1990 Ford F-250 Problems

What owners report

Owners of this model year mostly write about the dual fuel tank system: fuel moving from one tank to the other, overflow and a strong gasoline smell, often after switching tanks. Brake complaints center on the pedal going to the floor and braking fading under load or on grades. Most reports come in at higher mileage, and many owners say the vehicle was excluded from a related recall because of its VIN.

1. 1
   Fuel system

   Fuel moving between the two tanks and overflowing

   • 29 complaints (26%)
   • median 122,000 mi at 16.9 yrs old (9 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1995–2020

   Owners describe fuel being pushed from one tank into the other, so the receiving tank overflows and gasoline spills from the filler neck or cap. Several say the smell of gas is strong in and around the cab, and some describe having to shut the engine off or switch tanks to stop the flow. Complaints mention tank selector switches, check valves, fuel pumps and tank valves being replaced, in some cases more than once, without the problem going away; several owners say they were told the vehicle was not covered by the related campaign because of its VIN. Reported across a wide mileage range, often from about 60,000 to 200,000 miles, and frequently right after switching between tanks.

   Recall 93V125000Recall 89V141000

   What to check: Run both tanks and switch between them with the engine running, then look and smell for seepage around the filler necks, caps and lines underneath. Ask which fuel system parts have already been replaced, and check whether the VIN was covered by the tank check-valve campaign.

   2 excerpts from owner complaints in NHTSA records

   “Reference NHTSA campaign # 93v125000 recall # 93s68. (1) the vehicle had been driven about one hour - while parking in front of the house on the street, I noticed a strong smell of gasoline. I was running on the back tank and quickly switched to the front tank. After shutting off the ignition and exiting vehicle I saw gasoline spilling out of the front tank from under the cap (still on). This continued for some 5-10 seconds and then stopped. …”

   NHTSA complaint #10088911, filed 2004-08, 198,200 miles

   “I am the owner of a 1990 F-250, basically began smelling a fuel odor coming from the trucks cab while driving. Looked at the underside of the truck and found a small gas leak at the fuel lines under the pinch weld. Exact same issue as 94v040000, have not fixed problem because Ford cannot find this issue on there system.”

   NHTSA complaint #10328970, filed 2010-05, 137,255 miles
2. 2
   Brakes

   Brake pedal goes to the floor, braking fades under load

   • 20 complaints (18%)
   • median 69,000 mi at 15.9 yrs old (1 states mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1995–2005

   Complaints describe the brake pedal sinking to the floor with little or no warning, sometimes while towing or on long downhill grades, with drivers using the parking brake to stop. Several mention the fluid overheating, and some say the front wheels grabbed or locked after brake work. Others report repeated caliper, rotor or lining replacement, and a few say a dealer declined further work because of vehicle age or warranty status. Reported from moderate mileage upward, with some failures noted while towing a trailer or on steep downgrades.

   Recall 92V026000

   What to check: Ask for brake service records and check the fluid condition and pedal feel on a test drive, ideally with a load behind the truck. Confirm whether the front lining and cooling campaign work was ever performed for this VIN.

   2 excerpts from owner complaints in NHTSA records

   “Dt NHTSA recall 92v026000 was issued. However, this vehicle was not included in the recall due to VIN. My brakes failed. The dealer has not looked at the vehicle because they would charge the consumer for the repairs. Contacted Ford, they gave the run around. There was no warning before the brakes went out. The brake fluid was over heating. The brake pedal went down to the floor. Had to use emergency brake, and the brakes on the boat that I was towing. This happened on friday august 12, 2005.”

   NHTSA complaint #10132860, filed 2005-08, 69,000 miles

   “While driving vehicle the brakes sometimes go out, pedal goes all the way to the floor and feels the brakes loose. Although the manufacturer acknowledged the problem with the brake system, there were no recall notice issued. The consumer replaces the brakes caliper and rotors every 2000-7000 miles.”

   NHTSA complaint #814435, filed 1997-07
3. 3
   Electrical system

   Stalling, no-start and electrical shorts

   • 19 complaints (17%)
   • median 115,500 mi at 13.4 yrs old (1 states mileage, few)
   • 10 mention a crash, fire or injury
   • filed 1995–2003

   Complaints describe the engine dying at speed, at idle in traffic, or after running hot, sometimes followed by a restart after a cooldown. Owners report ignition modules, ignition switches and wiring repairs, and some describe smoke or fire from under the hood or behind the dashboard, including an alternator and a wiring harness. Complaints also mention a fuel pump relay staying energized after shutdown and glow plug controller wiring damage on diesel trucks. Reported at various mileages, with several owners noting stalling when the engine is hot or in warm weather.

   Recall 96V071000

   What to check: Ask whether the ignition switch campaign was completed for this VIN, and inspect under-dash and engine bay wiring for chafing, melted insulation or repairs. Note any history of intermittent stalling when hot.

   2 excerpts from owner complaints in NHTSA records

   “Continuing stalling of the engine since shortly after I purchased the vehicle. The truck had only 27000 miles on it when I purchased it. I thought it needed a tune up. However, a complete tune up which I had at approximately 50,000 miles did not fix the occasional stalling. I was told after a diagnostic systems check that it was the EGR valve and I had that replaced. It did not solve the problem. Now, with the heat of the summer the problem is getting worse with it stalling whenever I slow down for curves, highway exits, etc. …”

   NHTSA complaint #729713, filed 2000-08

   “Fire broke out in the dashboard.there was a recall regarding the ignition, however consumer was informed vehicle was not included due to the vehicle identification number.”

   NHTSA complaint #10006840, filed 2003-02, 115,500 miles
4. 4
   Electrical system

   Cruise control will not disengage, speed climbs

   Mentioned in 4 of 60 sampled complaints

   A few owners describe the cruise control failing to release with either the brake pedal or the off button, with the truck speeding up and the driver shutting off the ignition to stop it. Related complaints mention rough or delayed shifting and sensor replacements made while chasing the symptom. Reported at higher mileage on trucks with cruise control, with no single mileage pattern in the sample.

   What to check: Test the cruise control at low speed and confirm it cancels with the brake pedal and the off switch before relying on it. Ask whether the speed control components or sensors have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “Cruise control would not release either by applying the brakes or the cruise control off button. Vehicle accelerated from 65 to 85 MPH, and was finally brought to a stop by turning off the ignition and applying the brakes.”

   NHTSA complaint #522690, filed 1997-08

   “Nhtsa# 93 v 125 000 & mfr's# 93s68/fuel tank assembly: consumer states that the vehicle was not leaking any fuel until the dealer (empire Ford; arlington, va; phone# 276/628-2127) completed this recall repairs. Nlm”

   NHTSA complaint #8006538, filed 2002-03
5. 5
   Fuel system

   Fuel leaks from lines near the floor pan

   Mentioned in 4 of 60 sampled complaints

   Owners describe a gasoline smell in the cab while driving and, on inspection, a small leak where the steel fuel lines run near the floor pan pinch weld. Some report the truck catching fire from a metallic fuel line, and others say a dealer could not locate the campaign or declined work because the VIN was not included. Some owners also link a pump running on after shutdown to the same fuel system area. Reported mostly at higher mileage, typically above 100,000 miles.

   Recall 94V040000

   What to check: Inspect the steel fuel lines along the frame and near the floor pan for chafing, rust or wet spots, and check the routing against the pinch weld. Ask whether the fuel line campaign was applied to this VIN.

   2 excerpts from owner complaints in NHTSA records

   “Fuel pump motor continued to run, after the engine was shut off. The consumer disconnected battery. Apple Ford replaced the relay part but claimed the part was not covered by recall.”

   NHTSA complaint #10021923, filed 2003-07, 90,000 miles

   “Vehicle has a problem with the fuel line. While driving to the store, without prior warning, the vehicle caught on fire due to the metallic fuel line.”

   NHTSA complaint #834155, filed 1999-01

Buying note. On this model year the dual tank fuel system and the brakes are the two areas owners write about most, so check both carefully on a test drive and ask for service records. Many complaints involve trucks well past 100,000 miles, and owners often report being turned away from recall work because of their VIN, so confirm campaign coverage before buying.

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.