1991 FORD F-250 Recalls (7)

Campaign:: 92V026000 on 03/10/1992
Component:: Service brakes, hydraulic:foundation components:drum:shoes/linings
Manufactured:: 07/31/1987 - 07/31/1991
Affected:: 467,000
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.
Correction:: 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.
Notes:: System: brakes; front brake lining.vehicle description: f250 and f350 trucks with 7.3 l diesel and 7.5 l efiengines ; f250 and f350 4x4 models with 5.8 l efi engines.note: ford recommends vehicle operators do not exceed the gcwr and gvwr of theirvehicles, and proper maintenance of the brakes on these vehicles and any trailerparticularly when operating in mountainous areas with long, steep grades.
Campaign:: 93V066000 on 04/29/1993
Component:: Steering:wheel and handle bar
Affected:: 2,419
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.
Correction:: A shield will be positioned between the steering wheel and the ignition switch and held in place by the steering lock band.
Notes:: System: steering.vehicle description: ford trucks adapted for use on railroad tracks and as overthe road vehicles.
Campaign:: 93V125000 on 07/26/1993
Component:: Fuel system, gasoline:storage:tank assembly
Affected:: 1,131,000
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.
Correction:: Replacement of the fuel pressure regulator and installation of redundant check valves.
Notes:: System: fuel; fuel tank assembly.vehicle description: light trucks and chassis cabs with gasoline engines anddual fuel tanks.note: if your vehicle is presented to an authorized dealer on an agreed servicedate and the remedy is not corrected within a reasonable time without chargeor the remedy does not correct the safety-related defect or noncompliance,please contact ford's customer assistance center, 300 renaissance center,p.o. box 43360, detroit, mi 48243. also contact the national highway trafficsafety administration's auto safety hotline at 1-800-424-9393.
Campaign:: 94V040000 on 02/28/1994
Component:: Fuel system, gasoline:delivery:hoses, lines/piping, and fittings
Manufactured:: 07/31/1989 - 07/31/1991
Affected:: 89,770
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.
Correction:: Ford dealers will replace the fuel return tubes with flexible stainless steel braided/teflon tubes. dealers will also inspect the fuel supply tubes.
Notes:: System: fuel; fuel lines; metallic.vehicle description: light duty and super duty pickup trucks and chassis over 8,500 lbs. gross vehicle weight rating equipped with 7.5l engines.note: if your vehicle is presented to an authorized dealer on an agreed upon service date and the remedy is not provided within a reasonable time and free of charge or the remedy does not correct the defect or noncompliance, please contact ford service center at 1-800-392-3673. also, contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:: 96V071000 on 04/30/1996
Component:: Electrical system:ignition
Manufactured:: 07/31/1987 - 09/29/1992
Affected:: 7,900,000
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.
Correction:: Dealers will replace the ignition switch.
Notes:: System: electrical; ignition switch. vehicle description: passenger and multi-purpose vehicles and light duty trucks. note: owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time, should contact ford at 1-800-392-3673. also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:: 01X001000 on 05/21/2001
Component:: Tires:tread/belt
Affected:: 13,000,000
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.
Consequence:: Should the tread separate at highway speeds, a vehicle crash could occur, possibly resulting in personal injury or death.
Correction:: 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.
Campaign:: 01I008000 on 07/18/2001
Component:: Fuel system, gasoline
Manufactured:: 07/21/1989 - 08/23/1993
Affected:: 1,556,221
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.
Consequence:: Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap.
Correction:: 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.
Notes:: Ford has decided to conduct an extended coverage program to extend the warranty coverage for potential fuel cross flow problems. owners can contact ford at1-866-436-7332, concerning this program.

1991 FORD F-250 TSBs (52)

Bulletin:: BC4225
Component:: 063000 engine and engine cooling:exhaust system
Summary:: vehicles with manual transmission may have a lack of power or no start condition caused by a plugged catalytic converter or muffler. *tw
Bulletin:: 95524
Component:: 061100 engine and engine cooling:engine:gasoline
Summary:: there may be a concern of poor performance, coolant in the oil and engine knocking and/or hydraulic lock on some vehicles. *tw
Bulletin:: 9568
Component:: 061000 engine and engine cooling:engine
Summary:: revised oil pan gasket. *tw
Bulletin:: 95619
Component:: 103000 power train:automatic transmission
Summary:: new design transmission range sensor. *tw
Bulletin:: BC2681950503
Component:: 063000 engine and engine cooling:exhaust system
Summary:: lack of power or no start condition may be due to exhaust restriction caused by a plugged catalytic converter and/or muffler. *tw
Bulletin:: 95711
Component:: 063000 engine and engine cooling:exhaust system
Summary:: some vehicles may exhibit a lack of power or a no start condition due to an exhaust restriction. *tw
Bulletin:: 9588
Component:: 061100 engine and engine cooling:engine:gasoline
Summary:: knocking noise on initial start-up. *tw
Bulletin:: 9597
Component:: 021000 suspension:front
Summary:: Unknown
Bulletin:: 9598
Component:: 021000 suspension:front
Summary:: Unknown
Bulletin:: 95912
Component:: 111000 electrical system:battery
Summary:: Unknown
Bulletin:: BC4321950705
Component:: 103000 power train:automatic transmission
Summary:: vehicles experiencing occasional harsh reverse engagement concerns. *tw
Bulletin:: 951112
Component:: 103000 power train:automatic transmission
Summary:: revised design transmission rear case bushing. *tw
Bulletin:: 951113
Component:: 103000 power train:automatic transmission
Summary:: delayed forward engagement and/or heat stained forward clutch plates after installing center support service. *tw
Bulletin:: BC4225
Component:: 061000 engine and engine cooling:engine
Summary:: Unknown
Bulletin:: 951515
Component:: 013000 steering:gear box (other than rack and pinion)
Summary:: steering gear-replacement of bendix, steering gear with new ross steeering gear. *sd
Bulletin:: BC0131960102
Component:: 106000 power train:axle assembly
Summary:: 4x4 front axles must use hypoid 4x4 gear oil p/n f1tz-19580-a & high temp 4x4 front axle & wheel bearing grease when servicing. it is not recommended to use heavier weight lubes in these front axles.
Bulletin:: 95212
Component:: 036000 service brakes, hydraulic:antilock
Summary:: the use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. if petroleum-based grease is used to lubricate any par
Bulletin:: 96246
Component:: 114000 electrical system:wiring
Summary:: Wiring - electrical diode identification and service replacements. *tw
Bulletin:: 96249
Component:: 103700 power train:automatic transmission:torque converter
Summary:: Torque converter - leak test procedure - service tip. *tw
Bulletin:: 96221
Component:: 131000 visibility:windshield
Summary:: Windshield and interior glass - fog/film. *tw
Bulletin:: 962612
Component:: 103700 power train:automatic transmission:torque converter
Summary:: Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw
Bulletin:: 97215
Component:: 980000 unknown or other
Summary:: Diagnostic guides for out-of-warranty vehicles to be used as a master copy - diagnostic guides no longer available from adistra. *tw
Bulletin:: 97310
Component:: 021242 suspension:front:springs:leaf spring assembly:hanger,bracket
Summary:: Noise- "popping/creaking"- front frame or suspension brackets- frame- "popping/creaking"- fastener replacement. *jd
Bulletin:: 9747
Component:: 160000 structure
Summary:: Frame- rivet replacement with bolts- service tips. *jd
Bulletin:: 9748
Component:: 061110 engine and engine cooling:engine:gasoline:belts and associated pulleys
Summary:: Accessory drive belts- fead belt comes off- vehicles with 4.9l engine. *jd
Bulletin:: 97511
Component:: 103000 power train:automatic transmission
Summary:: Fluid- transmission fluid usage charts. *jd
Bulletin:: 9768
Component:: 980000 unknown or other
Summary:: Fuel economy- customer expectations versus vehicle usage. *jd
Bulletin:: 985A13
Component:: 034500 service brakes, hydraulic:foundation components:disc
Summary:: The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc
Bulletin:: 985A29
Component:: 034000 service brakes, hydraulic:foundation components
Summary:: Some vehicles may exhibit excessive brake pedal travel, irregular front lining wear, and brake pull. *yc
Bulletin:: 985A38
Component:: 034510 service brakes, hydraulic:foundation components:disc:caliper
Summary:: Front caliper piston boots damaged. *yc
Bulletin:: 9888
Component:: 103000 power train:automatic transmission
Summary:: Information on a new transmission fluid usage chart. *yc
Bulletin:: 9848
Component:: 353600 equipment:air conditioner
Summary:: Announcing the ford oem air conditioning retrofit kit availability. *yc
Bulletin:: 98419
Component:: 980000 unknown or other
Summary:: Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes (dtcs) 62,628, and/or 1728. *yc
Bulletin:: 9852
Component:: 190000 tires
Summary:: Information on tire company telephone numbers for customer assistance. *yc
Bulletin:: 9864
Component:: 063000 engine and engine cooling:exhaust system
Summary:: Information on a buzzing or rattle noise from the exhaust system. *tt
Bulletin:: 98246
Component:: 110000 electrical system
Summary:: Ford motor company has released a new electrical grease ( f8az - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals. *yc
Bulletin:: 010198
Component:: 061000 engine and engine cooling:engine
Summary:: Some vehicles may develop "cavitation" erosion in the cylinder wall of the engine. *tt
Bulletin:: 99816
Component:: 061100 engine and engine cooling:engine:gasoline
Summary:: Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt
Bulletin:: 99129
Component:: 353400 equipment:electrical:radio/tape deck/cd etc.
Summary:: Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump. *tt
Bulletin:: 12905
Component:: 106000 power train:axle assembly
Summary:: Some vehicles may experience axle wind up and / or clunking, popping, ratcheting type noises when making cornering maneuvers on vehicles equipped with a four wheel drive hi or low range mode. *tt
Bulletin:: 983074
Component:: 106000 power train:axle assembly
Summary:: Concerns with axle wind-up and / or clunking, popping, ratcheting type noises when making cornering maneuvers. *tt
Bulletin:: 99222
Component:: 114000 electrical system:wiring
Summary:: Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
Bulletin:: 99196
Component:: 353600 equipment:air conditioner
Summary:: Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
Bulletin:: 98158
Component:: 021000 suspension:front
Summary:: Front end shimmy may occur at various driving speeds and is usually induced when hitting bumps, such as large potholes or rough railroad crossings. shimmy is not always verified during road test. *ak
Bulletin:: 98167
Component:: 103000 power train:automatic transmission
Summary:: Transmission-e40d-no 2-3 upshift. some vehicles may exhibit a no 2-3 upshift condition. *ak
Bulletin:: 98168
Component:: 103000 power train:automatic transmission
Summary:: Transmission- e40d/4r100-1989-99-main controls, separator plates and separator plate gaskets usage chart. yd
Bulletin:: 0015
Component:: 103000 power train:automatic transmission
Summary:: Information regarding the new transmission cooler flusher- service tip. *mjs
Bulletin:: 0038
Component:: 103600 power train:automatic transmission:cooling unit and lines
Summary:: Vehicles may experience solid particle contaminants from prior transmission concerns or excess wear, may be trapped in the transmission fluid cooling system is not properly flushed, fluid in-line filter kit. *mjs
Bulletin:: 96728
Component:: 101000 power train:clutch assembly
Summary:: Service tip information regarding the reverse clutch piston and piston seal usage. *tt
Bulletin:: 985A12
Component:: 354600 equipment:mechanical:wrecker and wheel lift devices
Summary:: Recommended guidelines for towing behind recreational vehicles. *tt
Bulletin:: 99152
Component:: 103000 power train:automatic transmission
Summary:: Information on the new flush and fill tool available through rotunda. *tt
Bulletin:: 002310
Component:: 103600 power train:automatic transmission:cooling unit and lines
Summary:: Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt

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