1991 Ford F-250: Recalls, Problems & MPG
Here are the deets on the 1991 Ford F-250: 5 recalls, 107 owner complaints and up to 16 mpg combined.
Recalls
5 vehicle recalls from the manufacturer, plus 2 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Brakes (hydraulic) Vehicle recall #92V026000 · 1992 · 467,000 vehicles
What's wrong: 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.
Why it matters: 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.
The fix: 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.
Steering Vehicle recall #93V066000 · 1993 · 2,419 vehicles
What's wrong: 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.
Why it matters: The lodged keys can cause loss of steering control, whichcan result in an accident when the vehicle is being used on the highway.
The fix: A shield will be positioned between the steering wheel and the ignition switch and held in place by the steering lock band.
Fuel system Vehicle recall #93V125000 · 1993 · 1,131,000 vehicles
What's wrong: 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.
Why it matters: Spilled fuel can result in a fire when exposed to asource of ignition.
The fix: Replacement of the fuel pressure regulator and installation of redundant check valves.
Fuel system Vehicle recall #94V040000 · 1994 · 89,770 vehicles
What's wrong: 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.
Why it matters: Abrasion of the steel tube wall that eventually causes a fuel leak May result in a fire, if a source of ignition is present.
The fix: Ford dealers will replace the fuel return tubes with flexible stainless steel braided/teflon tubes. Dealers will also inspect the fuel supply tubes.
Electrical Vehicle recall #96V071000 · 1996 · 7,900,000 vehicles
What's wrong: The ignition switch could experience an internal short circuit.
Why it matters: This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
The fix: Dealers will replace the ignition switch.
2 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Tires Recall #01X001000 · 2001 · 13,000,000 vehicles
What's wrong: This is not a safety recall in accordance with the safety act. However, it is deemed a safety improvement campaign by the agency. Equipment description: Ford is replacing all firestone wilderness at 15, 16, and 17 inch tires mounted on Ford trucks and suvs. Ford reports tread separation can occur due to a combination of the sensitivity of the tire design to stress, aging, and manufacturing differences between…
Why it matters: Should the tread separate at highway speeds, a vehicle crash could occur, possibly resulting in personal injury or death.
The fix: The replacement/reimbursement program for this campaign expired on March 31, 2002. However, customers can contact Ford at 1-877-917-3673 or go on-line to www.Ford.com for possible assistance.
Fuel system Recall #01I008000 · 2001 · 1,556,221 vehicles
What's wrong: This is not a safety recall in accordance with the safety act. However, it is deemed a safety improvement campaign by the agency. Vehicle description: 1990-1993 Ford f-series vehicles equipped with dual fuel tanks and 4.9, 5.0,5.8, or 7.5 liter gasoline fueled engines. Some vehicles can experience a cross tank fuel flow condition due to a damaged check valve in the fuel pump/sender assembly. Fuel May be supplied…
Why it matters: Should this occur, the capacity of the receiving tank May be exceeded and fuel May overflow from the filler cap.
The fix: Ford is extending the warranty for potential fuel cross-flow to 12 years of service or 150,000 miles from the vehicle's warranty start date, whichever occurs first. This cover will automatically transfer to subsequent owners at no charge. If a vehicle already has more than 150,000 miles, this…
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 9 mention a fire, 4 injuries and 0 deaths were reported.
What owners describe
- Fuel system (26): the most common themes are leaks (7), fire / smoke (2), stalls / loses power (2).
- Brakes (hydraulic) (24): the most common themes are brake failure / soft pedal (7).
- Electrical (15): the most common themes are fire / smoke (5), electrical failure (4).
- Transmission & drivetrain (10): the most common themes are leaks (4).
The 1991 Ford F-250 has 107 owner complaints, ranking #17 of 22 F-250 model years for complaints (about average; the typical year has 177). Complaints peaked in 1996 (24 filed that year). The typical problem showed up when the car was about 6 years old, at a median of 102,000 miles. Neighboring years: 1992 (119 complaints, 4 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 4.9 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 14 | 19 | 16 | Regular |
| 4.9 L 6-cyl | Manual 4-spd | Rear-Wheel Drive | 15 | 17 | 16 | Regular |
| 4.9 L 6-cyl | Manual 5-spd | Rear-Wheel Drive | 15 | 18 | 16 | Regular |
| 5.0 L 8-cyl | Automatic 4-spd | Rear-Wheel Drive | 12 | 17 | 14 | Regular |
| 5.0 L 8-cyl | Manual 5-spd | Rear-Wheel Drive | 12 | 16 | 14 | Regular |
| 4.9 L 6-cyl | Manual 5-spd | 4-Wheel or All-Wheel Drive | 13 | 17 | 14 | Regular |
| 5.0 L 8-cyl | Manual 4-spd | Rear-Wheel Drive | 12 | 14 | 13 | Regular |
| 5.0 L 8-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 11 | 16 | 13 | Regular |
| 5.0 L 8-cyl | Manual 5-spd | 4-Wheel or All-Wheel Drive | 11 | 15 | 13 | Regular |
| 5.8 L 8-cyl | Automatic 4-spd | Rear-Wheel Drive | 11 | 15 | 12 | Regular |
| 5.8 L 8-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 10 | 15 | 12 | Regular |
| 5.0 L 8-cyl | Manual 4-spd | 4-Wheel or All-Wheel Drive | 11 | 12 | 11 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 1991 Ford F-250.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
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FAQ
Does the 1991 Ford F-250 have any recalls?
Yes. NHTSA lists 5 vehicle recalls for the 1991 Ford F-250, plus 2 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 1991 Ford F-250 problems?
Owners have filed 107 complaints with NHTSA. The most-reported areas are fuel system (26), brakes (hydraulic) (24), electrical (15).
What gas mileage does the 1991 Ford F-250 get?
EPA ratings run up to 16 mpg combined (4.9 L, Automatic 4-spd), across 12 engine and transmission combos.
Where can I get a 1991 Ford F-250 repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.