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1991 Ford F-250 Recalls, Problems & Maintenance

The 1991 Ford F-250 has no open NHTSA recalls. Owners report 5 recurring issue clusters, led by “Tire tread separation.” 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-250.

Reported to NHTSA

Tire tread separation

TIRES

9 NHTSA complaints · 2000-10 → 2015-06

“WHILE DRIVING, CONSUMER HEARD A LOUD NOISE AND PULLED OFF TO SIDE OF ROAD, FOUND FRONT REAR FIRESTONE TIRE HAD EXPERIENCED TREAD SEPARATIONH, TIRE SIZE P235/85R16, DOT VN0RTWT241. *SLC”
— Owner report, NHTSA ODI #880582
“CONSUMER WAS TRAVELING 58-59MPH AND PASSENGER'S REAR TIRE TREAD SEPARATED. ONLY WARNING WAS THAT VEHICLE SWAYED FORM SIDE TO SIDE. TREAD WAS HITTING REAR OF WHEEL WELL AND RUNNING WELL. VEHICLE HAD OVER $2407.00 WORTH OF DAMAGE. TIRE SIZE P265/75R16, APRROXIMATELY 3500,”
— Owner report, NHTSA ODI #888588
“RIGHT REAR TIRE SEPARATED THEN BLEW, THROWING THE TIRE CAP AROUND ,DAMAGING FENDER, SHOCK, MUFFLER AND WHEEL WELL SUPPORTS AS WELL AS OUR NERVES TRYING TO MAINTAIN CONTROL.*AK (DOT NUMBER: ? TIRESIZE: 255/85R16)”
— Owner report, NHTSA ODI #739728

Read all complaints on NHTSA →

Frame rust, floorboard cracks and seat weld failure

STRUCTURE

6 NHTSA complaints · 1995-09 → 1996-11

“FAILURE ON THE FRAME OF THE VEHICLE, THE FRAME IS RUSTED BETWEEN THE CAB AND THE BED OF THE VEHICLE. *AK”
— Owner report, NHTSA ODI #803530
“THE FLOOR BOARD THAT HOLDS THE SEAT AND BOLT ARE CRACKING . TT”
— Owner report, NHTSA ODI #972373
“DRIVER'S BUCK SEAT WELD CROSS RAIL BRACKET DEVELOPED STRESS CRACKS AND SEPERATED FROM THE FLOOR. *AK”
— Owner report, NHTSA ODI #801517

Read all complaints on NHTSA →

Fuel transfer between tanks and fuel leakage

FUEL SYSTEM, GASOLINE

28 NHTSA complaints · 1995-01 → 2020-01

“TL* THE CONTACT OWNS A 1991 FORD F-250. THE CONTACT STATED THAT AFTER REFUELING THE VEHICLE, GASOLINE WOULD OVERFLOW FROM THE REAR FUEL TANK INTO THE FRONT FUEL TANK, CAUSING SPILLAGE. THE CONTACT BELIEVED THAT THE FUEL PUMP WAS DEFECTIVE. THE VEHICLE WAS TAKEN TO THE DEALER WHO”
— Owner report, NHTSA ODI #10418150
“EA 99032 FUEL TANK IS OVERFLOWING REGARDLESS OF WHICH TANK IS ON. FUEL IS STILL BEING USED BY BOTH TANKS. *AK REAR TANK OVERFLOWED WHILE VEHICLE WAS PARKED IN DRIVEWAY.. *SLC”
— Owner report, NHTSA ODI #880255
“MALFUNCTIONING OF FUEL SWITCHING SYSTEM, CAUSING FUEL SPILLAGE, RESULTING IN A FIRE PRIOR TO/AFTER RECALL REPAIRS (93V-125). *AK”
— Owner report, NHTSA ODI #965901

Read all complaints on NHTSA →

Brake pedal loss, overheating and caliper wear

SERVICE BRAKES, HYDRAULIC

23 NHTSA complaints · 1995-03 → 2002-04

“WHEN DRIVING 25 MPH AND UPON ATTEMPTING TO STOP VEHICLE BY DEPRESSING BRAKE PEDAL , BRAKE PEDAL WENT TO THE FLOORBOARD, CAUSING EXTENDED STOPPING DISTANCE, WHICH RESULTED IN A REAR END CRASH. CONSUMER CONTACTED DEALER, DEALER NOTED THAT MASTER CYLINDER FAILED WHICH CAUSED THE”
— Owner report, NHTSA ODI #872290
“BRAKES OVERHEAT CAUSING CALIPERS TO BURN”
— Owner report, NHTSA ODI #531891
“THE BRAKE FLUID IS OVERHEATING, CAUSING INCREASED STOPPING DISTANCE AND INABLITITY TO STOP THE VEHICLE. RECALL #92S44. *AK BRAKES HAVE FADED FOUR TIMES FAILURE OCCURED WITHOUT WARNING, REPLACED FRONT PADS THREE TIMES, REPLACED ROTORS ONCE, CURRENTLY ROTORS APPEAR TO WARPED.*JB”
— Owner report, NHTSA ODI #984084

Read all complaints on NHTSA →

Ignition and headlight switch failure, burning

ELECTRICAL SYSTEM

14 NHTSA complaints · 1996-04 → 2005-02

“IGNITION SWITCH FAILED, CAUSING LOSS OF POWER, WINDSHIELD WIPER, HEADLIGHT, BATTERY, AND TURN SIGNAL FAILURE”
— Owner report, NHTSA ODI #514862
“WHILE DRIVING AT NIGHT THROUGH MOUNTAINS ALL LIGHTS WENT OUT, AND CAR WAS FILLED WITH FUMES THAT MADE CONSUMER'S EYES WATER. IT SMELLED LIKE PLASTIC WIRES BURNING. VEHICLE WAS STILL DRIVEABLE AS CONSUMER PLAYED WITH SWITCH, AND THEN THEY CAME BACK ON. THE SMELL GOT SO BAD THAT”
— Owner report, NHTSA ODI #861040
“HEADLIGHT SWITCH INTERMITTENTLY WORKS, THEN WOULD DROP OUT AND LEAVE DRIVER IN DARK. DEALER CONTACTED AND CANNOT REMEDY PROBLEM. RESULTS IN MELTING PLUG THAT CONNECTS TO SWITCH. PROBLEM STILL EXISTS. PROVIDE FURTHER INFORMATION. *AK”
— Owner report, NHTSA ODI #843523

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.

5

complaints mentioning a crash

9

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-250 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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