VehicleVerdict

1991 Ford F-150 problems

Verdict · NHTSA data

Worth extra scrutiny

The 1991 Ford F-150 is a recall-heavy year with an otherwise ordinary complaint record: 6 NHTSA recall campaigns apply, yet its 357 owner complaints run below the F-150 median. The recalls matter more than the complaint count here — verify every campaign was completed before buying.

The trouble concentrates in one system: fuel system issues account for 46% of all reports (165 of 357), far ahead of electrical system at 62.

357

NHTSA complaints

6

Recalls

12

Investigations

12

Crash-involved

52

Fires reported

8

Injuries

0

Deaths

—

NCAP overall

How does 1991 compare to other F-150 years?

F-150 NHTSA complaints by model year, 1991 highlighted3,920 complaints1955: 1 complaints1966: 1 complaints1968: 1 complaints1973: 0 complaints1975: 1 complaints1976: 0 complaints1977: 3 complaints1978: 13 complaints1979: 2 complaints1980: 3 complaints1981: 2 complaints1982: 5 complaints1983: 12 complaints1984: 16 complaints1985: 45 complaints1986: 78 complaints1987: 109 complaints1988: 170 complaints1989: 260 complaints1990: 315 complaints1991: 357 complaints1992: 553 complaints1993: 753 complaints1994: 908 complaints1995: 788 complaints1996: 383 complaints1997: 3,285 complaints1998: 1,624 complaints1999: 1,323 complaints2000: 1,274 complaints2001: 1,451 complaints2002: 964 complaints2003: 523 complaints2004: 2,429 complaints2005: 1,364 complaints2006: 741 complaints2007: 623 complaints2008: 455 complaints2009: 397 complaints2010: 1,134 complaints2011: 2,962 complaints2012: 2,431 complaints2013: 3,920 complaints2014: 1,898 complaints2015: 2,129 complaints2016: 2,500 complaints2017: 1,735 complaints2018: 2,758 complaints2019: 1,635 complaints2020: 850 complaints2021: 1,233 complaints2022: 768 complaints2023: 558 complaints2024: 237 complaints2025: 161 complaints2026: 1 complaints
F-150 NHTSA complaints by model year, 1991 highlighted. Red bars are years to avoid.

See all F-150 years to avoid →

What are the most common 1991 Ford F-150 problems?

ComponentComplaintsShare
Fuel System16546%
Electrical System6217%
Brakes288%
Engine195%
Tires & Wheels154%
Transmission144%
Speed Control113%
Body & Structure93%
Other72%
Steering72%
Seats62%
Airbags41%
Suspension41%
Seat Belts31%
Visibility & Wipers21%
Latches & Locks10%

Does the 1991 Ford F-150 have recalls?

6 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

01I008000Fuel SystemJuly 19, 2001 · 1,556,221 units

Defect

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 FROM ONE TANK AND SOME OR ALL OF THE UNUSED FUEL MAY BE RETURNED TO THE OTHER TANK.

Consequence

SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.

Remedy

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 OVERAGE WILL LAST UNTIL DECEMBER 31, 2001. IF THE VEHICLE IS EXPERIENCING A FUEL CROSS-FLOW CONDITION, DEALERS WILL REPAIR THE CONDITION FREE OF CHARGE.

01X001000Tires & WheelsMay 22, 2001 · 13,000,000 units

Defect

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 PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.

Consequence

SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

Remedy

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.

00T005000Tires & WheelsAugust 21, 2000 · 14,400,000 units

Defect

TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE TIRE TREAD.

Consequence

IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE ASSISTANCE.

96V071000Electrical SystemApril 25, 1996 · 7,900,000 units

Defect

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence

THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy

DEALERS WILL REPLACE THE IGNITION SWITCH.

93V125000Fuel SystemAugust 2, 1993 · 1,131,000 units

Defect

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.

Consequence

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.

93V066000SteeringApril 27, 1993 · 2,419 units

Defect

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.

Consequence

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“CAUGHT FIRE UNDER THE TRUCK BECAUSE OF FUEL LEAKAGE IN THE GAS TANK. *AK CONSUMER STATES FUEL CAME OUT OF THE FILL SPOT ON THE TRUCK AND CAUGHT FIRE. *SLC”

Complaint filed with NHTSA · Fuel System · August 2, 1996 · fire

“THE CONSUMER EXPERIENCED PROBLEMS WITH ALTERNATOR. WHILE THEY WERE DRIVING, THEY STARTED SMELLING SMOKE. IN ADDITION, STARTED NOTICING SMOKE COMING FROM THE HOOD. WHEN THEY PULLED OVER AND LIFTED THE HOOD THEY NOTICED THAT THE ALTERNATOR WAS ON FIRE. THE FIRE DEPARTMENT CAME AFTER THE FIRE DIED OUT…”

Complaint filed with NHTSA · Electrical System · fire

“DT: THE CONTACT OWNED A 1991 FORD F150. HE STATED THAT THE ABS BRAKES MALFUNCTIONED. NEEDED TO REPLACE THE ABS SENSOR IN THE DIFFERENTIAL UNIT AND THE ABS MODULE CONTROL. THE TOTAL COST TO REPAIR THEM WAS MORE THAN $1200.00. THE FORD MECHANIC TOLD CONTACT THAT THIS WAS A KNOWN PROBLEM FOR THE ABS…”

Complaint filed with NHTSA · Brakes · June 1, 2005

“AFTER PARKING THE TRUCK, TURNING OFF THE IGNITION, AND WALKING AWAY, SOME SOUNDS WERE HEARD COMING FROM THE VEHICLE. UPON LOOKING BACK, SMOKE WAS OBSERVED COMING FROM THE HOOD AREA. WHEN THE HOOD WAS OPENED, FIRE ERUPTED. IT IS NOT KNOWN IF THE FIRE WAS CAUSED BY FUEL OR ELECTRICAL FAILURE. RESULT…”

Complaint filed with NHTSA · Engine · August 27, 1999 · fire

“PE00020; TIRE TREAD SEPARATION: THREE TIRES ARE SHOWING SIGNS OF TREAD SEPARATION.TIRES HAVE A HAIRLINE CRACK 1/4 INCH BELOW THE TREAD, ALL THE WAY AROUND THE TIRE. ORIGINAL TIRE EQUIPMENT ON A 1991, FORD, F150. TIRE MILEAGE ABOUT 34,000, DOT # VNHL. *AK THE TIRES WERE FIRSTONE FR480,M & S,…”

Complaint filed with NHTSA · Tires & Wheels

1991 Ford F-150 — common questions

Is the 1991 Ford F-150 reliable?

Its record is better than the model's norm: 357 NHTSA complaints, below the typical F-150 year, with 6 recalls and no open investigations.

What are the most common 1991 F-150 problems?

According to NHTSA complaint data, the leading problem areas are fuel system (165 complaints), electrical system (62 complaints), brakes (28 complaints).

Does the 1991 Ford F-150 have recalls?

Yes — NHTSA lists 6 recall campaigns affecting the 1991 Ford F-150. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1991 Ford F-150 under NHTSA investigation?

NHTSA opened 12 investigations into this model year; all are now closed.

Which Ford F-150 years should you avoid?

Based on complaint rates and open investigations, the F-150 years to avoid are 2013, 1997, 2011, 2018, 2016, 2012, 2004, 2015, 2014, 2017, 2019, 1998, 2001, 2005, 1999, 2000, 2021, 2010, 2002, 1994, 2020. The cleanest record among F-150 years belongs to 1976.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.