1991 Ford Escort Problems

What owners report

Owners of this model year most often describe electrical troubles, especially around the ignition switch and under-dash wiring, where complaints mention smoke, melted wires and, in several cases, fire. Fuel leaks near the tank or fuel pump sending unit are also frequently reported, often noticed as a strong gasoline smell or fuel on the ground, and the automatic shoulder belts are a third recurring theme, described as jamming, failing to retract or tightening unexpectedly. Most mileage figures in the sample are high, generally above 80,000 miles, which fits a vehicle of this age.

1. 1
   Fuel system

   Fuel smell and leaks at the tank or fuel pump

   • 86 complaints (26%)
   • median 128,375 mi at 14.0 yrs old (8 state mileage, few)
   • 23 mention a crash, fire or injury
   • filed 1995–2013

   Owners describe a strong gasoline odor inside or around the car, fuel pooling under the rear seat or on the ground, and leaks traced to the top of the fuel tank, the fuel pump sending unit or a fuel line. Several mention the dealer replacing the fuel pump or tank, and a number report their vehicle was not covered by the fuel-system campaign despite matching the described symptoms. Some complaints note melted wiring or burnt carpeting in the trunk area in connection with the leak. Appears at a wide spread of mileages, from roughly 83,000 to 210,000 miles in complaints that record it, and often noticed right after refueling.

   Recall 92V117000

   What to check: Check for a fuel smell around the rear of the car and under the back seat after filling the tank, and look for staining or dampness at the top of the tank. Ask whether the fuel pump sending unit was ever replaced or inspected under the fuel-system campaign.

   2 excerpts from owner complaints in NHTSA records

   “I bought this car used from a Ford dealer (holiday Ford-blackburg, va) in 1/94 with 33,000 miles on the car. On 12/14/94 at 41,687 miles the car was brought to magic city Ford with a gas leak. Dealer said it was the fuel pump and said Ford may cover the repair because this car had a recall for the fuel pump. Ford did not honor the repair. I was told by the dealer that my car had already had the fuel pump replaced under Ford recall #92s54 back in 11/92. …”

   NHTSA complaint #713875, filed 1999-10

   “On 1/19/1999 I was stranded when the car would not start. My husband checked the fuel injection fuse and replaced it. He got it home and it refused to start. He then discovered a gas leak. We had it towed to lee adams tire and service center. They called us and told us that the fuel pump had been arcing and we were lucky to be alive. They said that because of the problem with the fuel pump, that they had to replace the pump, the automatic shutoff switch, and the fuel relay switch, so far. …”

   NHTSA complaint #702522, filed 1999-01
2. 2
   Electrical system

   Ignition switch and under-dash wiring smoke or fire

   • 89 complaints (27%)
   • median 132,000 mi at 13.6 yrs old (3 state mileage, few)
   • 40 mention a crash, fire or injury
   • filed 1995–2013

   Complaints describe smoke coming from the dashboard or steering column area, sometimes while driving and sometimes while the vehicle was parked with the engine off. Owners report melted wiring, a burning smell and, in several cases, the dash area around the ignition being damaged. Some say the engine kept cranking after the key was removed or that the starter stayed engaged with the engine running, and several note the dealer or manufacturer said no recall applied to their vehicle. Reported across a wide mileage range, from around 120,000 to 150,000 miles in the complaints that list mileage, and also on vehicles whose mileage was not recorded.

   Recall 93V057000

   What to check: Ask whether the ignition switch or ignition lock has been replaced and whether the vehicle was ever inspected under the ignition lock campaign. Look for scorching, melted insulation or a burnt smell around the steering column and fuse box.

   2 excerpts from owner complaints in NHTSA records

   “My daughter was driving a 1991 Ford Escort in downtown pittsburgh when smoke began pouring out of the dashboard behind the speedometer section. She pulled over and exited the car after turning off the ignition switch. The smoke ceased and a police officer stopped by to assist. He remained to direct traffic until the tow truck came to return the vehicle to my house. The vehicle has liability insurance only. I was not able to investigate the cause of the smoke for a few days. I needed more information in how to get behind the dashboard. …”

   NHTSA complaint #10082982, filed 2004-07, 136,000 miles

   “After filling up with gas and still beside the gas pumps I attempted to start the vehicle in park. The car kept cranking but not starting. Turned the ignition switch off and car kept cranking. Pulled the key out and car kept cranking. Put the key back in and got the vehicle in drive while cranking and it stopped. Turned key and vehicle started (in drive mode). Vehicle would not stop cranking in park or neutral modes but will in drive mode. With no key vehicle tries to start in both park and neutral. Major safety issue. …”

   NHTSA complaint #10525875, filed 2013-07, 124,750 miles
3. 3
   Seat belts

   Automatic shoulder belt jams or fails to retract

   • 64 complaints (20%)
   • median 135,000 mi at 13.2 yrs old (3 state mileage, few)
   • 12 mention a crash, fire or injury
   • filed 1995–2008

   Complaints describe the motorized front shoulder belts jamming partway along the track, failing to move when the door opens, or not retracting so the belt cannot be worn properly. Some owners report the belt tightening suddenly while driving, and others say the belt or its track broke loose in a collision. Several state the dealer was unwilling to repair the system, and a few report repeat failures after a repair. Mostly reported on vehicles with high mileage, and described as happening intermittently before becoming permanent.

   What to check: With the door open and closed, watch whether both front belts travel the full track smoothly and retract. Sit in the seat and confirm the belt can be buckled and adjusts without catching.

   2 excerpts from owner complaints in NHTSA records

   “I was involved in a little accident. I was going 20 MPH on impact and my automatic seat belt broke out of the track.I was not seriously hurt but could have been crippled.what can I do? My seat belt and track are now junk and I am worried about driving a Ford again because of the seat belt thing.”

   NHTSA complaint #737034, filed 2000-11

   “Automatic passive restraint system failed to operate when opening the door. Mechanism jammed, and had to be manually disconnected to get in and out of the vehicle.”

   NHTSA complaint #10057240, filed 2004-03, 135,000 miles
4. 4
   Transmission and drivetrain

   Transmission or transaxle failure and trouble engaging park

   • 23 complaints (7%)
   • typically at 5.5 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2002

   Owners report the car refusing to stay in park, slipping between shifts, or quitting entirely with transmission fluid running out. Some describe a hole in the transaxle case and metal parts found on the road after the vehicle stopped, and one notes the transmission failed before a related campaign was performed. Others mention the shifter sticking in park so the vehicle would not move out of gear. Reported at various ages of the vehicle; complaint mileage is often not recorded, and failures are described as sudden rather than gradual.

   What to check: On a test drive, shift through all gears and confirm park holds the car on a slight incline. Check transmission fluid level and color, and look for fluid residue under the transaxle.

   2 excerpts from owner complaints in NHTSA records

   “Consumer stated that while driving and without warning the vehicle will stick in park and will not shift gears causing a distraction to the consumer. Dealer notified. Ts”

   NHTSA complaint #8023400, filed 2002-11

   “Son driving vehicle to school, vehicle stopped for no reason, restarted vehicle, son saw pieces of metal on ground, tow person located hole in transaxle.”

   NHTSA complaint #985075, filed 1996-07

Buying note. On a car this old, condition and maintenance history matter more than the model itself, so have an inspection focus on the ignition switch and dash wiring, the fuel tank area, the automatic belts and the transmission. Ask for records showing whether the fuel-system and ignition-lock campaigns were ever performed on the specific vehicle.

Summary written with AI from a sample of 60 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.