH BAD BURNING SMELL, SHUT OFF ENGINE AND NOTICED INSULATION HAS COMPLETELY MELTED ,WIRES OFF ENGINE,A MAJOR CONNECTOR WAS ALSO BURNED, BUT NO FUSES WERE BLOWN. CONSUMER HAS ALREADY FILED COMPLAINT EVOQ#861040 BUT SAME DEFECT RECOOCURRED. SERVICE MANAGER AT DEALER CLAIMED DEFECT WAS NOT UNUSUAL AND WAS AWARE OF DEFECT.*AK THE CONSUMER BELIEVES THE PROBLEM WA NOT ELECTRICAL. *YH
WHEN SWITCHING FROM FRONT TANK TO REAR TANK THERE IS A LEAK PRESENT DUE TO FUEL LINE CLAMP THAT DOES NOT HOLD LINES SECURE. DEALER HAS NOT SEEN VEHICLE. *AK
WHILE DRIVING, CONSUMER HEARD A LOUD NOISE AND PULLED OFF TO SIDE OF ROAD, FOUND FRONT REAR FIRESTONE TIRE HAD EXPERIENCED TREAD SEPARATIONH, TIRE SIZE P235/85R16, DOT VN0RTWT241. *SLC
EA 99032 FUEL TANK IS OVERFLOWING REGARDLESS OF WHICH TANK IS ON. FUEL IS STILL BEING USED BY BOTH TANKS. *AK REAR TANK OVERFLOWED WHILE VEHICLE WAS PARKED IN DRIVEWAY.. *SLC
RIGHT REAR TIRE SEPARATED THEN BLEW, THROWING THE TIRE CAP AROUND ,DAMAGING FENDER, SHOCK, MUFFLER AND WHEEL WELL SUPPORTS AS WELL AS OUR NERVES TRYING TO MAINTAIN CONTROL.*AK (DOT NUMBER: ? TIRESIZE: 255/85R16)
THE REUSE OF THE SEATBELTS INSTALLED BY FORD AFTER EMERGENCY USE IS NOT CLEAR. INSURANCE COMPANY WAS NOT EVEN AWARE OF THIS SITUATION. THE SEATBELTS INSTALLED BY FORD MUST BE DEALER INSPECTED AFTER EMERGENCY USE . THESE SEATBELTS ARE DESIGNED FOR A ONE SHOT USE IN COLLISIONS OR MAJOR BRAKING. HOW MANY PEOPLE ARE DRIVING AROUND …
Read full complaint
THE REUSE OF THE SEATBELTS INSTALLED BY FORD AFTER EMERGENCY USE IS NOT CLEAR. INSURANCE COMPANY WAS NOT EVEN AWARE OF THIS SITUATION. THE SEATBELTS INSTALLED BY FORD MUST BE DEALER INSPECTED AFTER EMERGENCY USE . THESE SEATBELTS ARE DESIGNED FOR A ONE SHOT USE IN COLLISIONS OR MAJOR BRAKING. HOW MANY PEOPLE ARE DRIVING AROUND UNAWARE THAT THEIR SEATBELTS ARE SUBJECT TO FAILURE ,BECAUSE OF A MAJOR USE EARLIER? THERE IS THE CONSEPTION THAT IF A SEATBELT GOES AROUND AND HOOKS THE PERSON IS SAFE ,FALSE,FALSE,FALSE....... THEY ARE NOT DESIGNED FOR MULTIPLE USES. FORD DEALER INFORMED ME ON 01/16/01 THEY ARE A NON SERVICEABLE ITEM AND MUST BE REPLACED . THANK YOU WILLIAM SULLIVAN. *AK
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