VehicleVerdict

1991 Ford Thunderbird problems

Verdict · NHTSA data

One of the years to avoid

With 130 complaints filed to NHTSA — about 32.5 times the median Thunderbird year — the 1991 model ranks #9 of 37 Thunderbird years for complaint volume. It lands on the years-to-avoid list.

No single system dominates the record — complaints spread across brakes (20), seat belts (17), and electrical system (15), which usually points to general build quality rather than one defect.

130

NHTSA complaints

4

Recalls

2

Investigations

7

Crash-involved

14

Fires reported

5

Injuries

0

Deaths

—

NCAP overall

How does 1991 compare to other Thunderbird years?

Thunderbird NHTSA complaints by model year, 1991 highlighted559 complaints1960: 1 complaints1965: 1 complaints1967: 0 complaints1970: 1 complaints1971: 0 complaints1972: 0 complaints1973: 0 complaints1974: 0 complaints1975: 0 complaints1976: 0 complaints1977: 1 complaints1978: 1 complaints1979: 1 complaints1980: 3 complaints1981: 0 complaints1982: 0 complaints1983: 4 complaints1984: 33 complaints1985: 16 complaints1986: 32 complaints1987: 73 complaints1988: 116 complaints1989: 147 complaints1990: 179 complaints1991: 130 complaints1992: 234 complaints1993: 559 complaints1994: 426 complaints1995: 353 complaints1996: 295 complaints1997: 228 complaints1998: 4 complaints1999: 2 complaints2002: 116 complaints2003: 50 complaints2004: 40 complaints2005: 35 complaints
Thunderbird NHTSA complaints by model year, 1991 highlighted. Red bars are years to avoid.

See all Thunderbird years to avoid →

What are the most common 1991 Ford Thunderbird problems?

ComponentComplaintsShare
Brakes2015%
Seat Belts1713%
Engine1512%
Electrical System1512%
Speed Control108%
Fuel System108%
Lighting108%
Visibility & Wipers86%
Climate Control (A/C & Heat)65%
Tires & Wheels43%
Steering43%
Transmission43%
Suspension32%
Body & Structure22%
Seats11%
Airbags11%

Does the 1991 Ford Thunderbird have recalls?

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

09E012000LightingApril 7, 2009 · 16,270 units

Defect

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.

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.

91V076000Visibility & WipersMay 6, 1991 · 125,000 units

Defect

THE NUTS WHICH HOLD WINDSHIELD WIPER MOTOR TO THE WIPER MODULE MAY NOT HAVE BEEN SUFFICIENTLY TIGHTENED AND MAY LOOSEN OR COME OFF. THIS CAUSES CHANGED WIPER PATTERNS, OR THE WIPERS MAY JAM IF TWO OF THE THREE NUTS COME OFF.

Consequence

CHANGES IN THE WIPER PATTERN OR JAMMING OF THE WIPERSWOULD RESULT IN REDUCED DRIVER VISIBILTY IN INCLEMENT WEATHER CONDITIONS.

Remedy

APPLY TORQUE RETENTION MATERIAL TO WIPER MOTOR STUDS AND NUTS AND RETORQUE.

91V048000TransmissionMarch 18, 1991 · 6,800 units

Defect

THE PARK ROD ASSEMBLY CONTAINS A PARK CAM WITH INADEQUATE SURFACE HARDNESS, WHICH COULD LEAD TO PARK DISENGAGEMENT OR NO PARK ENGAGEMENT WHEN THE LEVER IS PLACED IN PARK.

Consequence

IF PARK IS NOT ENGAGED AND THE PARKING BRAKE IS OFF, AVEHICLE ROLL-AWAY COULD RESULT.

Remedy

REPLACE PARK ROD ASSEMBLY ON AUTOMATIC TRANSMISSIONS.

Consumer complaints filed with NHTSA

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

“I WAS ON MY WAY TO WORK WHEN THE TRUCK IN FRONT OF ME STOPPED IN FRONT OF ME TO LET A CAR IN OUR LANE. WE WERE GOING AROUND 15 MPH. WHEN I STEPPED ON THE BRAKE, I JUST KEPT ON GOING AND HIT THE TRUCK IN THE REAR. I PUT THE CAR IN PARK AND GOT OUT AND WENT OVER TO THE DRIVER OF THE TRUCK TO MAKE…”

Complaint filed with NHTSA · Brakes · August 21, 1999 · crash

“THE AUTOMATIC SHOULDER BELT ON THE PASSENGER'S SIDE GETS SUCKED IN THE MIDDLE OF THE RETRACTOR AND SOMETIMES THE BELT SHUDDERS IN THE MIDDLE OF THE TRACK BEFORE GOING IN THE OPEN OR CLOSE POSITION . VEHICLE HAS BEEN REPAIRED BY DEALER TWICE FOR THIS PROBLEM, SYSTEM NEEDS REPLACING AGAIN. *AK”

Complaint filed with NHTSA · Seat Belts

“WHILE ENTERING A PARKING LOT, NOTICED SMOKE COMING FROM STEERING COLUMN, NEAR IGNITION, PARKED VEHICLE, EVERYONE OUT OF VEHICLE; WENT TO MAKE PHONE CALL, VEHICLE WAS ENGULFED IN FLAMES; CALLED 911; SOMEONE WAS PUTTING FLAMES OUT BEFORE FIRE DEPT. ARRIVED. *AK”

Complaint filed with NHTSA · Electrical System · March 11, 1997 · fire

“3.8L V6 ENGINE OVER-HEATED DUE TO HEAD GASKET FAILURE IN #4 CYLINDER. BOTH HEADS WERE REWORKED AND GASKETS REPLACED. AFTER REPAIR ENGINE STARTED STALLING. IDLE AIR CONTROL VALVE WAS THEN REPLACED. NOW THERE IS A FLUCTUATION IN OIL PRESSURE. PRIOR TO HEAD GASKET FAILURE, POWER STEERING PUMP HAS TO…”

Complaint filed with NHTSA · Engine · June 2, 2004

“DRIVER TRAVELED TWO MILES, ,PARKED VEHICLE, SMOKE CAME FROM UNDERNEATH AND CAUGHT ON FIRE. FIRE DEPT. STATED GASOLINE LEAKAGE WAS THE CAUSE OF THE FIRE. *AK*JB”

Complaint filed with NHTSA · Fuel System · August 20, 1996 · fire

1991 Ford Thunderbird — common questions

Is the 1991 Ford Thunderbird reliable?

NHTSA data argues against it: 130 complaints put the 1991 model at #9 of 37 Thunderbird years. It is one of the Thunderbird years to avoid.

What are the most common 1991 Thunderbird problems?

According to NHTSA complaint data, the leading problem areas are brakes (20 complaints), seat belts (17 complaints), electrical system (15 complaints).

Does the 1991 Ford Thunderbird have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 1991 Ford Thunderbird. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1991 Ford Thunderbird under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Which Ford Thunderbird years should you avoid?

Based on complaint rates and open investigations, the Thunderbird years to avoid are 1993, 1994, 1995, 1996, 1992, 1997, 1990, 1989, 1991, 2002, 1988, 1987, 2003, 2004, 2005, 1984, 1986. The cleanest record among Thunderbird years belongs to 1982.

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.