Verdict · NHTSA data
Limited data — recalls on file
NHTSA has just 20 complaints on file for the 1991 Ford E-150 — too few to judge reliability from owner reports alone — but one recall campaign applies to this year, so any used example should have its VIN checked for completed recall work.
20
NHTSA complaints
1
Recalls
4
Investigations
0
Crash-involved
1
Fires reported
3
Injuries
0
Deaths
—
NCAP overall
| Component | Complaints | Share | vs prior year |
|---|---|---|---|
| Electrical System | 6 | 30% | ▼ down |
| Tires & Wheels | 4 | 20% | ▲ up |
| Fuel System | 4 | 20% | ▼ down |
| Transmission | 2 | 10% | — flat |
| Seats | 1 | 5% | — flat |
| Speed Control | 1 | 5% | ▼ down |
| Other | 1 | 5% | — flat |
| Engine | 1 | 5% | ▼ down |
1 NHTSA recall campaign on file. Recall repairs are free at franchised dealers.
Defect
THE DUAL FUEL TANK SELECTOR VALVE MAY MALFUNCTION AND CAUSE AN OVERFILL CONDITION IN ONE OF THE FUEL TANKS, RESULTING IN AN OVERFLOW OF FUEL PAST THE FILLER CAP.
Consequence
THE OVERFLOW OF FUEL PAST THE FILLER CAP CAUSES A FUELLEAKAGE, WHICH CAN RESULT IN A FIRE WHEN EXPOSED TO A SOURCE OF IGNITION.
Remedy
REPLACE THE DUAL FUEL TANK SELECTOR VALVE.
Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.
“WE HAVE SPENT MONEY TRYING TO FIX THE SAME PROBLEMSON OUR VAN OVER AND OVER WE HAVE A HANDICAP CHILD THAT HIS LIFE DEPENDS ON THE FUNCTION OF THE VAN WHEN WE PURCHASED THE VAN WE INFORMED DEALER OF THIS AND HE STATED THAT THE VAN WAS IN GREAT CONDITION TO TRAVEL ANY WHERE. WE ALSO LET THEM KNOW…”
“TL*THE CONTACT OWNS A 1991 FORD E150. WHILE DRIVING 35 MPH, THE CONTACT HEARD A LOUD HISSING SOUND COMING FROM THE VEHICLE. HE INSPECTED THE VEHICLE AND NOTICED BURN MARKINGS INSIDE THE FILLER CAP AS WELL AS OUTSIDE OF THE FUEL TANK. HE STATED THAT THE COMPONENTS ON THE INSIDE OF THE FUEL TANK WERE…”
“WHILE DRIVING TWO TIRES FAILED WITHIN 30 MINUTES OF EACH OTHER. THE ORIGINAL GENERAL TIRES (TIRE INFORMATION UNKNOWN) EXPERIENCED TREAD SEPARATION WHICH CAUSED SIGNIFICANT BODY DAMAGE. MANUFACTURER NOT WILLING TO DO ANYTHING. *TT ”
“WE HAVE SPENT MONEY TRYING TO FIX THE SAME PROBLEMSON OUR VAN OVER AND OVER WE HAVE A HANDICAP CHILD THAT HIS LIFE DEPENDS ON THE FUNCTION OF THE VAN WHEN WE PURCHASED THE VAN WE INFORMED DEALER OF THIS AND HE STATED THAT THE VAN WAS IN GREAT CONDITION TO TRAVEL ANY WHERE. WE ALSO LET THEM KNOW…”
The record is thin — 20 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 1 recall should be verified as completed.
According to NHTSA complaint data, the leading problem areas are electrical system (6 complaints), tires & wheels (4 complaints), fuel system (4 complaints).
Yes — NHTSA lists 1 recall campaign affecting the 1991 Ford E-150. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.
NHTSA opened 4 investigations into this model year; all are now closed.
Based on complaint rates and open investigations, the E-150 years to avoid are 1994, 1997, 1999, 1995, 1993, 1992, 1998, 1996, 2000, 2001, 1989, 2002, 2004, 2003, 2011. The cleanest record among E-150 years belongs to 2023.
Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.
Compiled by Sharon Ben-Moshe, Founder.