RecallRepo

1991 Ford F-150 Recalls

Recalls on record Updated July 2026

The 1991 Ford F-150 has 3 NHTSA recall campaigns affecting an estimated 9,033,419 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 357 complaints with NHTSA, most often about the fuel system, gasoline. Last updated July 5, 2026.

Recall campaigns

ELECTRICAL SYSTEM 96V071000 1996-04-25 7,900,000 affected
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.

FUEL SYSTEM, GASOLINE 93V125000 1993-08-02 1,131,000 affected
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.

STEERING 93V066000 1993-04-27 2,419 affected
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.

Complaints by component

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
49
2fires1injuries
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES
42
ELECTRICAL SYSTEM:IGNITION:SWITCH
25
19fires
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK
21
FUEL SYSTEM, GASOLINE
20
2fires
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
13
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
13
1crashes
TIRES:TREAD/BELT
10
VEHICLE SPEED CONTROL
10
2crashes1injuries
ELECTRICAL SYSTEM:IGNITION
9
3fires
Total complaints357

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“The contact owns a 1991 ford f-150. The contact stated that while driving at an undisclosed speed, the rear fuel tank gauge began indicating that the rear tank was losing fuel abnormally fast. After a visual inspection, the contact observed that fuel was flowing from the rear fuel tank into the…”

FUEL SYSTEM, GASOLINE · reported 2025-04-07

“The truck wont crank. When the key is turned off and removed some electrical systems still work and cause smoking. I have had to disconnect the battery in fear the truck will burn down. Ford was contacted about the issue and said they cant do anything because their records for recalls only go 10…”

ELECTRICAL SYSTEM · reported 2021-03-18

“Fuel spilling out around neck while parked at work, also rear fuel tank pumping gas into front gas tank while driving.... *tr”

FUEL/PROPULSION SYSTEM · reported 2015-09-15

“While the engine is running, the dual tanks cross-flow into one another. One tank has over-filled the other tank and visa versa to include spillage. I have contacted the local dealer and ford about it but they say they can't do anything for me as far as a recall is concerned even though this issue…”

FUEL/PROPULSION SYSTEM · reported 2014-11-30

“Tl* the contact owns a 1991 ford f-150. The contact stated that a portion of the unused fuel from one tank was being returned to the second tank, causing a fuel spillage. The contact also stated that the fuel pressure was low. The contact was not diagnosed. The manufacture was made aware of the…”

FUEL/PROPULSION SYSTEM · reported 2014-04-02

“Tl* the contact owns a 1991 ford f-150. The contact stated that one of the tanks in the vehicle would not work and caused the vehicle to stall. The vehicle was taken to an independent mechanic, but could not be repaired. The details of the diagnostic test could not be provided. The vin was not…”

FUEL SYSTEM, GASOLINE · reported 2013-10-04

“Tl* the contact owns a 1991 ford f-150. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer who stated the fuel pump failed. The vehicle was repaired but the failure recurred. The manufacturer was contacted about the failure. The failure mileage was 145,000.…”

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP · reported 2013-05-28

“Tl* the contact owns a 1991 ford f-150. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer who stated the fuel pump failed. The vehicle was repaired but the failure recurred. The manufacturer was contacted about the failure. The failure mileage was 145,000.…”

ELECTRICAL SYSTEM:12V/24V/48V BATTERY · reported 2013-05-28

Defect investigations

Investigation EA91031 Opened 1991-06-26 · closed 1991-11-01

FUEL EXPULSION

There is no summary currently available

Investigation EA91044 Opened 1991-10-30 · closed 1992-10-30

LOSS OF BRAKE EFFECTIVENES

===

Investigation EA92029 Opened 1992-08-27 · closed 1993-10-29

FRONT SEAT BACK FAILURE

There is no summary currently available

Investigation EA93001 Opened 1993-01-07 · closed 1993-08-20

FUEL EXPULSION

There is no summary currently available

Investigation EA93022 Opened 1993-07-30 · closed 1994-08-31

IDLE AIR SPD CTRL VLV MALF

There is no summary currently available

Investigation EA99032 Opened 1999-11-04 · closed 2001-12-06

DUAL FUEL TANK CROSSFLOW/LEAKAGE

ON JULY 14, 1993 FORD FILED A DEFECT INFORMATION REPORT CONCERNING FUEL TANK CROSS FLOW LEAKAGE ON F-SERIES LIGHT TRUCKS AND CAB CHASSIS BUILT FROM JULY 22, 1989 THROUGH DECEMBER 17, 1992.THE REMEDY WAS TO REPLACE THE FUEL PRESSURE REGULATOR AND INSTALL A CHECK VALVE BETWEEN EACH FUEL SUPPLY LINE AND FUEL TANK (2) TO…

Investigation EA99032 Opened 1999-11-04 · closed 2001-12-06

DUAL FUEL TANK CROSSFLOW/LEAKAGE

ON JULY 14, 1993 FORD FILED A DEFECT INFORMATION REPORT CONCERNING FUEL TANK CROSS FLOW LEAKAGE ON F-SERIES LIGHT TRUCKS AND CAB CHASSIS BUILT FROM JULY 22, 1989 THROUGH DECEMBER 17, 1992.THE REMEDY WAS TO REPLACE THE FUEL PRESSURE REGULATOR AND INSTALL A CHECK VALVE BETWEEN EACH FUEL SUPPLY LINE AND FUEL TANK (2) TO…

Investigation PE91064 Opened 1991-04-09 · closed 1991-07-05

TRANSMISSION FLUID FIRES

There is no summary currently available

Investigation PE91077 Opened 1991-05-23 · closed 1991-10-31

LOSS OF BRAKE EFFECTIVENES

There is no summary currently available

Investigation PE92042 Opened 1992-04-17 · closed 1992-08-27

FNT RECLNING SEAT BCK FAIL

There is no summary currently available

Investigation PE92077 Opened 1992-09-09 · closed 1993-01-07

FUEL EXPULSION

There is no summary currently available

Investigation PE93010 Opened 1993-03-02 · closed 1993-07-30

IDLE AIR SPD CTRL VLV MALF

There is no summary currently available

Investigation RQ98008 Opened 1998-05-29 · closed 1999-11-04

FORD F-SERIES DUAL FUEL TANK LEAKAGE

THESE VEHICLES CAN EXPERIENCE FUEL TRANSFER FROM ONE TANK TO THE OTHER DUE TO A MALFUNCTIONING FUEL PUMP.FROM THE INFORMATION GATHERED TO DATE, IT APPEARS THAT THERE CAN BE MULTIPLE CAUSES AND/OR A COMBINATION OF CAUSES FOR FUEL CROSS FLOW AND THAT THE RECALL REMEDY MAY BE INADEQUATE.FURTHER INVESTIGATION IS…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Ford F-150 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.