1995 Ford E-150 Problems

What owners report

Owners of this model year most often report brake problems — particularly ABS hydraulic unit trouble and front brake hardware — followed by front-end and steering component failures and fuel-system leaks at the filler neck and tank hoses. Many reports come in on high-mileage vans used as cargo or conversion vehicles, and a recurring theme is rusted or rotted rubber and plastic parts giving way. A separate cluster of complaints describes smoke or fire at the speed control switch on the master cylinder.

1. 1
   Brakes

   ABS warning light and brake pedal going soft or to the floor

   • 13 complaints (18%)
   • typically at 3.8 yrs old
   • filed 1995–2002

   Owners describe the ABS light coming on when the brakes are applied, a pedal that softens and then sinks to the floor on a second press, and front wheels locking on hard braking so the steering wheel will not turn. Several say the dealer diagnosed a failing hydraulic control unit, and one reported the unit had to be replaced repeatedly. Another said brake fluid leaked past a switch on the master cylinder and shorted the wiring, blowing a fuse and taking out the speedometer and odometer. Reported across a wide mileage range, from low-mileage vehicles to ones past 100,000 miles, often appearing during ordinary braking rather than hard use.

   What to check: Ask whether the ABS light comes on during a test drive and whether the hydraulic control unit has ever been replaced. Check the master cylinder and nearby wiring for fluid residue or corrosion.

   2 excerpts from owner complaints in NHTSA records

   “Abs light comes on whenever brakes are applied. Then, ABS brakes failed to work. Had taken vehicle to dealership, and was informed by mechanic that hydraulic control unit needed to be changed. After repairs, drove vehicle approximately 49,000 miles and problem reappeared. This was third time hydraulic control unit had to be replaced.”

   NHTSA complaint #877206, filed 2000-12

   “When driving the vehicle and applying the brakes the ABS brakes light keeps coming on and going off. The fuel blew out of the hydraulic brake unit due to fluid contamination.”

   NHTSA complaint #829534, filed 1998-10
2. 2
   Tires

   Tire tread separation and blowouts

   • 7 complaints (10%)
   • typically at 6.2 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2001

   Complaints describe the tread separating from the tire carcass while driving at highway speed, in some cases with a blowout, and vibration or an out-of-balance feel noticed beforehand. Owners report the tires were replaced by the manufacturer or retailer after the separation. A separate report notes all lug bolts shearing off one wheel. Reported at highway speeds on tires with roughly 36,000 to 50,000 miles in service, with the ownership reports filed around 1995 through 2002.

   What to check: Check tire date codes and sidewalls for cracking, bulges or separation, and inspect lug bolt torque. Older tires on this van should be replaced regardless of remaining tread.

   2 excerpts from owner complaints in NHTSA records

   “I purchased a set of 4 sears guardsman trailhandler ap tires for my 1995 E-150 econoline van on 4/20/98. The car had 36479 miles at the time. In june 2001, the car began handling as though the allignment was out or a tire needed balancing. Turned out that one tire had a tread separation. Iwas advised that it was only necessary to replace the one tire, but replaced a pair instead. Miles at the time: 50184. …”

   NHTSA complaint #749827, filed 2001-08

   “While driving 65mph, vehicle started to feel out of balance. Took vehicle to tire retailer for rebalancing & alignment. Mechanic showed driver that tread separated from tires. Later consumer contacted goodyear after hearing news about tires. Informed to exchange tires for new ones.”

   NHTSA complaint #877469, filed 2001-01
3. 3
   Fuel system

   Crumbling fuel filler and overflow hoses (fuel smell, drips)

   • 5 complaints (7%)
   • median 130,750 mi at 12.5 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1999–2011

   Complaints describe the rubber fuel filler hose and the overflow hose rotting and cracking, so that refueling produces strong gas fumes and fuel drips or puddles under the van. One owner said the metal filler section had rusted away entirely and that a hose clamp was being used to hold the remaining hose on. Owners report the leak appears with the tank over about three-quarters full and can drip while driving. Mostly reported on vans with well over 80,000 miles, often in older vehicles where the rubber has aged.

   What to check: Inspect the filler neck, filler hose and overflow hose for cracks, softness or rust, and look for fuel staining under the van. Ask whether these hoses have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The filler neck leaks gas at the rubber hose. Every time you add gas, does not have to be full tank. We were given this vehicle with the leak. Cannot afford to have fixed by mechanic, we have a hose clamp around the rubber to hold it on. The actual metal filler section in rotten rusted away. One time I parked at a gas station and they threatened to call police to have me towed, I never heard of the gas line leaking like this but see alot alot of similar complaints on this year range of e150s.”

   NHTSA complaint #10419503, filed 2011-08, 180,000 miles

   “The fuel filler hose and the overflow hose have rotted and cracked to the point where it is almost impossible to refuel the vehicle. After refueling, the gas fumes are are quite strong and the possibility of fuel blowing back onto the hot exhaust and brakes is extremely high. Ford does not have any recalls on the fuel hose for this particular vehicle although there are some vehicles manufactured at other locations which have been corrected.”

   NHTSA complaint #754189, filed 2001-11
4. 4
   Steering

   Steering gearbox and front-end mounting hardware giving way

   • 7 complaints (10%)
   • median 143,623 mi at 18.8 yrs old (1 states mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1996–2013

   Owners report the bolts holding the steering gearbox shearing off from the frame, which they describe as a sudden complete loss of steering. One complaint notes cracks and metal fatigue in the frame around the steering box mounting point. Related reports describe a tie rod end breaking at highway speed and an upper ball joint separating so the wheel folded inward. Reported from roughly 70,000 to over 140,000 miles, typically on vans used heavily over many years.

   What to check: Have a shop inspect the frame around the steering box for cracks, check that the gearbox mounting bolts are present and torqued, and check tie rod ends and ball joints for play.

   2 excerpts from owner complaints in NHTSA records

   “Noticed metal fatigue crack in frame near the steering box. Bolt goes directly through frame to steering box, in which the bolt came off. There was no steering/ spider cracks running through frame. Please provide any further information.”

   NHTSA complaint #8005633, filed 2002-03

   “1995 Ford e150 steering gearbox bolts sheared off from frame causing total steering failure, vehicle had to be towed, complete loss of steering, extremely dangerous, would have been a huge wreck if failure happened moments earlier.”

   NHTSA complaint #10347246, filed 2010-08
5. 5
   Vehicle speed control

   Speed control switch overheating, smoke or fire

   Mentioned in 5 of 46 sampled complaints

   Complaints describe smoke or fire in the engine compartment traced to the speed control switch, sometimes while the van was parked and had been sitting for hours. One owner reported the switch on the master cylinder melted and blew a fuse. Several owners reference Ford speed control switch recalls and state their vehicle either was not covered or had not been repaired. Reports mostly involve vans with 80,000 to 160,000 miles, and several occurred while the vehicle was parked, not running.

   Recall 09V399000Recall 06V286000Recall 08V051000

   What to check: Ask whether the speed control deactivation switch recall work has been completed, and check the switch on the master cylinder for discoloration, melted plastic or burn marks.

   2 excerpts from owner complaints in NHTSA records

   “Dt: contact stated the cruise control switch on the master cylinder melted. A fuse blew out, and the vehicle would not come out of park. This was how they came to notice the burned switch. This happened on 8-16-05. The vehicle is a 1995 Ford e- 150 club wagon. There were no problems prior to this. Neither the dealer nor Ford have been notified. There was no fire.”

   NHTSA complaint #10132999, filed 2005-08, 80,652 miles

   “Dt: the callers vehicle caught on fire. The vehicle was sitting for about 9 hours. The fire department came to put the fire out. They did file a report. Caller said it was a 3 alarm fire. The vehicle was totaled. Caller has 50 other fords. They are the e150 and e250 cargo vans. He has concerns about the other ones catching fire. The caller said there was a recall on this problem but this vehicle was not included. The building was damaged and some of the vehicles at the business. Dealer told him his vehicle was not in recall. …”

   NHTSA complaint #10134230, filed 2005-08, 120,000 miles

Buying note. These are aging vans, so condition depends heavily on maintenance history. Have a shop check the brakes and ABS, the frame and steering box area, the fuel filler hoses, and whether the speed control switch recalls were ever completed.

Summary written with AI from a sample of 46 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.