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.
1991 Ford F-350 Recalls
Recalls on record Updated July 2026
The 1991 Ford F-350 has 5 NHTSA recall campaigns affecting an estimated 9,590,189 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 34 complaints with NHTSA, most often about the service brakes, hydraulic. Last updated July 5, 2026.
Recall campaigns
Defect
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.
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.
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.
Defect
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.
Complaints by component
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
1crashes1fires
TIRES
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
1fires
FUEL SYSTEM, GASOLINE
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
1crashes
ELECTRICAL SYSTEM:IGNITION
1fires
ENGINE AND ENGINE COOLING:ENGINE
1fires
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
Total complaints34
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“About august 2012 I was informed by pettis tires, cordele, ga. That the two tires I had bought from them had been recalled. For approx. One year we traded phone calls and no progress was made. I called bf goodrich customer service and was told to go to sears auto in albany, ga. That lasted about…”
“Tl* the contact owns a 1991 ford f-350. The contact stated that while driving approximately 35 mph, the vehicle stalled. The vehicle would not restart and was towed where the contact examined the vehicle and noticed one of the dual fuel tanks was full and one was empty. The manufacturer was…”
“Dt: consumers states the brakes fade. Consumer steps on them and they go down to the floor slowly. It doesn't do any good to pump the brakes, it is almost impossible to have vehicle stop coming down a hill.*ak”
“The vehicle caught on fire due to malfunction of alternator in the engine compartment.*jb *ts”
“The vehicle caught on fire due to malfunction of alternator in the engine compartment.*jb *ts”
“Vehicle has two fuel tanks, and one of the tank has a damaged check valve. Front tank fills up rear tank, and will leak gasoline outside of vehicle.*ak”
“Belt separation (dot number: vdor1wt410 tiresize: 235/85r16)”
“Pe00-040; firestone, steel tex, r4s 23585r16lt original equipment with f350 van ford, 1991. Front driver's firestone steeltex r4s (p235 85 r16) tire exploded and shreaded into pieces. *ak there was damage to the vehicle because of the tire failure, all 4 tires and spare tire started to develop…”
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 EA93001 Opened 1993-01-07 · closed 1993-08-20
FUEL EXPULSION
There is no summary currently available
Investigation EA93014 Opened 1993-06-04 · closed 1994-07-29
ALTERNATOR BELT FAILURE
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 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 PE94004 Opened 1994-01-25 · closed 1994-04-29
HYDRAULIC BRAKE LINE CRACKS/LEAKS
There is no summary currently available
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-350 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.