1991 Ford F-250

Defect. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1990-1993 FORD F-SERIES VEHICLES EQUIPPED WITH DUAL FUEL TANKS AND 4.9, 5.0,5.8, OR 7.5 LITER GASOLINE FUELED ENGINES. SOME VEHICLES CAN EXPERIENCE A CROSS TANK FUEL FLOW CONDITION DUE TO A DAMAGED CHECK VALVE IN THE FUEL PUMP/SENDER ASSEMBLY. FUEL MAY BE SUPPLIED FROM ONE TANK AND SOME OR ALL OF THE UNUSED FUEL MAY BE RETURNED TO THE OTHER TANK.

Risk. SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.

Remedy. FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150,000 MILES FROM THE VEHICLE'S WARRANTY START DATE, WHICHEVER OCCURS FIRST. THIS COVER WILL AUTOMATICALLY TRANSFER TO SUBSEQUENT OWNERS AT NO CHARGE. IF A VEHICLE ALREADY HAS MORE THAN 150,000 MILES, THIS OVERAGE WILL LAST UNTIL DECEMBER 31, 2001. IF THE VEHICLE IS EXPERIENCING A FUEL CROSS-FLOW CONDITION, DEALERS WILL REPAIR THE CONDITION FREE OF CHARGE.

Defect. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.

Risk. SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

Remedy. THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.

Defect. THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Risk. THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy. DEALERS WILL REPLACE THE IGNITION SWITCH.

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.

Risk. 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.

Risk. 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.

Risk. 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.

Risk. 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.

FUEL LEAKED FROM HEATER WIRE IN FUEL FILTER. THE FUEL FOLLOWED THE WIRE UP THE COPPER CORE UNTIL IT REACHED A CRACK IN THE INSULATION ANY TIME THERE WAS FUEL PRESSURE, IE ENGINE RUNNING OR EVEN WITH BOOST PUMP PRESSURE WITH ENGINE OFF.

TL* THE CONTACT OWNS A 1991 FORD F-250. AFTER THE VEHICLE WAS PARKED, THE CONTACT NOTICED A STRONG FUEL ODOR FROM THE SIDE OF THE VEHICLE. THE CONTACT NOTICED FUEL POURING OUT OF THE OPENING OF THE TANK THAT SPILLED ONTO THE STREET AND UNDERNEATH ANOTHER VEHICLE. THE DEALER STATED THAT THE FUEL CHECK VALVE IN THE PUMP UNIT WAS DAMAGED, WHICH CAUSED THE FUEL TO TRAVEL FROM ONE TANK TO THE OTHER AND OVERFLOW. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT INFORMED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 137,000.

TL* THE CONTACT OWNS A 1991 FORD F-250. AFTER REFUELING THE VEHICLE, FUEL STARTED LEAKING FROM THE FUEL TANK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CONTACT WAS AWARE OF NHTSA CAMPAIGN NUMBER: 01I008000 (FUEL SYSTEM, GASOLINE) BUT THE VIN WAS NOT INCLUDED. THE FAILURE MILEAGE WAS 161,000. ..UPDATED 05/20/15 *BF THE CONSUMER HAS EXPERIENCED THE FUEL SWITCH OVER ISSUE AND WOULD LIKE TO BE ADDED TO THE RECALL. UPDATED 7/6/2015 *JS

I HAD JUST BEEN JUMPED BY AAA BECAUSE MY TRUCK WASN'T STARTING; THE AAA AGENT ALSO CLEANED THE BATTERY TERMINALS. I INTENDED TO HAVE IT TOWED TO THE FORD DEALER BECAUSE I DIDN'T THINK IT WOULD START. SINCE THE AAA AGENT WAS ABLE TO GET TO START, I DECIDED TO STILL TAKE IT TO THE DEALER TO FIND OUT WHY THE BATTERY WAS DEAD (GIVEN THEY HAD THE CAR FOR A MONTH AND HAD PUT IN A NEW BATTERY AND STARTER, AMONG OTHER REPAIRS). DRIVING THE 7 MILES TO THE DEALERSHIP THE CAR SEEMED TO BE ACCELERATING ON ITS OWN, THE ENTIRE WAY, I ONLY STEPPED ON THE GAS ONCE; IT WAS GOING 35 MILES/HOUR BY ITSELF (PER THE SPEEDOMETER). I DIDN'T KNOW WHY THIS WAS HAPPENING AND WHEN I TRIED TO SLOW DOWN USING THE BRAKES, THE TRUCK WAS VERY DIFFICULT TO STOP, SUCH THAT I NEARLY REAR-ENDED MULTIPLE CARS. IT WAS ALL I COULD DO TO PUSH THE BRAKE DOWN AND TWICE HUGE AMOUNTS OF SMOKE CAME FROM UNDER THE VEHICLE (PROBABLY THE BRAKES WERE NOW OVERHEATING?). WHEN I WAS 500 FEET FROM THE DEALERSHIP I TOOK A QUICK LEFT TURN AND HONESTLY COULD NOT STOP THE TRUCK, I THREW IT INTO PARK AND SHUT IT OFF JUST IN TIME TO MISS PLOWING INTO PARKED VEHICLES. SMOKE BILLOWED OUT FROM BELOW THE HOOD. I HAVE NEVER BEEN SO FRIGHTENED IN MY LIFE-I WAS SURE I WAS EITHER GOING TO SMASH INTO SOMEONE SINCE I COULDN'T STOP OR THE TRUCK WAS GOING TO IMPLODE IN FIRE, OR SOMETHING AND I WOULD BE DEAD. I WAS NOT ABLE TO SUCCESSFULLY STOP IT USING THE BRAKES. THE PARKING BRAKE WAS ALSO NOT WORKING (WHICH IS ALSO WHY I WAS RETURNING IT TO THE

THE VEHICLE IS A 1990 AND THE SITE DOES NOT PROVIDE A SPACE CHOICE FOR THE 1990, ONLY '91 AND UP. THE TRUCK HAS THE EXACT SAME PROBLEM AS THE OTHER MANY FORD TRUCKS. WHILE IDLING, OR UNDERWAY, THE VEHICLE SPEWS GASOLINE FROM THE FRONT TANK, OUT ONTO THE ROAD, OR ANY DRIVEWAY, IF IDLING. IT'S CLEAR THAT ONCE YOU FILL THE REAR TANK AND THEN TRAVEL, THE FUEL, WHICH SHOULD RETURN TO THE REAR TANK IN A CYCLE, DOES NOT. IT SIMPLY RETURNS TO THE FRONT TANK, UNTIL IT FILLS THE FRONT TANK AND FLOODS OUT. THE PUMP IN THE REAR TANK APPEARS TO JUST CONTINUE TO RUN, FOR EXAMPLE,,,, YOU HAVE A FULL REAR TANK. YOU HAVE HALF A TANK OF FUEL IN THE FRONT TANK. YOU DRIVE. THE REAR TANK PUMP, PUMPS ALL OF THE FULL REAR TANK INTO THE FRONT TANK. SO, HALF A TANK OF GAS FLOWS OUT OF THE FRONT TANK, ONTO THE GROUND. OBVIOUSLY, THE CYCLE, WHERE THE FUEL SHOULD GO FROM REAR, TO ENGINE AND BACK, ISN'T HAPPENING. INSTEAD, THE FUEL ROLLS BY THE ENGINE AND RETURNS TO A FULL FRONT TANK, RATHER THAN THE REAR TANK, SO, ONTO THE GROUND GOES THE FUEL. ON AN OLDER RECALL REPORT, THE REPAIR IS DESCRIBED, WHERE THE 'JUMPER' MUST BE REPLACED, DESPITE THE FACT THERE'S NO SUCH THING, THERE'S A FUEL PUMP AND PROBABLY SOME SORT OF 'BI-VALVE' THAT SOMEONE'S POOR ENGINEERING FAILED ON THE WHOLE, AT THE TIME OF DESIGN. I THINK I'LL JUST PULL INTO THE LOCAL FORD LOT AND IDLE OUT A FEW GALLONS NOW AND THEN. BUT SINCE THE 90 ISN'T ON THE RECALL, DESPITE THE OBVIOUS EXACT PROBLEM AS THE 91'S AND UP, THERE'S NO USE. IT WOULD

TL* THE CONTACT OWNS A 1991 FORD F250. THE CONTACT STATED THAT GASOLINE FUEL WAS LEAKING FROM THE VEHICLE AND ONTO THE DRIVEWAY. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR INSPECTION OR REPAIRS. THE MANUFACTURER WAS CONTACTED AND THEY ADVISED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL AND PROVIDED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 102,311 AND THE CURRENT MILEAGE WAS 102,622. ..UPDATED 09/07/12 *BF UPDATED 09/17/2012 *JS

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 ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 93V125000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY). THE DEALER ADVISED THAT THE ENTIRE FUEL TANK WOULD NEED REPLACING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 150,000.

TL*THE CONTACT OWNS A 1991 FORD F250. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 45 MPH, HE NOTICED GASOLINE SPILLING OUT OF THE TANK. PRIOR TO THE SPILL, HE SMELLED A GASOLINE ODOR FOR ABOUT 6 MONTHS. THE VEHICLE WAS INSPECTED BY PEPBOYS WHO INFORMED THE CONTACT THAT THE FUEL TANK SELECTOR NEEDED TO BE REPLACED. THE VIN WAS UNKNOWN. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 38,525.

TL*THE CONTACT OWNS A 1991 FORD F-250. THE CONTACT STATED THAT WHEN HE FILLED THE FRONT TANK, THE FUEL WOULD BE SHIFTED TO THE REAR TANK. THE FAILURE OCCURRED EVERYTIME HE FUELED THE VEHICLE. THE CONTACT STATED THAT BECAUSE OF THE FAILURE, A PRESSURE WAS CREATED WITHIN THE TWO TANKS. THE VEHICLE. THE CONTACT CALLED THE DEALERSHIP AND REFERENCED RECALL 93V125000 (FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY) AND WAS TOLD THAT THERE WERE NO ACTIVE RECALLS ON HIS VEHICLE. THE CONTACT CALLED THE MANUFACTURER WHO VERIFIED THAT THERE WERE NO ACTIVE RECALLS FOR THE VEHICLE. THE VEHICLE HAD NOT BEEN REPAIRED. THE CURRENT MILEAGE WAS APPROXIMATELY 250,000. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000.

DISCOVERER A/T TIRES SIZE LT265/75R16 CATASTROPHICALLY FAILED WHILE DRIVING AT HIGHWAY SPEED. TREAD COMPLETELY PEELED OFF. HAD ONLY BEEN DRIVING FOR 30 MINUTES AND OUTSIDE TEMPERATURE WAS 70 DEGREES F. TIRES HAD ABOUT 23,000 MILES ON THEM. 1-2 YEARS PREVIOUSLY, THE SAME TYPE TIRE ON OPPOSITE WHEEL DEVELOPED A BULGE IN THE SIDEWALL AND HAD TO BE REPLACED. *TR

I HAD 2 FAILURES WITH THE FIRST ABOUT 9/21/07 AND THE SECOND 10/6/07. THE VEHICLE IS A 1991 F250 HD AND IS OCCASIONALLY USED TO HAUL A SLIDE-IN CAMPER. ON BOTH OCCASIONS I HAD THE CAMPER ON THE TRUCK, LOADING THE TRUCK TO NEAR THE RATED CAPACITY OF THE TIRES BUT NOT OVER TO MY KNOWLEDGE. IN BOTH INSTANCES THE TIRE PRESSURE WAS CHECKED BEFORE LEAVING THE HOUSE, WERE WE TRAVELING A MODERATE SPEED, ABOUT 55 MPH, AND IT WAS COOL. IN BOTH CASES I NOTICED A VIBRATION BUT BEFORE I COULD EFFECT A SUBSTANTIAL RESPONSE THE TIRE EXPLODED. THE TRUCK REMAINED IN CONTROL BUT THERE WAS SUBSTANTIAL DAMAGE TO THE TRUCK. THE TIRES WERE ON THE REAR SO THERE WAS DAMAGE TO BOTH SIDES. THE FIRST TIME I HAD THE TIRE REPLACED BY THE DEALER AND HE GAVE ME OVER A 50% CREDIT, REFLECTING THE AMOUNT OF TREAD LEFT ON THE TIRE. THE SECOND TIME I HAD THE TIRE REPLACED WITH A DIFFERENT BRAND AND KEPT THE OLD TIRE FOR INSPECTION. *TR

DAD: THE CONTACT STATES THERE IS NHTSA RECALL CAMPAIGN 93V125000 CONCERNING THE FUEL SYSTEM: TANK ASSEMBLY. THIS VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL, BUT II IS NOT INCLUDED IN THE RECALL DUE TO VIN. THE CONTACT REPAIRED THE VEHICLE AT HIS OWN EXPENSE. *AK THE DEALER CHARGED THE CONSUMER 500.00 TO REPLACE THE FUEL PUMP WHICH WAS DIFFERENT FROM THE RECALL. UPDATED 01/11/06. *JB

THERE WAS AN ACRID ODOR IN THE CABIN ON SEVERAL OCCASIONS. THE RADIO LIGHT BEGAN FUNCTIONING INTERMITTENTLY. THE DASH LIGHTS FAILED TO WORK TWICE. THE HEAD LIGHTS FAILED TO WORK TWICE, ON SEPARATE OCCASIONS FROM THE DASH LIGHTS. I WENT TO REPLACE THE HEADLAMP SWITCH, AND FOUND THE CONNECTOR CHARRED AND MELTED, AND THE B2 TERMINAL ON THE SWITCH WAS LOOSE AND DISCOLORED. THE SWITCH WAS CHARRED AROUND THE B2 TERMINAL.. I AM GOING TO REPLACE THE CONNECTOR ALSO. *JB

AFTER FUELING THE VEHICLE, CONSUMER NOTICED GAS BEING PUMPED OUT OF THE FRONT FILL POINT LIKE A FIRE HOSE. *PH THIS WAS THE THIRD FAILURE WITH THE CROSSOVER. CONSUMER THEN LEARNED THAT THIS FAILURE WASN'T GOING TO BE COVERED UNDER THE EXTENDED WARRANTY LIKE THE FIRST TWO. *PH

THE GASOLINE WAS NOT TRANSFERRING BETWEEN THE FUEL TANKS, CAUSING VEHICLE TO STALL DUE TO LOW GASOLINE. THE DEALER REPLACED THE FUEL TANK SENDER AND THE FUEL PUMP. *AK THERE WERE FOUR ATTEMPTS TO REMEDY THE TRANSFERRING OF FUEL FROM THE REAR TANK TO THE FRONT TANK THROUGHOUT THE FILLER CAP AND CAUSED LEAKAGE. THE CONSUMER REQUESTED THAT FORD COVER THE CHARGES. *SC *JB

WHEN THE FRONT TANK WAS EMPTY AND THE CONSUMER SWITCHED TO THE REAR FULL TANK, SOMEHOW THE GAS FROM THE REAR TANK PUMPED BACK INTO THE FRONT TANK WHICH RESULTED IN THE REAR TANK BEING EMPTY. *NLM *CB *NLM

FRONT SEATBELT WILL NOT EXTEND TO GIVE ROOM FOR CONSUMER TO PUT IT ON, CAUSING CONSUMER NOT TO HAVE A SEATBELT ON WHILE DRIVING. CAUSE UNKNOWN. DEALER NOTIFIED.*AK

WHILE DRIVING, VEHICLE WILL SHUT OFF.*AK *YH

BRAKES FAIL SOMETIMES. I NEED HELP. I JUST FOUND OUT ABOUT THIS RECALL OF 03/11/92TO LATE FOR THIS RECALL ?. NHTSA CAMPAIGN 92VO26000 .*AK

VEHICLE WAS EXAMINED BY THE DEALERSHIP FOR RECALL CAMPAIGN 01I008000 CONCERNING FUEL CROSSOVER. AFTER REPAIR WORK WAS PERFORMED, PROBLEM BECAME WORSE THAN IT HAD BEEN BEFORE DEALER MADE ADJUSTMENTS TO VEHICLE. POWER FAILURE OCCURS, THE MOTOR SHUTS DOWN AS IF IDLING. *JG *AK