1991 Ford F-250 Problems

What owners report

Owners of this model year most often describe fuel moving between the two tanks, overflowing or spilling after refueling, and brake complaints where the pedal feels low or stopping distance grows. Fuel reports span from low mileage to well past 150,000 miles, while brake reports tend to appear on trucks with lower odometer readings.

1. 1
   Fuel system

   Fuel crossing between front and rear tanks, spillage

   • 18 complaints (17%)
   • median 94,177 mi at 15.1 yrs old (7 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2013

   Owners describe fuel returning to the wrong tank so that one tank overfills and gasoline spills from the filler neck or cap, sometimes while the truck is parked or after refueling. Several mention being told the vehicle was not included in a fuel tank recall, or that a prior recall repair did not stop the problem. Some report repeated pump or tank replacements without a lasting fix. Reported across a wide mileage range, from around 38,000 miles to over 160,000, often noticed right after filling a tank.

   Recall 93V125000

   What to check: Fill both tanks and watch for fuel transferring between them or appearing at the filler neck, and ask whether the fuel tank recall work was done on this specific truck.

   2 excerpts from owner complaints in NHTSA records

   “My gas tanks overflow out my filler caps. I called Ford they told me my truck had been fixed in 1994 when they sent out a recall for this problem. Well I still have the problem, and when I talked to one of your reps they told me there is an ongoing ivestigation for this problem. Maybe their fix wasn't a fix after all. What should I do ? Do I have someone try to fix the problem according to what Ford says to fix it , or am I wasting money on something they really don't have a fix for. …”

   NHTSA complaint #719592, filed 2000-03

   “The gasoline was not transferring between the fuel tanks, causing vehicle to stall due to low gasoline. The dealer replaced the fuel tank sender and the fuel pump. There were four attempts to remedy the transferring of fuel from the rear tank to the front tank throughout the filler cap and caused leakage. The consumer requested that Ford cover the charges.”

   NHTSA complaint #10046352, filed 2003-12, 94,177 miles
2. 2
   Brakes

   Brake pedal low or stopping distance feels longer

   • 21 complaints (20%)
   • median 55,000 mi at 24.4 yrs old (1 states mileage, few)
   • 4 mention a crash, fire or injury
   • filed 1995–2015

   Complaints describe the brake pedal sinking toward the floor, a delay between pressing the pedal and the truck slowing, and stopping distances that feel longer than expected. Some owners mention the pedal fading during repeated or hard braking, and several say the problem could not be reproduced at the dealer or returned after a master cylinder or caliper repair. Mostly reported under about 80,000 miles, sometimes after repeated braking or when the pedal is held.

   Recall 92V026000

   What to check: Test the pedal for firmness and travel on a test drive, and ask for service records on brake fluid, master cylinder and caliper work; confirm whether the brake lining recall applies.

   2 excerpts from owner complaints in NHTSA records

   “When driving 25 MPH and upon attempting to stop vehicle by depressing brake pedal , brake pedal went to the floorboard, causing extended stopping distance, which resulted in a rear end crash. Consumer contacted dealer, dealer noted that master cylinder failed which caused the problem.”

   NHTSA complaint #872290, filed 2000-10

   “The brake fluid is overheating, causing increased stopping distance and inablitity to stop the vehicle. Recall #92s44. Brakes have faded four times failure occured without warning, replaced front pads three times, replaced rotors once, currently rotors appear to warped.”

   NHTSA complaint #984084, filed 1996-07
3. 3
   Tires

   Tread separation and tire blowouts

   • 10 complaints (9%)
   • median 22,466 mi at 17.0 yrs old (3 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2000–2009

   Complaints describe tread peeling away from the tire casing at highway speed, sometimes with the separated tread damaging fenders, wheel liners and exhaust parts. Others mention sidewall bulges and uneven wear or flat spots found despite recent alignment. Reported at both very low mileage and high mileage, often at 55-65 mph.

   What to check: Inspect tire date codes and sidewalls for cracking or bulges, and replace older tires regardless of remaining tread.

   2 excerpts from owner complaints in NHTSA records

   “I had 2 failures with the first about 9/21/07 and the second 10/6/07. The vehicle is a 1991 f250 hd and is occasionally used to haul a slide-in camper. On both occasions I had the camper on the truck, loading the truck to near the rated capacity of the tires but not over to my knowledge. In both instances the tire pressure was checked before leaving the house, were we traveling a moderate speed, about 55 MPH, and it was cool. In both cases I noticed a vibration but before I could effect a substantial response the tire exploded. …”

   NHTSA complaint #10208696, filed 2007-11, 10,800 miles

   “Discoverer a/t tires size lt265/75r16 catastrophically failed while driving at highway speed. Tread completely peeled off. Had only been driving for 30 minutes and outside temperature was 70 degrees f. Tires had about 23,000 miles on them. 1-2 years previously, the same type tire on opposite wheel developed a bulge in the sidewall and had to be replaced.”

   NHTSA complaint #10270248, filed 2009-05, 198,400 miles
4. 4
   Electrical system

   Engine or ignition cut-out and electrical faults

   • 14 complaints (13%)
   • median 138,323 mi at 19.5 yrs old (2 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1995–2015

   Owners report ignition switches that fail to turn or need to be jiggled to start, and electrical trouble after ignition switch replacement. Others describe melted or charred headlight switch connectors, dash and head lights that stop working, and smoke or burned wiring in the engine compartment. Reported on older, higher-mileage trucks, often past 100,000 miles.

   Recall 96V071000Recall 93V066000

   What to check: Check that the ignition switch and headlight switch recall work was completed, and inspect the headlight switch connector and underhood wiring for heat damage or a burnt smell.

   2 excerpts from owner complaints in NHTSA records

   “There was an acrid odor in the cabin on several occasions. The radio light began functioning intermittently. The dash lights failed to work twice. The head lights failed to work twice, on separate occasions from the dash lights. I went to replace the headlamp switch, and found the connector charred and melted, and the b2 terminal on the switch was loose and discolored. The switch was charred around the b2 terminal.. I am going to replace the connector also.”

   NHTSA complaint #10109905, filed 2005-02, 115,646 miles

   “Would turn on vehicle glow plug would not heat up to move or start engine. Would need to jiggle it off/on a lot of times before starting vehicle. Would have a gauge to indicate that vehicle was on. Had not been to dealer. Jiggling it off and on to start the vehicle could possibly cause explosion or permanent damage to the engine.”

   NHTSA complaint #877355, filed 2001-01
5. 5
   Fuel system

   Unexpected or uneven engine speed / stalling

   • 8 complaints (7%)
   • median 102,500 mi at 23.5 yrs old (2 state mileage, few)
   • filed 1995–2015

   Owners report the engine revving up on its own at a stop or while cruising, and stalling repeatedly in traffic or when fuel stops moving between the tanks. Some link the stalling to fuel pump or fuel sender work; others describe rough running and a strong running-on after the ignition is switched off. Reported at cruising and idling speeds, often tied to fuel delivery or pump service.

   Recall 93V125000

   What to check: Drive at steady highway speed and at idle and watch for surging or stalling, and ask whether the fuel pump, sender and speed control have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “I had just been jumped by aaa because my truck wasn't starting; the aaa agent also cleaned the battery terminals. I intended to have it towed to the Ford dealer because I didn't think it would start. Since the aaa agent was able to get to start, I decided to still take it to the dealer to find out why the battery was dead (given they had the car for a month and had put in a new battery and starter, among other repairs). …”

   NHTSA complaint #10689779, filed 2015-02, 55,000 miles

   “Vehicle was examined by the dealership for recall campaign 01i008000 concerning fuel crossover. After repair work was performed, problem became worse than it had been before dealer made adjustments to vehicle. Power failure occurs, the motor shuts down as if idling.”

   NHTSA complaint #898195, filed 2001-10

Buying note. Ask for recall-completion paperwork for the fuel tank and ignition switch campaigns on the specific truck, since owners report the fuel crossover problem returning even after repair. Budget for a brake and tire inspection before regular use, and check underhood 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.