1991 Ford F-150 problems & reliability
304 owner complaints filed with NHTSA for the 1991 Ford F-150. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
7 complaints report injuries (8 injured).
Federal crash records (FARS 2020–2023): 1991 Ford F-150 vehicles were involved in 19 fatal crashes with 10 occupant deaths. Involvement counts are not adjusted for how many are on the road and do not imply fault or a vehicle defect.
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Fuel System, Gasoline | 149 | 49% |
| Electrical System | 50 | 16% |
| Service Brakes, Hydraulic | 23 | 8% |
| Engine and Engine Cooling | 17 | 6% |
| Tires | 14 | 5% |
| Power Train | 13 | 4% |
| Vehicle Speed Control | 10 | 3% |
| Structure | 8 | 3% |
| Steering | 7 | 2% |
| Unknown OR Other | 6 | 2% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Mileage when problems occurred
Half of the failures with a reported odometer reading occurred by 107,000 miles (middle 50% between 82,650 and 141,000 miles), based on 39 complaints that included mileage.
Complaints by incident year
What owners report
“The contact owns a 1991 Ford F-150. The contact stated that while driving at an undisclosed speed, the rear fuel tank gauge began indicating that the rear tank was losing fuel abnormally fast. After a visual inspection, the contact observed that fuel was flowing from the rear fuel tank into the front fuel tank. No…”
Fuel System, Gasoline · filed Apr 8, 2025
“The truck wont crank. When the key is turned off and removed some electrical systems still work and cause smoking. I have had to disconnect the battery in fear the truck will burn down. Ford was contacted about the issue and said they cant do anything because their records for recalls only go 10 years. Even though the…”
Electrical System · filed Mar 29, 2021
“Fuel spilling out around neck while parked at work, also rear fuel tank pumping gas into front gas tank while driving.... *tr”
Fuel/propulsion System · filed Jan 6, 2017
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- DUAL FUEL TANK CROSSFLOW/LEAKAGE
Engineering Analysis EA99032 · opened Nov 4, 1999 · closed Dec 6, 2001 · led to recall 01I008000
- FORD F-SERIES DUAL FUEL TANK LEAKAGE
Recall Query RQ98008 · opened May 29, 1998 · closed Nov 4, 1999 · led to recall 93V125000
- IDLE AIR SPD CTRL VLV MALF
Engineering Analysis EA93022 · opened Jul 30, 1993 · closed Aug 31, 1994
- IDLE AIR SPD CTRL VLV MALF
Preliminary Evaluation PE93010 · opened Mar 2, 1993 · closed Jul 30, 1993
- FUEL EXPULSION
Engineering Analysis EA93001 · opened Jan 7, 1993 · closed Aug 20, 1993 · led to recall 93V125000
- FUEL EXPULSION
Preliminary Evaluation PE92077 · opened Sep 9, 1992 · closed Jan 7, 1993
- FRONT SEAT BACK FAILURE
Engineering Analysis EA92029 · opened Aug 27, 1992 · closed Oct 29, 1993
- FNT RECLNING SEAT BCK FAIL
Preliminary Evaluation PE92042 · opened Apr 17, 1992 · closed Aug 27, 1992
Technical service bulletins
45 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 1991 Ford F-150. The 10 most recent:
Information regarding transmission fluid usage charts. *slc
01157 · Service Bulletin/Repair Instructions · issued Aug 6, 2001
Some vehicles may exhibit heater core leaks. *slc
01156 · Service Bulletin/Repair Instructions · issued Aug 6, 2001
Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt
002310 · Service Bulletin/Repair Instructions · issued Nov 13, 2000
Transmission- e40d/4r100-1989-99-main controls, separator plates and separator plate gaskets usage chart. Yd
98168 · Service Bulletin/Repair Instructions · issued Apr 7, 2000
Transmission-e40d-no 2-3 upshift. Some vehicles may exhibit a no 2-3 upshift condition. *ak
98167 · Service Bulletin/Repair Instructions · issued Apr 7, 2000
Vehicles may experience solid particle contaminants from prior transmission concerns or excess wear, may be trapped in the transmission fluid cooling system is not properly flushed, fluid in-line filter kit. *mjs
0038 · Service Bulletin/Repair Instructions · issued Feb 7, 2000
Information regarding the new transmission cooler flusher- service tip. *mjs
0015 · Service Bulletin/Repair Instructions · issued Jan 10, 2000
Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
99222 · Service Bulletin/Repair Instructions · issued Oct 18, 1999
Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
99196 · Service Bulletin/Repair Instructions · issued Sep 20, 1999
Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump. *tt
99129 · Service Bulletin/Repair Instructions · issued Jun 14, 1999
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
No NHTSA recall campaigns name the 1991 Ford F-150 in our current data. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 1991 Ford F-150?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.
- · Owners most often reported problems around 107,000 miles — budget accordingly if the car is approaching that mileage.