Verdict · NHTSA data
One of the years to avoid
With 37 complaints filed to NHTSA — about 24.7 times the median Econoline year — the 1991 model ranks #12 of 48 Econoline years for complaint volume. It lands on the years-to-avoid list. Complainants reported 22 injuries in total across these filings.
No single system dominates the record — complaints spread across fuel system (8), brakes (6), and engine (6), which usually points to general build quality rather than one defect.
37
NHTSA complaints
3
Recalls
2
Investigations
11
Crash-involved
1
Fires reported
22
Injuries
0
Deaths
—
NCAP overall
| Component | Complaints | Share | vs prior year |
|---|---|---|---|
| Fuel System | 8 | 22% | ▲ up |
| Brakes | 6 | 16% | ▼ down |
| Tires & Wheels | 6 | 16% | — flat |
| Engine | 6 | 16% | ▲ up |
| Seats | 2 | 5% | ▼ down |
| Transmission | 2 | 5% | ▼ down |
| Lighting | 1 | 3% | — flat |
| Speed Control | 1 | 3% | ▼ down |
| Steering | 1 | 3% | — flat |
| Body & Structure | 1 | 3% | ▼ down |
| Electrical System | 1 | 3% | ▼ down |
| Visibility & Wipers | 1 | 3% | — flat |
| Seat Belts | 1 | 3% | — flat |
3 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.
Defect
THE REAR SHOCK CROSSMEMBER OF THE FRAME CAN CRACK AND SEPARATE FROM THE FRAME.
Consequence
SEPARATION OF THE REAR SHOCK CROSSMEMBER FROM THE FRAMECAN RESULT IN LOSS OF VEHICLE CONTROL AND AN ACCIDENT.
Remedy
REPLACE THE REAR CHOCK CROSSMEMBER WITH A SHOCK CROSSMEMBER MADE OF HIGH STRENGTH STEEL.
Defect
THE SAFETY BELT ANCHORAGE FOR THE REAR BENCH SEAT FAILED TO COMPLY WITH THE STANDARDS OF FMVSS 210.
Consequence
FAILURE TO MEET THE LOAD REQUIREMENTS OF FMVSS 210 PLACETHE SEAT OCCUPANTS IN INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOPOR ACCIDENT.
Remedy
THE MANUFACTURE WILL REPLACE THE NON-COMPLYING SAFETY BELT ANCHORAGE WITH A NEW ANCHORAGE THAT MEETS THE REQUIREMENTS OF FMVSS 210.
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.
“THE CONSUMER HAS EXPERIENCED PROBLEMS WITH THE FOLLOWING : TIRES (DIRECTIONAL/4 WAY), COURTESY LIGHTS, CRUISE CONTROL, STEERING (NOISE), BRAKES/REAR ANTI-LOCK, SEAT BELTS, SEATS (LOOSE), GAS LEAK, REAR DOOR(S) LEAK/DRIVER SIDE DOOR HINGE, DASH CRACKED, LOOSE RUNNING BOARD, FRONT FENDER (PASSENGER…”
“THE CONSUMER HAS EXPERIENCED PROBLEMS WITH THE FOLLOWING : TIRES (DIRECTIONAL/4 WAY), COURTESY LIGHTS, CRUISE CONTROL, STEERING (NOISE), BRAKES/REAR ANTI-LOCK, SEAT BELTS, SEATS (LOOSE), GAS LEAK, REAR DOOR(S) LEAK/DRIVER SIDE DOOR HINGE, DASH CRACKED, LOOSE RUNNING BOARD, FRONT FENDER (PASSENGER…”
“THE CONSUMER HAS EXPERIENCED PROBLEMS WITH THE FOLLOWING : TIRES (DIRECTIONAL/4 WAY), COURTESY LIGHTS, CRUISE CONTROL, STEERING (NOISE), BRAKES/REAR ANTI-LOCK, SEAT BELTS, SEATS (LOOSE), GAS LEAK, REAR DOOR(S) LEAK/DRIVER SIDE DOOR HINGE, DASH CRACKED, LOOSE RUNNING BOARD, FRONT FENDER (PASSENGER…”
“CONSUMER STATES THAT THE ENGINE FAN BELT SLIPS AND LOSE THREAD OF THE SERPENTINE BELT.OWNER HAS BELT REPLACED FIVE TIMES IN FIVE YEARS. THE DEALER ACKNOWLEDGED THAT THERE WERE PROBLEMS WITH THE 1991 ECONOLINE VAN. OWNER HAS REGISTERED A COMPLAINT WITH THE FORD MOTRO CORP.”
“TRANSMISSION HAS BEEN REPLACED THREE TIMES WITHIN LESS THEN 60,000 MILES. DEALER NOTIFIED AND REPAIRED TRANSMISSION ON TWO OCCASIONS, BUT REFUSED TO REPAIR ON THE THIRD UNLESS COST IS PICKED UP BY THE CONSUMER. *AK”
NHTSA data argues against it: 37 complaints put the 1991 model at #12 of 48 Econoline years. It is one of the Econoline years to avoid.
According to NHTSA complaint data, the leading problem areas are fuel system (8 complaints), brakes (6 complaints), engine (6 complaints).
Yes — NHTSA lists 3 recall campaigns affecting the 1991 Ford Econoline. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.
NHTSA opened 2 investigations into this model year; all are now closed.
Based on complaint rates and open investigations, the Econoline years to avoid are 1994, 1992, 1999, 1997, 1995, 1996, 1993, 1998, 2000, 1989, 1990, 1991, 1988, 2001. The cleanest record among Econoline years belongs to 2026.
Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.
Compiled by Sharon Ben-Moshe, Founder.