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.
The worst 1991 Ford F-250 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Fuel system31
- Brakes27
- Electrical15
- Tires10
- Transmission10
- Engine8
- Body5
- Acceleration4
- Seat belts4
- Lights3
- Seats3
- Steering3
- Suspension3
- Visibility2
Specific symptoms reported on the 1991 Ford F-250
Fuel pump 9Tire blowout 7Brake failure 6Fuel leak 5Headlights 5Overheating 5
Recalls 5
Electrical system: ignition
- What is wrong
- The ignition switch could experience an internal short circuit.
- Risk
- This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
- Remedy
- Dealers will replace the ignition switch.
Recall number 96V071000 · Recall details
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings
- What is 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.
- Risk
- 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.
Recall number 94V040000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is 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.
- Risk
- 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.
Recall number 93V125000 · Recall details
Steering: steering wheel/handle bar
- What is 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.
- Risk
- 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.
Recall number 93V066000 · Recall details
Service brakes, hydraulic: foundation components: drum: shoes/linings
- What is 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.
- Risk
- 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.
Recall number 92V026000 · Recall details
See all 5 recalls for the 1991 Ford F-250
Defect investigations
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 repair the supply side fuel cross flow problem (recall 93v‑125).odi opened rq98-008 on may 29, 1998 because of the large number of alleged remedy failures and reports of fuel cross flow on vehicles outside of the recall population.based onthe information received from ford on august 11, september 30, and december 15, 1998, and the increasing trend of remedy failures and out of scope crossflow reports, odi opened ea99-032 on november 4, 1999.the attached engineering analysis closing report fully describes the results of this investigation and reason for closing.the subject vehicles can experience fuel transfer from one tank to the other due to malfunctions in the fuel system.when fuel is pumped or returned to the non-operating tank (cross flow), the capacity of the non-operating tank can be exceeded, causing fuel to overflow past the filler cap, creating a fire potential.
EA99032
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 needed.this investigation is upgraded to ea99-032.click on document search button for additional information.
RQ98008
Idle air spd ctrl vlv malf
There is no summary currently available
EA93022
Alternator belt failure
There is no summary currently available
EA93014
Idle air spd ctrl vlv malf
There is no summary currently available
PE93010
Fuel expulsion
There is no summary currently available
EA93001
Fuel expulsion
There is no summary currently available
PE92077
Loss of brake effectivenes
===
EA91044
Fuel expulsion
There is no summary currently available
EA91031
Loss of brake effectivenes
There is no summary currently available
PE91077
Transmission fluid fires
There is no summary currently available
PE91064
Technical service bulletins for the 1991 Ford F-250 52
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the...
- TRANSMISSION-E40D-NO 2-3 upshift
- Transmission- E40D/4R100-1989-99-MAIN controls, separator plates and separator plate gaskets usage chart
- Vehicles may experience solid particle contaminants from prior transmission concerns or excess wear, may...
- Information regarding the new transmission cooler flusher- service tip
- Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses
- Information on identifying non-approved / alternate refrigerants which could cause safety, and performance...
- Information on the new flush and fill tool available through rotunda
- Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on...
- Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making...
1991 Ford F-250 fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 4.9L 6‑cyl | RWD | 14-15 | 17-19 | 16 |
| 5.0L 8‑cyl | RWD | 12 | 14-17 | 13-14 |
| 4.9L 6‑cyl | 4WD | 13 | 17 | 14 |
| 5.0L 8‑cyl | 4WD | 11 | 12-16 | 11-13 |
| 5.8L 8‑cyl | RWD | 11 | 15 | 12 |
| 5.8L 8‑cyl | 4WD | 10 | 15 | 12 |
What 1991 Ford F-250 owners say
Most recent owner complaints, unedited.
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 unit was damaged, which caused the fuel to travel from one tank to the other and overflow. The vehicle was not repaired. The manufacturer was not informed of the failure. The approximate failure mileage was 137,000.
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 the federal safety agency campaign number: 01i008000 (fuel system, gasoline) but the VIN was not included. The failure mileage was 161,000. ..updated 05/20/15 *bf the consumer has experienced the fuel switch over issue and would like to be added to the recall. Updated 7/6/2015
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 why the battery was dead (given they had the car for a month and had put in a new battery and starter, among other repairs). Driving the 7 miles to the dealership the car seemed to be accelerating on its own, the entire way, I only stepped on the gas once; it was going 35 miles/hour by itself (per the speedometer). I didn't know why this was happening and when I tried to slow down using the brakes, the truck was very difficult to stop, such that I nearly rear-ended multiple cars. It was all I could do to push the brake down and twice huge amounts of smoke came from under the vehicle (probably the brakes were now overheating?). When I was 500 feet from the dealership I took a quick left turn and honestly could not stop the truck, I threw it into park and shut it off just in time to miss plowing into parked vehicles. Smoke billowed out from below the hood. I have never been so frightened in my life-I was sure I was either going to smash into someone since I couldn't stop or the truck was going to implode in fire, or something and I would be dead. I was not able to successfully stop it using the brakes. The parking brake was also not working (which is also why I was returning it to the dealer). When I asked the service person at the ford dealership if he'd seen a stuck throttle like this before, he said, "yes, sometimes when vehicles sit for a while". This is a saturday, so they are going to evaluate the problem on monday. The service rep also said sometimes cleaning the terminals might contribute to extra conduction, which might have caused the acceleration issue.
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 that once you fill the rear tank and then travel, the fuel, which should return to the rear tank in a cycle, does not. It simply returns to the front tank, until it fills the front tank and floods out. The pump in the rear tank appears to just continue to run, for example,,,, you have a full rear tank. You have half a tank of fuel in the front tank. You drive. The rear tank pump, pumps all of the full rear tank into the front tank. So, half a tank of gas flows out of the front tank, onto the ground. Obviously, the cycle, where the fuel should go from rear, to engine and back, isn't happening. Instead, the fuel rolls by the engine and returns to a full front tank, rather than the rear tank, so, onto the ground goes the fuel. On an older recall report, the repair is described, where the 'jumper' must be replaced, despite the fact there's no such thing, there's a fuel pump and probably some sort of 'bi-valve' that someone's poor engineering failed on the whole, at the time of design. I think I'll just pull into the local ford lot and idle out a few gallons now and then. But since the 90 isn't on the recall, despite the obvious exact problem as the 91's and up, there's no use. It would seem common sense, that dealers could simply be notified that the 1990 f 250's are doing the exact thing as many other makes and the least the dealer could do, is be a little more specific about the repair. But not if their corporate engineers and repair centers keep the mechanical information secret, or written in some manufacturer 'code language'.
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 recall and provided no further assistance. The failure mileage was 102,311 and the current mileage was 102,622. ..updated 09/07/12 *bf updated 09/17/2012
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 vehicle was not included in the federal safety agency campaign id number: 93v125000 (fuel system, gasoline: storage: tank assembly). The dealer advised that the entire fuel tank would need replacing. The manufacturer was not made aware of the failure. The vehicle was not repaired and the VIN was unavailable. The failure mileage was 150,000.
Tl*the contact owns a 1991 ford f250. The contact stated while driving approximately 45 MPH, he noticed gasoline spilling out of the tank. Prior to the spill, he smelled a gasoline odor for about 6 months. The vehicle was inspected by pepboys who informed the contact that the fuel tank selector needed to be replaced. The VIN was unknown. The vehicle was repaired. The failure mileage was 38,525.
Tl*the contact owns a 1991 ford f-250. The contact stated that when he filled the front tank, the fuel would be shifted to the rear tank. The failure occurred everytime he fueled the vehicle. The contact stated that because of the failure, a pressure was created within the two tanks. The vehicle. The contact called the dealership and referenced recall 93v125000 (fuel system, gasoline:storage:tank assembly) and was told that there were no active recalls on his vehicle. The contact called the manufacturer who verified that there were no active recalls for the vehicle. The vehicle had not been repaired. The current mileage was approximately 250,000. The failure mileage was approximately 50,000.
Discoverer a/t tires size lt265/75r16 catastrophically failed while driving at highway speed. Tread completely peeled off. Had only been driving for 30 minutes and outside temperature was 70 degrees f. Tires had about 23,000 miles on them. 1-2 years previously, the same type tire on opposite wheel developed a bulge in the sidewall and had to be replaced.
Compare the 1991 Ford F-250
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Questions about the 1991 Ford F-250
Is the 1991 Ford F-250 reliable?
Owners have filed 107 complaints about the 1991 Ford F-250, fewer than a typical F-250 model year.
What is the most common problem with the 1991 Ford F-250?
Fuel and propulsion system, with 31 complaints, typically around 102,000 miles. Next is brakes (27).
How many recalls does the 1991 Ford F-250 have?
5 recalls, covering electrical system, fuel system, gasoline and steering.
Was there a recall on the 1991 Ford F-250 fuel system?
Yes, 2 recalls: 94V040000, 93V125000. Check your VIN to see if your car still needs the free repair.
What year does the Ford F-250 have the most fuel system problems?
The Ford F-250 model years with the most fuel system complaints are 1999 (41 complaints), 1990 (40 complaints) and 1993 (37 complaints).
What gas mileage does the 1991 Ford F-250 get?
Official estimates for the 1991 Ford F-250 range from 11 to 16 mpg combined. The most efficient version (4.9L 6-cyl, RWD) gets 14-15 city and 17-19 highway.
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