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1991 Ford Ranger Recalls, Problems & Maintenance

The 1991 Ford Ranger has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Corroded front spring mounts and shock towers.” 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 Ranger.

Reported to NHTSA

Corroded front spring mounts and shock towers

SUSPENSION

14 NHTSA complaints · 1997-06 → 2011-06

“FRONT PASSENGER SIDE SHOCK TOWER CORRODED AND RUSTED OUT , EVENTUALLY CAUSING IT TO BREAK, AND CAUSING FRONT END TO FALL DOWN. *AK”
— Owner report, NHTSA ODI #865119
“RIGHT FRONT SPRING BRACKET RUSTED THROUGH ALLOWING BODY TO DROP ONTO FRONT TIRE, AND I NOTICED THERE ARE A LOT OF COMPLAINTS ON THIS ISSUE AND WAS WANTING TO KNOW IS FORD GOING TO FIX THIS PROBLEM OR ARE WE THE PUBLIC GOING TO GET STUCK WITH THIS PROBLEM ? *JB”
— Owner report, NHTSA ODI #10021440
“STRUCTURE: DRIVING AT APPROXIMATELY 45MPH AND THE BRACKET ON FRAME THAT HOLDS THE SHOCKS AND SPRINGS IN PLACE RUSTED THROUGH AND BROKE, VEHICLE IS ONLY HELD UP BY THE SPRINGS”
— Owner report, NHTSA ODI #812690

Read all complaints on NHTSA →

Side mirrors folding in or not holding position

VISIBILITY

12 NHTSA complaints · 1995-10 → 2004-10

“BOTH OUTSIDE MIRRORS FAILED FOR 3RD TIME. THEY FOLD IN WHILE DRIVING, AND CONSUMER IS UNABLE TO SEE TRAFFIC. *AK”
— Owner report, NHTSA ODI #880566
“THE SIDE MIRRORS ON THE TRUCK WILL FOLD IN AT HIGHWAY SPEEDS. THE PROBLEM STARTED AFTER I HAD THE TRUCK A YEAR OR SO AND HAS GOTTEN PROGRESSIVELY WORSE. I HAVE TALKED TO SEVERAL OWNERS OF RANGERS WITH THIS STYLE OF MIRROR, AND THEY ALL REPORT THE SAME PROBLEM”
— Owner report, NHTSA ODI #711120
“EXTERIOR MIRRORS PUSHED FORWARD BY WIND WHEN TRAVELING AT 60 MPH OR MORE, REDUCING VISIBILITY. *DH”
— Owner report, NHTSA ODI #506097

Read all complaints on NHTSA →

Tire tread separation

TIRES

11 NHTSA complaints · 2000-08 → 2002-12

“REAR TIRE HAD MAJOR TREAD SEPARATION WHILE DRIVE AT ABOUT THIRTY MILES PER HOUR. *AK( DOT NUMBER: )”
— Owner report, NHTSA ODI #726489
“WHILE DRIVING VEHICLE 70MPH, FELT THE FRONT STARTING TO VIBRATE. HAD PULLED OVER AND CHECKED TIRES. THE RIGHT FRONT TIRE HAD A LARGE BUBBLE. THE TREAD WAS STARTING TO SEPARATE. WENT TO AN INDEPENDENT TIRE DEALER AND THE SPARE TIRE REPLACED THE BLOWN TIRE. NOT ORIGINAL TIRES”
— Owner report, NHTSA ODI #8021914
“THE TIRE FAILED AS MY WIFE APPROACHED THE OFF RAMP TO OUR HOUSE OFF THE FREEWAY. THE TIRE WAS QUITE DESTROYED AND THE ONE ON THE OTHER SIDE WAS ALSO UNSAFE(ALTHOUGH THE TREAD LOOKED GOOD), BOTH WERE REPLACED AND I NO LONGER HAVE THE GOOD TIRE I DO HAVE THE DESTROYED TIRE”
— Owner report, NHTSA ODI #728057

Read all complaints on NHTSA →

Cracked firewall at clutch master cylinder

STRUCTURE

5 NHTSA complaints · 1999-02 → 2002-05

“FIREWALL SEPARATING AND CRACKING AT CLUTCH MASTER CYLINDER. *AK”
— Owner report, NHTSA ODI #762363
“VEHICLE HAS A CRACK IN FIREWALL WHICH CAUSES PROBLEMS WHEN SHIFTING GEARS. DEALER NOT AWARE OF PROBLEM. PROBLEM STILL EXISTS. PROVIDE FURTHER INFORMATION. *AK”
— Owner report, NHTSA ODI #836584
“CLUTCH CYLINDER LOCATED AT THE BASE OF FIREWALL BROKE THROUGH THE FIREWALL, CAUSING THE GEAR TO BECOME STUCK. WILL NOT MOVE OUT OF GEAR. THIS CAN RESULT IN AN ACCIDENT”
— Owner report, NHTSA ODI #834663

Read all complaints on NHTSA →

Brake line and hydraulic component failures

SERVICE BRAKES, HYDRAULIC

4 NHTSA complaints · 1995-11 → 2001-07

“CONSUMER STATES HE WAS UNABLE TO STOP VEHICLE BECAUSE OF A HIGHLY CORRODED RUPTURED BRAKE LINE, VEHICLE REAR ENDED ANOTHER VEHICLE AND CONSUMERS VEHICLE WAS DEEMED TOTALED, CONSUMER IS SEEKING REIMBURSEMENT FROM MANUFACTURER FOR THE REPAIRS OF THE BRAKES.*YH”
— Owner report, NHTSA ODI #562154
“BRAKE LINE WAS CORRODED, AND WHEN PRESSURE WAS APPLIED, IT BLEWOUT BRAKE LINE. AN ACCIDENT OCCURRED BECAUSE OF THIS PROBLEM. *AK *JB”
— Owner report, NHTSA ODI #886462
“WHILE DRIVING THE PARKING BRAKE CABLE RUBBED AGAINST BRAKE LINE, CAUSING OWNER TO LOSE BRAKE FLUID, AND TOTAL LOSS OF BRAKE POWER. *AK”
— Owner report, NHTSA ODI #824628

Read all complaints on NHTSA →

Vehicle fires linked to ignition switch and wiring

ELECTRICAL SYSTEM

17 NHTSA complaints · 1995-03 → 2012-07

“WHILE PARKED THE VEHICLE CAUGHT ON FIRE. THE STATE FIRE MARSHAL PERFORMED A DETAILED INVESTIGATION AND DETERMINED THAT THE CAUSE OF THE FIRE WAS FROM THE IGNITION SWITCH. THE DEALER HAS NOT BEEN NOTIFIED. OWNER WILL CONTACT THE MANUFACTURER. *AK”
— Owner report, NHTSA ODI #819488
“DRIVING FROM WORK, STARTED & WARMED UP ENGINE, SMELLED SOMETHING, TURNED ON INTERIOR LITE, NOTICED SMOKE FROM DASHBOARD, AMBER GLOWED AT FEET AREA, PULLED OVER, FLAMES ENGULFED TRUCK; VEHICLE TOTALED. *AK”
— Owner report, NHTSA ODI #805813
“VEHICLE PARKED. INFORMED VEHICLE ON FIRE. POPPED HOOD & NOTICED FLAMES COMING FROM ALTERNATOR AREA. PUT FLAMES OUT 3 TIMES. NOTICED THE WIRE CONNECTOR HAD CAUSED THE ALTERNATOR TO CATCH ON FIRE. *AK”
— Owner report, NHTSA ODI #845769

Read all complaints on NHTSA →

Throttle sticking and unintended acceleration

VEHICLE SPEED CONTROL

4 NHTSA complaints · 1999-04 → 2001-02

“AT HIGHWAY SPEED THROTLE STUCK AT FULL.SCARED THE SH__! OUT OF ME . WAS GOING OVER 90 MPH BEFORE GETTING IT PULLED OVER. HELP !*AK”
— Owner report, NHTSA ODI #740540
“I NOTICED I DID NOT HAVE PASSING GEAR SO I DEPRESSED THE ACCELERATOR AND COULD NOT STOP THE VEHICLE”
— Owner report, NHTSA ODI #730985
“RQ97015, WHILE IN PARK POSITION AND IN A SLIGHT INCLINE THE VEHICLE HAD A NOISE AND SUDDENLY ACCELERATED UNEXPECTEDLY, CAUSED AN ACCIDENT. PLEASE PROVIDE FURTHER INFORMATION AND VIN#. *AK”
— Owner report, NHTSA ODI #836822

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)

723 crashes 1990–2024

How the 723 occupant deaths break down

575

driver deaths

147

passenger deaths

1

not recorded by seat

723

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.

9

complaints mentioning a crash

23

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 Ranger 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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