1991 Ford F-250 Fuel system Problems
- Complaints
- 30about this part
- Share
- 28%of 107 total for the year
- Median mileage
- 102,000miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 30 complaints about the fuel system of the 1991 Ford F-250, 28% of the 107 complaints for this model year. Where a mileage was given, the median is 102,000 miles. 1 a fire, according to the filers. 2 recall campaigns on record are filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“The vehicle is a 1990 and the site does not provide a space choice for the 1990, only '91 and up. The truck has the exact same problem as the other many Ford trucks. While idling, or underway, the vehicle spews gasoline from the front tank, out onto the road, or any driveway, if idling. It's clear that once you fill the rear tank and then travel, the fuel, which should return to the rear tank in a cycle, does not. It simply returns to the front tank, until it fills the front tank and floods out. …”
NHTSA complaint #10508195, filed 2013-04, 150,000 miles“Dad: the contact states there is NHTSA recall campaign 93v125000 concerning the fuel system: tank assembly. This vehicle has the same problems as indicated in the recall, but ii is not included in the recall due to VIN. The contact repaired the vehicle at his own expense. The dealer charged the consumer 500.00 to replace the fuel pump which was different from the recall. Updated 01/11/06.”
NHTSA complaint #10144562, filed 2005-12, 80,150 miles“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“When the front tank was empty and the consumer switched to the rear full tank, somehow the gas from the rear tank pumped back into the front tank which resulted in the rear tank being empty.”
NHTSA complaint #10017807, filed 2003-07, 111,046 miles“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 2000-03Related recalls
- 94V040000Feb 23, 1994The steel fuel return tubes that connect the frame fuel return lines with the engine fuel rail can contact the pinch weld flange connecting the dash panel to…Covers: Ford F-250 1990–1991, F-350 1990–1991, Super Duty 1990–1991
- 93V125000Aug 2, 1993A malfunctioning check valve within the fuel pump assembly causes a portion of the unused fuel from one tank to be returned to the second tank. When this…Covers: Ford F-250 1990–1993, F-150 1990–1993, F-350 1990–1993 +1 more
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2014 | 11 | 8% |
| 2013 | 9 | 9% |
| 2012 | 20 | 8% |
| 2011 | 22 | 9% |
| 2010 | 7 | 10% |
| 2009 | 2 | 4% |
| 2008 | 6 | 3% |
| 2007 | 4 | 7% |
| 2006 | 17 | 8% |
| 2005 | 19 | 13% |
| 2004 | 19 | 12% |
| 2003 | 13 | 11% |
| 2002 | 8 | 5% |
| 2001 | 4 | 2% |
| 2000 | 8 | 2% |
| 1999 | 41 | 7% |
| 1998 | 6 | 11% |
| 1997 | 29 | 10% |
| 1996 | 15 | 9% |
| 1995 | 16 | 9% |
| 1994 | 13 | 11% |
| 1993 | 37 | 28% |
| 1992 | 32 | 27% |
| 1991 | 30 | 28% |
| 1990 | 40 | 36% |
| 1989 | 30 | 27% |
| 1988 | 11 | 18% |
| 1987 | 4 | 11% |
| 1986 | 3 | 8% |
| 1985 | 2 | 10% |
| 1984 | 1 | 10% |
Other parts of the 1991 Ford F-250
27 complaintsElectrical system
15 complaintsTires
10 complaintsTransmission and drivetrain
10 complaintsEngine cooling
8 complaintsBody and structure
5 complaintsSeat belts
4 complaintsExterior lighting
3 complaintsSeats
3 complaintsSteering
3 complaintsSuspension
3 complaintsVehicle speed control
3 complaints
← All problems reported for the 1991 Ford F-250
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology