Problems owners report
Complaints filed with NHTSA about the 1991 Ford F-250, by the system named in each complaint. One complaint can name several.
- Fuel system, gasoline26
- Service brakes, hydraulic24
- Electrical system15
- Power train10
- Tires10
- Engine and engine cooling8
- Structure5
- Seat belts4
- Fuel/propulsion system4
- Steering3
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 4 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 9 1991 F-250 vehicles were involved in crashes on US public roads in which someone died; 7 people died inside them, and 1 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 1991 Ford F-250 failed the safety check 0.99% of the time — 12% less often than the average 1991 passenger car (1.13%). Median odometer at inspection: 69,355 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls in Canada
2 Transport Canada recalls for the 1991 Ford F-250.
| 1994043 3 Mar 1994 | Fuel System NOTE: VEHICLES EQUIPPED WITH 7.5 LITRE ENGINES. THE FUEL RETURN TUBE, WHICH CONNECTS THE FRAME FUEL RETURN LINE WITH THE ENGINE FUEL RAIL, MAY CONTACT THE PINC… |
| 1992026 10 Mar 1992 | Brakes NOTE: VEHICLES WITH 7.3 LITRE DIESEL AND 7.5 LITRE EFI ENGINES OVER 8500 LB. GVWR AND 4X4 MODELS WITH 5.8 LITRE EFI ENGINES. WHEN VEHICLES ARE OPERATED AT OR… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
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.
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.
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.
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 1991 Ford F-250: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 616522 | SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT |
| 613350 | SERVICE TIP INFORMATION REGARDING THE REVERSE CLUTCH PISTON AND PISTON SEAL USAGE. *TT |
| 612343 | VEHICLES 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 |
| 612203 | INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS |
| 609737 | TRANSMISSION- E40D/4R100-1989-99-MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART. YD |
| 609736 | TRANSMISSION-E40D-NO 2-3 UPSHIFT. SOME VEHICLES MAY EXHIBIT A NO 2-3 UPSHIFT CONDITION. *AK |
| 609538 | FRONT 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. *AK |
| 6090087 | INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT |
| 6089681 | SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT |
| 608431 | INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT |
| 607369 | CONCERNS WITH AXLE WIND-UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS. *TT |
| 606937 | SOME 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. *TT |
| 606460 | EXPERIENCING 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. *TT |
| 606420 | FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT |
| 605721 | SOME VEHICLES MAY DEVELOP "CAVITATION" EROSION IN THE CYLINDER WALL OF THE ENGINE. *TT |
| 604059 | FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC |
| 601312 | INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT |
| 601290 | INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC |
| 601280 | SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES (DTCS) 62,628, AND/OR 1728. *YC |
| 601269 | ANNOUNCING THE FORD OEM AIR CONDITIONING RETROFIT KIT AVAILABILITY. *YC |
| 601238 | INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC |
| 601045 | FRONT CALIPER PISTON BOOTS DAMAGED. *YC |
| 601036 | SOME VEHICLES MAY EXHIBIT EXCESSIVE BRAKE PEDAL TRAVEL, IRREGULAR FRONT LINING WEAR, AND BRAKE PULL. *YC |
| 601012 | THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC |
| 601010 | RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
DUAL FUEL TANK CROSSFLOW/LEAKAGE
FORD F-SERIES DUAL FUEL TANK LEAKAGE
IDLE AIR SPD CTRL VLV MALF
ALTERNATOR BELT FAILURE
IDLE AIR SPD CTRL VLV MALF
FUEL EXPULSION
FUEL EXPULSION
LOSS OF BRAKE EFFECTIVENES
FUEL EXPULSION
LOSS OF BRAKE EFFECTIVENES
TRANSMISSION FLUID FIRES
NHTSA Office of Defects Investigation