1991 Ford F-250
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-250 › 1991
These records cover every 1991 Ford F-250. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 1991 Ford F-250. Newest first.
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…
Risk and remedy
Risk
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 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.
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…
Risk and remedy
Risk
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.
The ignition switch could experience an internal short circuit.
Risk and remedy
Risk
This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Remedy
Dealers will replace the ignition switch.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
Owner complaints
107 complaints5 involved a crash9 involved a fire4 injuries
What owners report most
Latest complaints
- Fuel/propulsion system
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.
- Electrical system
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…
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.
- Fuel/propulsion system
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…
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
- Service brakes · Vehicle speed control
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…
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
- Fuel/propulsion system
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…
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
- Fuel/propulsion system
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…
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
- Fuel system, gasoline
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…
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.
- Fuel system, gasoline
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.
- Fuel system, gasoline
Tl*the contact owns a 1991 ford F-250. The contact stated that when he filled the front tank, the fuel would be shifted to the rear tank. The failure occurred everytime he fueled the vehicle. The contact stated that because of the failure, a pressure was created within the two tanks. The vehicle.…
Tl*the contact owns a 1991 ford F-250. The contact stated that when he filled the front tank, the fuel would be shifted to the rear tank. The failure occurred everytime he fueled the vehicle. The contact stated that because of the failure, a pressure was created within the two tanks. The vehicle. The contact called the dealership and referenced recall 93v125000 (fuel system, gasoline:storage:tank assembly) and was told that there were no active recalls on his vehicle. The contact called the manufacturer who verified that there were no active recalls for the vehicle. The vehicle had not been repaired. The current mileage was approximately 250,000. The failure mileage was approximately 50,000.
- Tires
Discoverer a/t tires size lt265/75r16 catastrophically failed while driving at highway speed. tread completely peeled off. had only been driving for 30 minutes and outside temperature was 70 degrees f. tires had about 23,000 miles on them. 1-2 years previously, the same type tire on opposite wheel developed a bulge in the sidewall and had to be replaced. *Tr
- Tires
I had 2 failures with the first about 9/21/07 and the second 10/6/07. the vehicle IS a 1991 F250 HD and IS occasionally used to haul a slide-in camper. on both occasions I had the camper on the truck, loading the truck to near the rated capacity of the tires but not over to my knowledge. in both…
I had 2 failures with the first about 9/21/07 and the second 10/6/07. the vehicle IS a 1991 F250 HD and IS occasionally used to haul a slide-in camper. on both occasions I had the camper on the truck, loading the truck to near the rated capacity of the tires but not over to my knowledge. in both instances the tire pressure was checked before leaving the house, were we traveling a moderate speed, about 55 mph, and it was cool. in both cases I noticed a vibration but before I could effect a substantial response the tire exploded. the truck remained in control but there was substantial damage to the truck. the tires were on the rear so there was damage to both sides. the first time I had the tire replaced by the dealer and he gave me over a 50% credit, reflecting the amount of tread left on the tire. the second time I had the tire replaced with a different brand and kept the old tire for inspection. *tr
- Fuel system, gasoline › Delivery › Fuel pump · Fuel system, gasoline › Storage › Tank assembly
Dad: the contact states there IS nhtsa recall campaign 93v125000 concerning the fuel system: tank assembly. this vehicle has the same problems as indicated in the recall, but II IS not included in the recall due to vin. the contact repaired the vehicle at his own expense. *Ak the dealer charged the consumer 500.00 to replace the fuel pump which was different from the recall. Updated 01/11/06. *Jb
- Electrical system
There was an acrid odor in the cabin on several occasions. the radio light began functioning intermittently. the dash lights failed to work twice. the head lights failed to work twice, on separate occasions from the dash lights. I went to replace the headlamp switch, and found the connector…
There was an acrid odor in the cabin on several occasions. the radio light began functioning intermittently. the dash lights failed to work twice. the head lights failed to work twice, on separate occasions from the dash lights. I went to replace the headlamp switch, and found the connector charred and melted, and the B2 terminal on the switch was loose and discolored. the switch was charred around the B2 terminal.. I am going to replace the connector also. *Jb
- Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
After fueling the vehicle, consumer noticed gas being pumped out of the front fill point like a fire hose. *ph this was the third failure with the crossover. Consumer then learned that this failure wasn't going to be covered under the extended warranty like the first two. *ph
- Fuel system, gasoline › Storage › Tank assembly
The gasoline was not transferring between the fuel tanks, causing vehicle to stall due to low gasoline. the dealer replaced the fuel tank sender and the fuel pump. *ak there were four attempts to remedy the transferring of fuel from the rear tank to the front tank throughout the filler cap and caused leakage. the consumer requested that ford cover the charges. *sc *jb
- Tires
Front tire wearing unevenly even with recent alignment. took to americas tire co. For rotation and was told tire had flat spots and rotation would not help-tire defective. IS this tire on the recall? ****dimsii ivoq entry after 12/12/02 cut-over to artemis****73413
- Fuel system, gasoline › Delivery
When the front tank was empty and the consumer switched to the rear full tank, somehow the gas from the rear tank pumped back into the front tank which resulted in the rear tank being empty. *nlm *cb *nlm
- Electrical system › Alternator/generator/regulator · Service brakes, hydraulic › Foundation components › Drum · Tires
Front tire wearing unevenly evem with recent alinement-took to americas tire co. For rotation and was told tire had flat spots and rotation would not help-tire defective. IS this tire on the recall? (Tiresize: lt21585r16)( dot number: tire size: lt21585r16 )
- Seat belts
Front seatbelt will not extend to give room for consumer to put it on, causing consumer not to have a seatbelt on while driving. Cause unknown. Dealer notified.*ak
- Engine and engine cooling › Engine › Gasoline
While driving, vehicle will shut off.*ak *yh
- Exterior lighting › Headlights › Switch
Headlight switch IS faulty causing the lights to fail while driving. nlm
- Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittings
Brakes fail sometimes. I need help. I just found out about this recall of 03/11/92to late for this recall ?. Nhtsa campaign 92vo26000 .*ak
- Fuel system, gasoline › Storage › Auxillary tank › Selector devices
Vehicle was examined by the dealership for recall campaign 01i008000 concerning fuel crossover. after repair work was performed, problem became worse than it had been before dealer made adjustments to vehicle. Power failure occurs, the motor shuts down as if idling. *jg *ak
- Tires › Tread/belt
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 )
- Electrical system › Ignition › Switch
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
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- 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…
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
- Idle air spd ctrl vlv malf
There is no summary currently available
- Fuel expulsion
There is no summary currently available
- Fuel expulsion
There is no summary currently available
- Loss of brake effectivenes
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- Fuel expulsion
There is no summary currently available
- Loss of brake effectivenes
There is no summary currently available
- Transmission fluid fires
There is no summary currently available
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 6090087Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems.
- 6089681Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses.
- 3055147Unknown
- 616522Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system.
- 613350Service tip information regarding the reverse clutch piston and piston seal usage.
- 612343Vehicles 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
- 612203Information regarding the new transmission cooler flusher- service tip. *Mjs
- 609737Transmission- e40d/4r100-1989-99-main controls, separator plates and separator plate gaskets usage chart. Yd
- 609736Transmission-e40d-no 2-3 upshift. Some vehicles may exhibit a no 2-3 upshift condition.
- 609538Front end shimmy may occur at various driving speeds and IS usually induced when hitting bumps, such as large potholes or rough railroad crossings. Shimmy IS not always verified during road test.
- 608431Information on the new flush and fill tool available through rotunda.
- 607369Concerns with axle wind-up and / or clunking, popping, ratcheting type noises when making cornering maneuvers.
- 606937Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making cornering maneuvers on vehicles equipped with a four wheel drive hi or low range mode.
- 606460Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump.
- 606420Ford motor company now recommends sae 5W-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year.
- 605721Some vehicles may develop "cavitation" erosion in the cylinder wall of the engine.
- 604059Ford motor company has released a new electrical grease ( F8AZ - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals.
- 601312Information on a buzzing or rattle noise from the exhaust system.
- 601290Information on tire company telephone numbers for customer assistance.
- 601280Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes (dtcs) 62,628, and/or 1728.
- 601269Announcing the ford oem air conditioning retrofit kit availability.
- 601238Information on a new transmission fluid usage chart.
- 601045Front caliper piston boots damaged.
- 601036Some vehicles may exhibit excessive brake pedal travel, irregular front lining wear, and brake pull.
- 601012The use of petroleum-based grease as a lubricant in servicing disc brakes IS no longer acceptable.
- 601010Recommended guidelines for towing behind recreational vehicles.
- 51987Fuel economy- customer expectations versus vehicle usage.
- 51945Fluid- transmission fluid usage charts.
- 51691Accessory drive belts- fead belt comes off- vehicles with 4.9L engine.
- 51689Frame- rivet replacement with bolts- service tips.
- 51669Noise- "popping/creaking"- front frame or suspension brackets- frame- "popping/creaking"- fastener replacement.
- 51401Diagnostic guides for out-of-warranty vehicles to be used as a master copy - diagnostic guides no longer available from adistra.
- 50997Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip.
- 50940Windshield and interior glass - fog/film.
- 50908Torque converter - leak test procedure - service tip.
- 50905Wiring - electrical diode identification and service replacements.
- 46478The use of petroleum-based grease as a lubricant in servicing disc brakes IS no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. If petroleum-based grease IS used to lubricate any part of the disc brake system, it could cause rubber parts to swell if lubricant contacts the rubber material.
- 464384X4 front axles must use hypoid 4X4 gear oil p/n f1tz-19580-a & high temp 4X4 front axle & wheel bearing grease when servicing. It IS not recommended to use heavier weight lubes in these front axles.
- 45943Steering gear-replacement of bendix, steering gear with new ross steeering gear.
- 45086Delayed forward engagement and/or heat stained forward clutch plates after installing center support service.
Every Ford F-250 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.