VehicleVerdict

1991 Ford F-150 fuel system problems

The 1991 Ford F-150 has 165 fuel system complaints filed with NHTSA — 46% of the year's total, and roughly flat versus the prior model year.

165

Fuel System complaints

46%

Share of year

0

Crash-involved

2

Related recalls

Fuel System complaints by year

Related recalls

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.

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.

What owners report

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

Common questions

How many fuel system complaints does the 1991 Ford F-150 have?

NHTSA has 165 complaints about the 1991 Ford F-150 fuel system — 46% of all complaints filed for that model year.

Are there recalls for the 1991 Ford F-150 fuel system?

Yes — 2 NHTSA recall campaigns for this model year are tied to the fuel system: 01I008000, 93V125000.

Related

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

Compiled by Sharon Ben-Moshe, Founder.