Defect
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Consequence
THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
Remedy
DEALERS WILL REPLACE THE IGNITION SWITCH.
1991 Ford F-250 Recalls
Recalls on record Updated July 2026
The 1991 Ford F-250 has 5 NHTSA recall campaigns affecting an estimated 9,590,189 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 145 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
Recall campaigns
Defect
THE 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 THE FLOOR PAN. CONTINUED CONTACT LEADS TO ABRASION OF THE STEEL FUEL RETURN TUBE AND EVENTUALLY RESULTS IN A FUEL LEAK.
Consequence
ABRASION OF THE STEEL TUBE WALL THAT EVENTUALLY CAUSES A FUEL LEAK MAY RESULT IN A FIRE, IF A SOURCE OF IGNITION IS PRESENT.
Remedy
FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.
Defect
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.
Consequence
SPILLED FUEL CAN RESULT IN A FIRE WHEN EXPOSED TO ASOURCE OF IGNITION.
Remedy
REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.
Defect
KEYS ATTACHED TO THE KEY RING OF AN IGNITION KEY WHILE IT IS IN THE VEHICLE IGNITION CAN BECOME LODGED IN THE STEERING LOCK RECEIVER AS THE STEERING WHEEL IS BEING TURNED.
Consequence
THE LODGED KEYS CAN CAUSE LOSS OF STEERING CONTROL, WHICHCAN RESULT IN AN ACCIDENT WHEN THE VEHICLE IS BEING USED ON THE HIGHWAY.
Remedy
A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN PLACE BY THE STEERING LOCK BAND.
Defect
A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.
Consequence
INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.
Remedy
ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.
Complaints by component
ELECTRICAL SYSTEM:IGNITION:SWITCH
4fires
TIRES
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
1fires
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
2injuries
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
2crashes1injuries
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
1fires
FUEL/PROPULSION SYSTEM
POWER TRAIN:AUTOMATIC TRANSMISSION
1crashes1injuries
Total complaints145
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“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.”
“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…”
“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…”
“I had just been jumped by aaa because my truck wasn't starting; the aaa agent also cleaned the battery terminals. I intended to have it towed to the ford dealer because I didn't think it would start. Since the aaa agent was able to get to start, I decided to still take it to the dealer to find out…”
“I had just been jumped by aaa because my truck wasn't starting; the aaa agent also cleaned the battery terminals. I intended to have it towed to the ford dealer because I didn't think it would start. Since the aaa agent was able to get to start, I decided to still take it to the dealer to find out…”
“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…”
“Tl* the contact owns a 1991 ford f250. The contact stated that gasoline fuel was leaking from the vehicle and onto the driveway. The vehicle was not taken to the dealer for inspection or repairs. The manufacturer was contacted and they advised the contact that the vehicle was not included in the…”
“Tl* the contact owns a 1991 ford f-250. The contact stated that after refueling the vehicle, gasoline would overflow from the rear fuel tank into the front fuel tank, causing spillage. The contact believed that the fuel pump was defective. The vehicle was taken to the dealer who advised that the…”
Defect investigations
Investigation EA91031 Opened 1991-06-26 · closed 1991-11-01
FUEL EXPULSION
There is no summary currently available
Investigation EA91044 Opened 1991-10-30 · closed 1992-10-30
LOSS OF BRAKE EFFECTIVENES
===
Investigation EA93001 Opened 1993-01-07 · closed 1993-08-20
FUEL EXPULSION
There is no summary currently available
Investigation EA93014 Opened 1993-06-04 · closed 1994-07-29
ALTERNATOR BELT FAILURE
There is no summary currently available
Investigation EA93022 Opened 1993-07-30 · closed 1994-08-31
IDLE AIR SPD CTRL VLV MALF
There is no summary currently available
Investigation EA99032 Opened 1999-11-04 · closed 2001-12-06
DUAL FUEL TANK CROSSFLOW/LEAKAGE
ON JULY 14, 1993 FORD FILED A DEFECT INFORMATION REPORT CONCERNING FUEL TANK CROSS FLOW LEAKAGE ON F-SERIES LIGHT TRUCKS AND CAB CHASSIS BUILT FROM JULY 22, 1989 THROUGH DECEMBER 17, 1992.THE REMEDY WAS TO REPLACE THE FUEL PRESSURE REGULATOR AND INSTALL A CHECK VALVE BETWEEN EACH FUEL SUPPLY LINE AND FUEL TANK (2) TO…
Investigation EA99032 Opened 1999-11-04 · closed 2001-12-06
DUAL FUEL TANK CROSSFLOW/LEAKAGE
ON JULY 14, 1993 FORD FILED A DEFECT INFORMATION REPORT CONCERNING FUEL TANK CROSS FLOW LEAKAGE ON F-SERIES LIGHT TRUCKS AND CAB CHASSIS BUILT FROM JULY 22, 1989 THROUGH DECEMBER 17, 1992.THE REMEDY WAS TO REPLACE THE FUEL PRESSURE REGULATOR AND INSTALL A CHECK VALVE BETWEEN EACH FUEL SUPPLY LINE AND FUEL TANK (2) TO…
Investigation PE91064 Opened 1991-04-09 · closed 1991-07-05
TRANSMISSION FLUID FIRES
There is no summary currently available
Investigation PE91077 Opened 1991-05-23 · closed 1991-10-31
LOSS OF BRAKE EFFECTIVENES
There is no summary currently available
Investigation PE92077 Opened 1992-09-09 · closed 1993-01-07
FUEL EXPULSION
There is no summary currently available
Investigation PE93010 Opened 1993-03-02 · closed 1993-07-30
IDLE AIR SPD CTRL VLV MALF
There is no summary currently available
Investigation RQ98008 Opened 1998-05-29 · closed 1999-11-04
FORD F-SERIES DUAL FUEL TANK LEAKAGE
THESE VEHICLES CAN EXPERIENCE FUEL TRANSFER FROM ONE TANK TO THE OTHER DUE TO A MALFUNCTIONING FUEL PUMP.FROM THE INFORMATION GATHERED TO DATE, IT APPEARS THAT THERE CAN BE MULTIPLE CAUSES AND/OR A COMBINATION OF CAUSES FOR FUEL CROSS FLOW AND THAT THE RECALL REMEDY MAY BE INADEQUATE.FURTHER INVESTIGATION IS…
Sources & methodology
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Ford F-250 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.