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1991 Ford F-150 Recalls, Problems & Maintenance

The 1991 Ford F-150 has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Dual fuel tank crossflow and overflow.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 1991 Ford F-150.

Reported to NHTSA

Dual fuel tank crossflow and overflow

FUEL SYSTEM, GASOLINE

88 NHTSA complaints · 1997-02 → 2025-04

“THE VEHICLE WAS EQUIPPED WITH A DUAL FUEL TANK. THE CONTACT OBSERVED FUEL LEAKAGE IN THE SECOND FUEL TANK SPILLING FUEL INTO THE FIRST FUEL TANK AND CAUSING AN EXCESSIVE OVERFLOW”
— Owner report, NHTSA ODI #10320094
“WHILE DRIVING THE FRONT TANK EMPTIED INTO THE REAR TANK WITHOUT WARNING AND CAUSED THE FUEL TO LEAK OUT”
— Owner report, NHTSA ODI #10039925
“A MALFUNCTIONING CHECK VALVE ALLOWS FUEL FROM ONE TANK TO TRANSFER FUEL TO SECOND TANK, RESUTLING IN FUEL LEAKAGE”
— Owner report, NHTSA ODI #881233

Read all complaints on NHTSA →

Fuel tank, seam and fuel line leaks

FUEL SYSTEM, GASOLINE

21 NHTSA complaints · 1997-02 → 2011-05

“THE FUEL TANK STRAPS ON MY 1991 FORD F-150 HAVE RUSTED AND CAUSED MY FUEL TANKS TO LEAK GASOLINE”
— Owner report, NHTSA ODI #10399869
“FUEL LINE BETWEEN TANK AND ENGINE RUPTURED”
— Owner report, NHTSA ODI #752601
“THE REAR FUEL TANK LEAKS AT THE SEAM WHEN THE TANK IS HALF FULL OR MORE”
— Owner report, NHTSA ODI #855084

Read all complaints on NHTSA →

Tire tread separation

TIRES

14 NHTSA complaints · 2000-01 → 2007-06

“I WAS DRIVING WEST ON I-40 NEAR LUDLOW, CALIFORNIA, WHEN THE RIGHT REAR TIRE TREAD SEPARATED”
— Owner report, NHTSA ODI #730509
“WHILE DRIVING THE LEFT REAR TIRE TREAD SEPARATED CAUSING IT TO SUDDENLY GO FLAT CAUSING DAMAGE TO THE REAR SIDE PANEL OF THE TRUCK AND WRAPPED AROUND THE AXLE”
— Owner report, NHTSA ODI #560087

Read all complaints on NHTSA →

ABS light and brake grab or lock-up

SERVICE BRAKES, HYDRAULIC

6 NHTSA complaints · 1997-11 → 2005-08

“ABS ANTI-LOCK BRAKE LIGHT STAYS ON AND BRAKES GRAB WHEN WET”
— Owner report, NHTSA ODI #744108
“WHEN DRIVING THE TRUCK IN DAMP OR COOL WHEATHER THE BRAKES GRAB AND THEY LOCK UP”
— Owner report, NHTSA ODI #819380

Read all complaints on NHTSA →

Exterior paint peeling

UNKNOWN OR OTHER

5 NHTSA complaints · 1997-06 → 2007-02

“THE PAINT ON THE FRONT HOOD HAS PEELED RIGHT DOWN TO THE METAL”
— Owner report, NHTSA ODI #10183798
“PAINT IS PEELING OFF THE EXTERIOR OF THE BODY”
— Owner report, NHTSA ODI #517632

Read all complaints on NHTSA →

Underhood and column electrical fires, ignition switch

ELECTRICAL SYSTEM

19 NHTSA complaints · 1997-02 → 2021-03

“DRIVING IN TOWN AT APPROXIMATELY 25 MPH WITHOUT WARNING SMOKE JUST STARTED COMING OUT FROM THE STEERING COLUMN”
— Owner report, NHTSA ODI #813826
“VEHICLE CAUGHT ON FIRE, AND BURNED HOOD, WIRE HARNESS AND ALTERNATOR, ETC”
— Owner report, NHTSA ODI #885600
“KEY GOT STUCK IN THE ON POSTION”
— Owner report, NHTSA ODI #872572

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

761 crashes 1990–2024

How the 761 occupant deaths break down

591

driver deaths

170

passenger deaths

761

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 1991 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

12

complaints mentioning a crash

42

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 1991 Ford F-150 reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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