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.
1991 Ford F-250 fuel system problems
31 complaints (29% of all complaints for this car). Typical mileage when it fails: 102,000.
- owner complaints
- 31
- of this car's complaints
- 29%
- typical mileage
- 102,000
- crashes
- 0
- recalls
- 2
Which part fails
- Storage: tank assembly8
- Storage: auxillary tank: selector devices5
- Delivery: fuel pump5
- Storage: tank assembly: filler pipe and cap2
- Storage: auxillary tank2
- Delivery: hoses, lines/piping, and fittings2
- Storage: fuel gauge system1
- Delivery1
At what mileage
Complaints by mileage at the time of the problem.
Ford F-250 fuel system problems in other years
Specific symptoms reported on the 1991 Ford F-250 fuel system
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Related recalls
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
Related investigations
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
What 1991 Ford F-250 owners say
Most recent owner complaints, unedited.
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
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.
Dad: the contact states there is the federal safety agency recall campaign 93v125000 concerning the fuel system: tank assembly. This vehicle has the same problems as indicated in the recall, but ii is not included in the recall due to VIN. The contact repaired the vehicle at his own expense. *ak the dealer charged the consumer 500.00 to replace the fuel pump which was different from the recall. Updated 01/11/06.
After fueling the vehicle, consumer noticed gas being pumped out of the front fill point like a fire hose. *ph this was the third failure with the crossover. Consumer then learned that this failure wasn't going to be covered under the extended warranty like the first two.
The gasoline was not transferring between the fuel tanks, causing vehicle to stall due to low gasoline. The dealer replaced the fuel tank sender and the fuel pump. *ak there were four attempts to remedy the transferring of fuel from the rear tank to the front tank throughout the filler cap and caused leakage. The consumer requested that ford cover the charges. *sc
Questions about the 1991 Ford F-250 fuel system
Does the 1991 Ford F-250 have fuel system problems?
Owners have filed 31 complaints about the fuel system of the 1991 Ford F-250, 29% of all its complaints, more than any other problem.
At what mileage do 1991 Ford F-250 fuel system problems start?
The typical (median) mileage in owner complaints is 102,000 miles.
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).
Other 1991 Ford F-250 problems
Brakes 27Electrical 15Tires 10Transmission 10Engine 8Body 5Acceleration 4Seat belts 4Lights 3Seats 3Steering 3Suspension 3Visibility 2
VIN decoder
See the problems and recalls for an exact car
Buying a used 1991 Ford F-250?
Check the exact car before you pay: accidents, salvage or flood titles, odometer readings and previous owners.
Check its history