1996 Ford F-250 Fuel system Problems
- Complaints
- 15about this part
- Share
- 9%of 176 total for the year
- Median mileage
- 115,669miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 15 complaints about the fuel system of the 1996 Ford F-250, 9% of the 176 complaints for this model year. Where a mileage was given, the median is 115,669 miles. 2 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Front fuel tank stopped working. Vehicle runs using rear fuel tank. If I take off the front tank fuel cap, gas pours out sometimes sprays ( about 8 ounces or so) . Front fuel tank seems to become pressurized. This can happen every time you drive it ( if you remove the front cap). In my opinion this is a definite safety hazard that needs to be addressed. I did some searches on the internet and this problem is quite common. Big fire hazard.”
NHTSA complaint #10837715, filed 2016-02, 231,000 miles“The air/fuel separator (similar to a throttle body) on my 1996 Ford f250 diesel developed a hole away from any moving part. It sprayed fuel at about a gallon a minute onto the hot engine as my wife pulled into our driveway. It could have caused a fire going down the road with gallons of fuel all over the engine compartment and fuel all down the bottom of my truck and 30 foot trailer. The local Ford dealer said this is very common on my year pickup and they replace them regularly when they leak. I took digital photos and kept the part. I contacted Ford and their attitude was who cares. …”
NHTSA complaint #10151053, filed 2006-02, 104,692 miles“1996 Ford f250 pickup with dual gas tanks had malfunctioning check valve in fuel pump assembly in one tank which caused unused fuel to be returned to second tank which caused constant overflow and fuel spillage. Fuel pump assembly was replaced which corrected the problem. This same problem occurred in 1989 to 1993 Ford f250 pickups and resulted in a recall to fix the problem.”
NHTSA complaint #10137133, filed 2005-09, 78,000 miles“A 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 occurs, the capacity of the second tank can be exceeded, causing fuel spillage.”
NHTSA complaint #10289346, filed 2009-10, 176,489 miles“A 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 occurs, the capacity of the second tank can be exceeded, causing fuel spillage. About 5 gallons of fuel spilled out of fill tube.”
NHTSA complaint #11469663, filed 2022-06Fuel 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 1996 Ford F-250
35 complaintsEngine cooling
28 complaintsTransmission and drivetrain
19 complaintsSteering
17 complaintsVehicle speed control
16 complaintsBrakes
15 complaintsSuspension
14 complaintsElectrical system
11 complaintsSeat belts
5 complaintsBody and structure
5 complaintsOther or unknown
4 complaintsSeats
4 complaints
← All problems reported for the 1996 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