1991 Ford F-250 Recalls, Complaints & Specs

5 safety recalls list the 1991 Ford F-250, and owners have filed 107 complaints with NHTSA. Check your own VIN below.

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5 safety recalls for the 1991 Ford F-250

Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.

1. Ignition (electrical system)

   NHTSA 96V071000 Reported April 25, 1996 7,900,000 vehicles potentially affected FORD MOTOR COMPANY

   The ignition switch could experience an internal short circuit.

   Remedy: Dealers will replace the ignition switch.

2. Hoses, lines/piping, and fittings (fuel system)

   NHTSA 94V040000 Reported February 23, 1994 89,770 vehicles potentially affected FORD MOTOR COMPANY

   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.

   Remedy: Ford dealers will replace the fuel return tubes with flexible stainless steel braided/teflon tubes. Dealers will also inspect the fuel supply tubes.

3. Tank assembly (fuel system)

   NHTSA 93V125000 Reported August 2, 1993 1,131,000 vehicles potentially affected FORD MOTOR COMPANY

   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.

   Remedy: Replacement of the fuel pressure regulator and installation of redundant check valves.

4. Steering wheel/handle bar (steering)

   NHTSA 93V066000 Reported April 27, 1993 2,419 vehicles potentially affected FAIRMONT TAMPER

   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.

   Remedy: A shield will be positioned between the steering wheel and the ignition switch and held in place by the steering lock band.

5. Shoes/linings (service brakes)

   NHTSA 92V026000 Reported March 3, 1992 467,000 vehicles potentially affected FORD MOTOR COMPANY

   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.

   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.

107 owner complaints filed with NHTSA

Owners of the 1991 Ford F-250 have filed 107 complaints with NHTSA; 5 describe a crash and 9 describe a fire. Reports cite 4 injuries and 0 deaths. The average mileage at failure in those reports is 98,414 miles. Complaints peaked in 1996 with 28 filed that year.

Most-reported components

• Electrical system: switch10
• Tires9
• Fuel system, gasoline: tank assembly8
• Service brakes, hydraulic: foundation components7
• Service brakes, hydraulic: antilock/traction control/electronic limited slip6
• Fuel system, gasoline: fuel pump5
• Fuel system, gasoline: selector devices5
• Engine and engine cooling: gasoline4

What owners are reporting

“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 b”

Owner complaint to NHTSA, January 1, 2020 · Fuel/propulsion 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 ta”

Owner complaint to NHTSA, May 21, 2015 · Electrical system

Fuel economy and specs

EPA ratings for the 1991 Ford F250 (F250 Pickup 2WD, F250 Pickup 4WD). Ranges cover every tested configuration.

Compare Ford F-250 model years

Recall and complaint counts for every Ford F-250 model year in NHTSA's database.

Checking a specific 1991 Ford F-250

Other Ford models

• F-15037,961 complaints
• Explorer34,566 complaints
• Escape27,430 complaints
• Fusion22,405 complaints
• Focus22,096 complaints
• Taurus18,159 complaints
• Windstar14,158 complaints
• Edge14,065 complaints

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.