1991 Ford F-250 Sd recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-20. Recalls apply to specific VINs — run your VIN to confirm.
7 safety recalls, most serious first
1. Wheels / tires
What's wrong, in plain English: A wheel or tire can fail while driving. 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…
What could happen: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.
The fix: 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.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 01X001000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-877-917-3673.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: TIRES:TREAD/BELT
Summary: 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.
Notes:
2. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. THE STEEL FUEL RETURN TUBES THAT CONNECT THE FRAME FUEL RETURN LINES WITH THE ENGINE FUEL RAIL CAN CONTACT THE PINCH WELD FLANGE CONNECTING THE DASH PANEL TO THE FLOOR PAN. CONTINUED CONTACT LEADS TO ABRASION OF THE STEEL FUEL RETURN TUBE AND EVENTUALLY RESULTS IN A FUEL LEAK.
What could happen: ABRASION OF THE STEEL TUBE WALL THAT EVENTUALLY CAUSES A FUEL LEAK MAY RESULT IN A FIRE, IF A SOURCE OF IGNITION IS PRESENT.
The fix: FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 94V040000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
Summary: THE STEEL FUEL RETURN TUBES THAT CONNECT THE FRAME FUEL RETURN LINES WITH THE ENGINE FUEL RAIL CAN CONTACT THE PINCH WELD FLANGE CONNECTING THE DASH PANEL TO THE FLOOR PAN. CONTINUED CONTACT LEADS TO ABRASION OF THE STEEL FUEL RETURN TUBE AND EVENTUALLY RESULTS IN A FUEL LEAK.
Consequence: ABRASION OF THE STEEL TUBE WALL THAT EVENTUALLY CAUSES A FUEL LEAK MAY RESULT IN A FIRE, IF A SOURCE OF IGNITION IS PRESENT.
Remedy: FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.
Notes: SYSTEM: FUEL; FUEL LINES; METALLIC. VEHICLE DESCRIPTION: LIGHT DUTY AND SUPER DUTY PICKUP TRUCKS AND CHASSIS OVER 8,500 LBS. GROSS VEHICLE WEIGHT RATING EQUIPPED WITH 7.5L ENGINES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT FORD SERVICE CENTER AT 1-800-392-3673. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
3. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: SPILLED FUEL CAN RESULT IN A FIRE WHEN EXPOSED TO ASOURCE OF IGNITION.
The fix: REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 93V125000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
Summary: 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.
Notes: SYSTEM: FUEL; FUEL TANK ASSEMBLY.VEHICLE DESCRIPTION: LIGHT TRUCKS AND CHASSIS CABS WITH GASOLINE ENGINES ANDDUAL FUEL TANKS.NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED SERVICEDATE AND THE REMEDY IS NOT CORRECTED WITHIN A REASONABLE TIME WITHOUT CHARGEOR THE REMEDY DOES NOT CORRECT THE SAFETY-RELATED DEFECT OR NONCOMPLIANCE,PLEASE CONTACT FORD'S CUSTOMER ASSISTANCE CENTER, 300 RENAISSANCE CENTER,P.O. BOX 43360, DETROIT, MI 48243. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFICSAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
4. Electrical system
What's wrong, in plain English: Wiring, modules, batteries. Short circuits can cause stalls or fires. THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
What could happen: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
The fix: DEALERS WILL REPLACE THE IGNITION SWITCH.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 96V071000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: ELECTRICAL SYSTEM:IGNITION
Summary: 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.
Notes: SYSTEM: ELECTRICAL; IGNITION SWITCH. VEHICLE DESCRIPTION: PASSENGER AND MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
5. Steering
What's wrong, in plain English: If steering fails you can lose control of the car. 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.
What could happen: THE LODGED KEYS CAN CAUSE LOSS OF STEERING CONTROL, WHICHCAN RESULT IN AN ACCIDENT WHEN THE VEHICLE IS BEING USED ON THE HIGHWAY.
The fix: A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN PLACE BY THE STEERING LOCK BAND.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 93V066000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: STEERING: STEERING WHEEL/HANDLE BAR
Summary: 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.
Notes: SYSTEM: STEERING.VEHICLE DESCRIPTION: FORD TRUCKS ADAPTED FOR USE ON RAILROAD TRACKS AND AS OVERTHE ROAD VEHICLES.
6. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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 FRO…
What could happen: SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.
The fix: 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…
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 01I008000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE
Summary: 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.
Notes: FORD HAS DECIDED TO CONDUCT AN EXTENDED COVERAGE PROGRAM TO EXTEND THE WARRANTY COVERAGE FOR POTENTIAL FUEL CROSS FLOW PROBLEMS. OWNERS CAN CONTACT FORD AT 1-866-436-7332, CONCERNING THIS PROGRAM.
7. Brakes
What's wrong, in plain English: Anything that slows the car down. Treat brake recalls as urgent. A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.
What could happen: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.
The fix: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 F-250 SD.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 92V026000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS
Summary: A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.
Consequence: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.
Remedy: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.
Notes: SYSTEM: BRAKES; FRONT BRAKE LINING.VEHICLE DESCRIPTION: F250 AND F350 TRUCKS WITH 7.3 L DIESEL AND 7.5 L EFIENGINES ; F250 AND F350 4X4 MODELS WITH 5.8 L EFI ENGINES.NOTE: FORD RECOMMENDS VEHICLE OPERATORS DO NOT EXCEED THE GCWR AND GVWR OF THEIRVEHICLES, AND PROPER MAINTENANCE OF THE BRAKES ON THESE VEHICLES AND ANY TRAILERPARTICULARLY WHEN OPERATING IN MOUNTAINOUS AREAS WITH LONG, STEEP GRADES.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- Portable jump starter
- Digital tire pressure gauge
- 1991 Ford F-250 Sd owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Wheels / tires (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (1)
06/18/2015 · Wheels / tires
FORTUNATELY THE TIRE CAME APART WHILE LYING IN THE BACK OF MY PICK UP TRUCK. I WAS USING IT AS A WINTER TIME SPARE. THE TIRE WAS NOT IN USE AT THE TIME OF THE SEPARATION OF THE TIRE LAYERS. I HAVE 2 OF THEM AND ARE THE ONES I USE FOR SUMMER TIME DRIVING. TREAD IS ABOUT 50%. THE TIRE BURST FROM THE INSIDE OF THE TIRE RIPPING AWAY THE TREAD AND LEAVING T…