1991 Ford Ranger Problems
- Complaints
- 132filed with NHTSA
- Median mileage
- 82,500miles, 8 complaints with mileage
- Recalls
- 2campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 19 mpgcombined, 3.0L 6-cyl RWD · 17 city / 23 hwy
Sources: NHTSA records for the 1991 Ford Ranger (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of the 1991 Ford Ranger most often describe rust-related failures in the front suspension, electrical fires starting at the ignition switch or alternator wiring, and tire tread separations. Many reports come from trucks well past 100,000 miles, though several suspension and mirror complaints involve low-mileage vehicles, so corrosion rather than wear is the recurring theme.
- Suspension
Front spring/shock tower rust failure
- 16 complaints (12%)
- median 65,000 mi at 20.4 yrs old (3 state mileage, few)
- 1 mention a crash, fire or injury
- filed 1997–2011
Owners describe the right front spring mount or shock tower rusting through and separating from the frame, sometimes letting the front corner of the truck drop onto the tire. Several say the truck made a bang or snapping sound while driving or turning, and that a dealer or mechanic told them the vehicle was not safe to drive. Complaints also note that replacement parts were hard to find. Reported from roughly 58,000 to 65,000 miles in the sampled complaints, often on trucks used in wet or road-salt conditions.
What to check: Inspect the front spring mounts and shock towers on both sides for rust, flaking metal, or separation from the frame, and check whether the front corners sit level.
2 excerpts from owner complaints in NHTSA records
“Right front spring bracket rusted through allowing body to drop onto front tire, and I noticed there are a lot of complaints on this issue and was wanting to know is Ford going to fix this problem or are we the public going to get stuck with this problem ?”
NHTSA complaint #10021440, filed 2003-06, 58,212 miles“I recently purchased a 1991 Ranger pickup used. Since the purchase I have driven the vehicle about 1500 miles. I noticed while installing new shock absorbers that the spring mount (top bracket) was rusted. Within 500 miles of the installation the bracket has started to seperate from the frame and the right front corner of the truck was noticablly lower. I went to a Ford dealer and was told the truck was dangerous to drive and that the spring could be ejected from its position causing a accident. …”
NHTSA complaint #728484, filed 2000-08 - Electrical system
Engine bay and dashboard fires (wiring, ignition switch)
- 26 complaints (20%)
- median 100,000 mi at 18.6 yrs old (3 state mileage, few)
- 21 mention a crash, fire or injury
- filed 1995–2012
Complaints describe smoke and flames from the dash vent area, the ignition switch housing, or the alternator wiring, sometimes while the truck was parked and unused. Several owners report the vehicle was totaled, and fire investigators in some cases attributed the fire to wiring or the ignition switch. Mostly reported on vehicles over 100,000 miles, with several fires occurring while parked.
What to check: Look for scorched or repaired wiring near the ignition switch and alternator, ask whether any electrical repairs or harness work were done, and have a mechanic inspect the under-dash and charging circuit.
2 excerpts from owner complaints in NHTSA records
“While parked the vehicle caught on fire. The state fire marshal performed a detailed investigation and determined that the cause of the fire was from the ignition switch. The dealer has not been notified. Owner will contact the manufacturer.”
NHTSA complaint #819488, filed 1997-12“Driving from work, started & warmed up engine, smelled something, turned on interior lite, noticed smoke from dashboard, amber glowed at feet area, pulled over, flames engulfed truck; vehicle totaled.”
NHTSA complaint #805813, filed 1996-12 - Tires
Tire tread separation and sidewall bubbles
- 13 complaints (10%)
- typically at 9.9 yrs old
- 1 mention a crash, fire or injury
- filed 2000–2002
Owners report tread peeling away from the belt or large bubbles forming in the sidewall, often noticed as vibration at highway speed. Several mention the tires were a specific Firestone model at the sizes used on this truck, and in a few cases the failure led to loss of control. Mostly described at highway speeds; mileage is not stated in most sampled complaints.
What to check: Check tire date codes and sidewalls for bubbles or cracking, and replace any tire showing age-related deterioration regardless of remaining tread.
2 excerpts from owner complaints in NHTSA records
“A complete tread separation. I typed additional information, but your page apparently won't let me paste in this space and I'm too lazy to type it all again. Call me if you want to know more. (DOT number: w2hyink330 tiresize: p215/70r14)”
NHTSA complaint #737475, filed 2000-12“Tire seperating from steel belt. Still have one tire and I will ship it on request. Firestone needs to broden tis recall. They have made bad tires that I know of for 20 years!( DOT number: w2hyfr5 tire size: 215/70/r15 )”
NHTSA complaint #729438, filed 2000-08 - Brakes
Brake line corrosion and hydraulic leaks
- 9 complaints (7%)
- typically at 5.0 yrs old
- 2 mention a crash, fire or injury
- filed 1995–2001
Complaints describe corroded brake lines that burst under pressure, a parking brake cable rubbing through a brake line, and repeated front brake and rotor wear. One complaint references the brake booster and master cylinder campaign, saying the dealer disputed the campaign coverage. Reported across a wide mileage range; corrosion-related failures appear on older, higher-mileage trucks.
What to check: Inspect the steel brake lines along the frame for rust and wet spots, check the parking brake cable routing, and ask whether campaign 96V024001 work was completed.
An excerpt from owner complaints in NHTSA records
“Ford dealer in this case disputes current NHTSA campaigns on this vehicle. Campaign #s are 96v024001 (brakes-regional) & 91v189000- warranty history reports no attention to this matter. Dealer is listed in this form, original selling dealer - holmes tuttle Ford, tucson arizona.”
NHTSA complaint #710422, filed 1999-08 - Visibility (wipers, defrost, mirrors)
Exterior mirrors fold in while driving
- 9 complaints (7%)
- typically at 9.5 yrs old
- filed 1995–2004
Owners describe the outside mirrors folding back against the body at highway speeds, leaving no rearward view, and repeat replacements that failed again within a year or two. Some mention the cost of replacement parts as a concern. Reported on trucks of various mileages, often at 55 mph and above.
What to check: At highway speed, confirm both mirrors hold position; check the pivot for looseness and ask whether either mirror has been replaced.
2 excerpts from owner complaints in NHTSA records
“Both mirrors folded up against the vehicle when driving. Driver's side was replaced three times, and the passenger's side twice. However, driver's side mirror malfunctioned again. Truck is in garage from 11-1 tomay 1. And I stikk only get1 year to 18 months per mirror. I realize the vehicle is 13 years old and redesigning the mirror is not anoption. However, Ford motor corp surely could do something about the price! Retail is closre to $7500 per piece. …”
NHTSA complaint #10095230, filed 2004-10“Both mirrors have been replaced more than one time because they do not stay positioned. Dealer has been notified. Nlm consumer stated that when the mirrors do not stay in positioned drivers have no view of rear lanes, the mirrors fold back at highway speeds.”
NHTSA complaint #8018649, filed 2002-09
Buying note. Corrosion is the main thing to look at on this model year: front spring mounts, frame areas, fuel tank straps and brake lines are worth a close inspection before purchase. Electrical and tire history is also worth asking about, since several owners describe fires and tread separations.
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.
NHTSA recorded 132 consumer complaints for the 1991 Ford Ranger. 8 of the complaints include a mileage, and 13% of those were filed for vehicles with under 50,000 miles; the median is 82,500 miles. Of all complaints, 9 involved a crash, 21 a fire, 14 an injury, according to the filers. NHTSA lists 2 recall campaigns and 0 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Electrical system20 15%
- Suspension17 13%
- Engine cooling16 12%
- Body and structure13 9.8%
- Tires13 9.8%
- Brakes12 9.1%
- Transmission and drivetrain12 9.1%
- Vehicle speed control5 3.8%
- Fuel system4 3.0%
Also reported: Seat belts (3), Seats (3), Latches, locks and linkages (2), Other or unknown (2), Wheels (2), Equipment (1).
Example complaints
Electrical system: “The contact owned a 1991 Ford Ranger. The contact stated that the vehicle was parked when it caught on fire. The fire department was notified and no injuries were reported at the scene. The vehicle was destroyed. The dealer was not notified. The manufacturer was not notified. The failure and current mileages were 150,000. Updated 8/23/12”
NHTSA complaint #10467104, filed 2012-07, 150,000 milesSuspension: “Noticed rust fell off near front right tire. Had mechanic at work check he said that it is ready to break and the truck is not safe to drive. I have not contacted Ford I looked at your site and found many trucks with same problem.not sure what to do since it is obviously a problem that not only my truck had. I feel Ford should be replacing them. My truck also has low milage.”
NHTSA complaint #729321, filed 2000-08Engine cooling: “The contact owns a 1991 Ford Ranger. While driving 5 MPH with the defroster activated, the vehicle began to smoke. The contact pulled the vehicle over and noticed flames under the hood. The fire department was called and stated that there was a faulty wire under the hood that caused the fire. Prior to the failure, the clutch and power steering were repaired and the gas line was cleaned. The vehicle has not been taken to a dealer or mechanic. A police report was filed. The current and failure mileages were 100,000. Updated 062909 updated 07/01/09”
NHTSA complaint #10270103, filed 2009-05, 100,000 milesBody and structure: “The frame has horrible corrosion. All the spring hangers are were failing bad. I don't even think it can be welded because it is rusted from one end to another. Ford really messed this one up. And why do all the fuel gauges quit working?”
NHTSA complaint #10392824, filed 2011-03, 100,000 milesMileage when problems were reported
13% of the 8 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 58,212 and 100,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 1991 Ford Ranger. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.
| Version | Overall | Frontal | Side | Side pole | Rollover |
|---|---|---|---|---|---|
| Ranger · coupe | not rated | 1 / 4 | — | — | — |
Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.
Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.
Fuel economy and running cost
EPA ratings for each 1991 Ford Ranger version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Ranger Pickup 2WD | 2.3L 4-cyl | 5-speed manual | 21 | 26 | 23 | $2,900 |
| Ranger Pickup 2WD | 2.3L 4-cyl | 4-speed automatic | 18 | 22 | 20 | $3,350 |
| Ranger Pickup 2WD | 3.0L 6-cyl | 5-speed manual | 17 | 23 | 19 | $3,550 |
| Ranger Pickup 2WD | 3.0L 6-cyl | 4-speed automatic | 16 | 21 | 18 | $3,700 |
| Ranger Pickup 2WD | 4.0L 6-cyl | 5-speed manual | 16 | 22 | 18 | $3,700 |
| Ranger Pickup 2WD | 4.0L 6-cyl | 4-speed automatic | 15 | 21 | 17 | $3,950 |
| Ranger Pickup 4WD | 2.3L 4-cyl | 5-speed manual | 19 | 23 | 21 | $3,200 |
| Ranger Pickup 4WD | 2.9L 6-cyl | 5-speed manual | 16 | 20 | 18 | $3,700 |
| Ranger Pickup 4WD | 2.9L 6-cyl | 4-speed automatic | 15 | 20 | 17 | $3,950 |
| Ranger Pickup 4WD | 4.0L 6-cyl | 5-speed manual | 15 | 20 | 17 | $3,950 |
| Ranger Pickup 4WD | 4.0L 6-cyl | 4-speed automatic | 15 | 19 | 16 | $4,200 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 96V024001Feb 5, 1996Service brakes, hydraulic › Power assist › HydraulicCovers: Ford Ranger 1991–1994, Explorer 1991–1994
The studs which attach the brake master cylinder to the power brake vacuum booster assembly can develop stress corrosion cracking after being operated for an extended period of time in the southern california location.
- 91V189000Nov 4, 1991Power train › Automatic transmissionCovers: Ford Ranger 1990–1991, Aerostar 1989–1991, Explorer 1991 +1 more
When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Recall details for the 1991 Ford Ranger → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
No technical service bulletins are on record for the 1991 Ford Ranger.
Other model years of the Ford Ranger
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2026 | 9 | 32 | 8 | 4 | 23 | — | Too new |
| 2025 | 44 | 1,050 | 13 | 4 | 23 | Too new to compare | Too new |
| 2024 | 96 | 4,200 | 13 | 4 | 22 | Too new to compare | Too new |
| 2023 | 18 | 1,850 | 4 | 4 | 23 | — | Too new |
| 2022 | 38 | 15,500 | 5 | 4 | 23 | 26 · Fewer | Rising |
| 2021 | 119 | 32,800 | 6 | 4 | 23 | 67 · More | Rising |
| 2020 | 130 | 20,000 | 7 | 4 | 23 | 71 · More | Rising |
| 2019 | 271 | 19,500 | 11 | 4 | 23 | 90 · More | Rising |
| 2011 | 235 | 48,750 | 5 | 2 | 20 | 44 · Typical | Falling |
| 2010 | 156 | 51,000 | 8 | — | 21 | 41 · Typical | Falling |
| 2009 | 169 | 36,250 | 7 | — | 21 | 52 · Typical | Falling |
| 2008 | 326 | 62,500 | 5 | — | 18 | 47 · Typical | Falling |
| 2007 | 270 | 65,000 | 5 | — | 18 | Not compared (before 2008) | Falling |
| 2006 | 272 | 69,720 | 12 | — | 18 | Not compared (before 2008) | Falling |
| 2005 | 289 | 57,500 | 9 | — | 18 | Not compared (before 2008) | Stable |
| 2004 | 405 | 66,803 | 10 | — | 18 | Not compared (before 2008) | Falling |
| 2003 | 243 | 56,000 | 1 | — | 17 | Not compared (before 2008) | Falling |
| 2002 | 346 | 55,700 | 3 | — | 17 | Not compared (before 2008) | Falling |
| 2001 | 515 | 82,000 | 4 | — | 18 | Not compared (before 2008) | Falling |
| 2000 | 670 | 82,000 | 3 | — | 18 | Not compared (before 2008) | Falling |
| 1999 | 755 | 89,000 | 4 | — | 18 | Not compared (before 2008) | Falling |
| 1998 | 576 | 100,000 | 5 | — | 17 | Not compared (before 2008) | Falling |
| 1997 | 411 | 100,000 | 1 | — | 18 | Not compared (before 2008) | Falling |
| 1996 | 413 | 116,500 | 2 | — | 19 | Not compared (before 2008) | Falling |
| 1995 | 321 | 139,026 | 1 | — | 19 | Not compared (before 2008) | Falling |
| 1994 | 438 | 115,915 | 4 | — | 19 | Not compared (before 2008) | Stable |
| 1993 | 232 | 93,904 | 3 | — | 19 | Not compared (before 2008) | Stable |
| 1992 | 189 | 93,324 | 2 | — | 19 | Not compared (before 2008) | Stable |
| 1991 | 132 | 82,500 | 2 | — | 19 | Not compared (before 2008) | Stable |
| 1990 | 105 | 145,500 | 3 | — | 18 | Not compared (before 2008) | Stable |
| 1989 | 73 | 82,000 | 1 | — | 18 | Not compared (before 2008) | Stable |
| 1988 | 89 | 89,000 | 1 | — | 21 | Not compared (before 2008) | Stable |
| 1987 | 50 | 109,117 | 4 | — | 20 | Not compared (before 2008) | Stable |
| 1986 | 35 | 109,368 | 4 | — | 21 | Not compared (before 2008) | Stable |
| 1985 | 27 | 27,000 | 1 | — | 20 | Not compared (before 2008) | Stable |
| 1984 | 12 | 135,000 | 6 | — | 19 | — | Not enough data |
| 1983 | 11 | — | 5 | — | — | — | Not enough data |
All Ford Ranger model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 1991 Ford Ranger?
Owners of the 1991 Ford Ranger most often describe rust-related failures in the front suspension, electrical fires starting at the ignition switch or alternator wiring, and tire tread separations. The issues reported most often: Front spring/shock tower rust failure; Engine bay and dashboard fires (wiring, ignition switch); Tire tread separation and sidewall bubbles.
How many NHTSA complaints does the 1991 Ford Ranger have?
NHTSA recorded 132 consumer complaints for the 1991 Ford Ranger as of Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 1991 Ford Ranger is reported most often?
Electrical system is named most often, in 20 complaints (15% of the total), followed by suspension with 17.
Has the 1991 Ford Ranger been recalled?
NHTSA lists 2 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 1991 Ford Ranger get?
The EPA rates the 1991 Ford Ranger (Ranger Pickup 2WD, 3.0L 6-cyl) at 19 mpg combined, 17 city and 23 highway, with an estimated annual fuel cost of $3,550 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 1991 Ford Ranger reported?
Among the 8 complaints that include a mileage, the median is 82,500 miles and the middle half falls between 58,212 and 100,000 miles; 13% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.