1991 Ford F-250 problems & reliability

Each complaint is counted once (by NHTSA case number), even when it names several vehicles.

Most reported problems

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.

Complaints by incident year

What owners report

• “Fuel leaked from heater wire in fuel filter. The fuel followed the wire up the copper core until it reached a crack in the insulation any time there was fuel pressure, ie engine running or even with boost pump pressure with engine off.”

  Fuel/propulsion System · filed Jan 1, 2020

• “Tl* the contact owns a 1991 ford f-250. After the vehicle was parked, the contact noticed a strong fuel odor from the side of the vehicle. The contact noticed fuel pouring out of the opening of the tank that spilled onto the street and underneath another vehicle. The dealer stated that the fuel check valve in the pump…”

  Electrical System · filed May 21, 2015

• “Tl* the contact owns a 1991 ford f-250. After refueling the vehicle, fuel started leaking from the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The contact was aware of nhtsa campaign number: 01i008000 (fuel system, gasoline) but the vin was not included. The…”

  Fuel/propulsion System · filed Apr 17, 2015

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

• ALTERNATOR BELT FAILURE

  Engineering Analysis EA93014 · opened Jun 4, 1993 · closed Jul 29, 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

• LOSS OF BRAKE EFFECTIVENES

  Engineering Analysis EA91044 · opened Oct 30, 1991 · closed Oct 30, 1992 · led to recall 92V026000

Technical service bulletins

52 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 1991 Ford F-250. The 10 most recent:

• 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

• Information on the new flush and fill tool available through rotunda. *tt

  99152 · Service Bulletin/Repair Instructions · issued Jul 26, 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

• Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making cornering maneuvers on vehicles equipped with a four wheel drive hi or low range mode. *tt

  12905 · Service Bulletin/Repair Instructions · issued Jun 1, 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-250 in our current data. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.