1991 Ford F-150 Problems

What owners report

Owners of this model year most often describe fuel moving between the two tanks and spilling out, along with fuel leaks and hard- or no-start conditions. Many complaints reference the fuel tank recall and note that either the vehicle was excluded by VIN or the problem returned after the recall work. A smaller group describes electrical faults in the dash and ignition wiring.

1. 1
   Fuel system

   Fuel cross-flow between dual tanks and spillage

   • 132 complaints (43%)
   • median 112,000 mi at 16.3 yrs old (25 state mileage)
   • 3 mention a crash, fire or injury
   • filed 1995–2025

   Owners of trucks with dual tanks describe unused fuel from one tank returning to the other, so the receiving tank overfills and gasoline spills from the filler neck or cap, sometimes while driving. Several report the problem reappearing after recall repairs, and others were told by the dealer or manufacturer that their VIN was not covered or that the recall had expired. Dealers who did inspect typically pointed to the check valve or valves inside the fuel pump assembly. Reported across a wide mileage range, from about 46,000 to over 200,000 miles, on trucks with the dual-tank option.

   Recall 93V125000

   What to check: On a dual-tank truck, fill both tanks and watch for fuel appearing at either filler neck, and check whether recall 93V125000 work was ever performed. Look for a strong fuel smell or stains around the tanks and filler tubes.

   2 excerpts from owner complaints in NHTSA records

   “While the engine is running, the dual tanks cross-flow into one another. One tank has over-filled the other tank and visa versa to include spillage. I have contacted the local dealer and Ford about it but they say they can't do anything for me as far as a recall is concerned even though this issue was a safety recall issue in the past. I do not know if the previous owner addressed the recall but it is a problem right now. …”

   NHTSA complaint #10853825, filed 2016-04, 46,300 miles

   “I own a 1991 f150 pickup. Something is happining with fuel tanks. Its like fuel from the front tank is being transfered to the back tank, resulting in overflowing fuel from the back. I think the mfg. Should repair the problem as it is a bad safetly issue.”

   NHTSA complaint #10128177, filed 2005-07, 135,000 miles
2. 2
   Electrical system

   Electrical shorts, dash and under-hood fires

   • 42 complaints (14%)
   • median 83,100 mi at 14.3 yrs old (3 state mileage, few)
   • 32 mention a crash, fire or injury
   • filed 1995–2021

   Complaints describe smoke coming from the defroster vents or from under the dash near the steering column, and in several cases flames and wiring damage, sometimes with the truck parked and switched off. Others describe the ignition switch shorting internally, draining or burning out the ignition circuit, and the truck then failing to crank. Owners also report the alternator wiring or harness overheating. Reported from under 80,000 to about 149,000 miles, including vehicles parked overnight.

   Recall 96V071000

   What to check: Ask whether the ignition switch was replaced under recall 96V071000, and inspect under the dash and around the steering column for melted insulation, scorching, or spliced wiring. Check that the battery stays connected without drain when the key is off.

   2 excerpts from owner complaints in NHTSA records

   “On august 24, 2001, a fire spontaneously began under the hood of my 1991 Ford f150 pickup truck while it was turned off and parked in the driveway at night. The fire caused expensive damage to the vehicle and would have probably caught my house on fire had the truck been parked in the garage. I checked with the local Ford dealership (centroplex Ford in killeen, texas, which is now automax Ford) about Ford's liability and they said repairs would not be covered because the factory warranty had long expired. …”

   NHTSA complaint #10137896, filed 2005-09, 149,000 miles

   “In august-september 1997 I responded to NHTSA recall 96v071000. The dealer in puyallup, wa replaced the ignition switch. However, every since then when the temperature drops down below 40 degrees the ignition switch seems to freeze up. This only happens in the fall or winter. I am unable to turn the ignition switch to start the truck. The switch becomes very stiff unless I first warm the steering column with a space heater or blow dryer. I am afraid that one of these days I will break the switch while attempting to start the truck.”

   NHTSA complaint #720454, filed 2000-03
3. 3
   Fuel system

   Fuel leaks and strong fuel odor

   • 48 complaints (16%)
   • median 110,000 mi at 14.5 yrs old (7 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1995–2011

   Complaints describe gasoline leaking onto the ground after filling, fuel odor in or around the truck, and in some cases fuel lines or fittings that failed so fuel reached the exhaust. Some owners report the leak as intermittent and say the dealer could not confirm a covered recall for their vehicle. Where a tank was inspected, rust at the top of the tank was sometimes the stated cause. Mostly described on trucks with well over 60,000 miles, often noticed right after refueling.

   Recall 93V125000

   What to check: Fill the truck and then look under it and around the tank seams for drips or damp spots, and note any fuel smell in the cab or engine bay. Ask whether fuel lines and the tank have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “After the fuel tank was filled and the consumer drove for a short for a short period of time fuel started to leak through the front tank and out the filler neck.”

   NHTSA complaint #10012511, filed 2003-03, 161,000 miles

   “Fuel line between tank and engine ruptured. Dealer (jerry duncan Ford, harriman tn) performing repair said plastic line melted. Fuel poured down on exhaust system creating fire hazzard. Sudden loss of fuel to engine caused immediate loss of power.”

   NHTSA complaint #752601, filed 2001-09
4. 4
   Fuel system

   No-start condition and fuel pump faults

   Mentioned in 5 of 60 sampled complaints

   Owners report the truck turning over but not starting, or stalling and quitting, with diagnosis pointing to the fuel pump or pump assembly or a tank that stopped delivering fuel. Some had the pump replaced and the problem came back; others were told by an independent shop that the fault could not be resolved. Related reports describe the fuel gauge reading fuel that is not there. Reported from roughly 77,000 to about 145,000 miles.

   Recall 93V125000

   What to check: Ask whether the fuel pump or pump assembly has been replaced and when, and check that the fuel gauge reads sensibly when switching tanks. Confirm the truck starts reliably from cold and after sitting.

   2 excerpts from owner complaints in NHTSA records

   “Consumer complained about the fuel gauge system registering a quarter tank of fuel, when in reality, vehicle had no fuel and stopped runing. The dealer was not notified at this time. Consumer stated the dual fuel tank failed.”

   NHTSA complaint #10111146, filed 2005-03, 90,000 miles

   “The contact owns a 1991 Ford F-150. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer who stated the fuel pump failed. The vehicle was repaired but the failure recurred. The manufacturer was contacted about the failure. The failure mileage was 145,000. The consumer stated the battery failed and the seal around the speedometer went bad.”

   NHTSA complaint #10525094, filed 2013-07, 145,000 miles

Buying note. On a dual-tank truck, verify the fuel cross-flow recall work and check both tanks for leaks and spillage before buying, since that is the most frequently reported problem. Also ask about ignition switch recall service and inspect the dash wiring for heat damage.

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.