Model year record

1996 Ford F-250 recalls & problems

The 1996 Ford F-250 has 5 safety recalls and 176 owner complaints on file with NHTSA. The most-reported problem area is tires (39 complaints).

Recalls5safety recalls

Complaints176filed by owners

Crashes · fires10 · 25reported in complaints

Injuries · deaths3 · 0reported in complaints

Safety recalls

Vehicle speed controlAug 1, 2006

Vehicle speed control

Recall 06V2860001,200,000 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Risk: OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.
Fix: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE: ALSO SEE RECALLS 05V017 AND 05V388)

Exterior lightingMay 24, 2006

Exterior lighting

Recall 06E04900027,176 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

Vehicle speed controlSep 7, 2005

Vehicle speed control

Recall 05V3880004,500,000 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
Risk: A FIRE AT THE SWITCH COULD OCCUR.
Fix: BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)

EquipmentAug 29, 1996

Other › Labels

Recall 96V161000134,770 vehicles

Problem: THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Risk: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .
Fix: OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.

StructureAug 1, 1996

Frame and members

Recall 96V146000200 vehicles

Problem: THE CROSSMEMBER FRAME GUSSETS WERE INSTALLED WITH UNDERSIZED THREADED FASTENERS FOLLOWING A BREAKDOWN OF THE PRODUCTION RIVET GUN THAT IS GENERALLY USED. THIS GUSSET IS THE ATTACHMENT POINT FOR THE REAR STRAP OF THE MID-SHIP FUEL TANK.
Risk: THE SUBJECT FASTENERS CAN SEPARATE CAUSING IN THE REAR STRAP OF THE AFFECTED FUEL TANK TO BECOME DISCONNECTED. A LOOSE OR DISCONNECTED REAR STRAP ALLOWS THE FUEL TANK TO POSSIBLY CONTACT THE ROAD SURFACE INCREASING THE RISK OF A VEHICLE FIRE.
Fix: DEALERS WILL REPLACE THE CROSSMEMBER GUSSET FASTENERS WITH THE SPECIFIED ALTERNATIVE FASTENERS (BOLTS).

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

F250

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

4.9 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $4,800/year to fuel

F250

14mpg combined

City / highway	12 / 17 mpg
Fuel	Regular Gasoline

5 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel

F250

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5 L · 8 cyl · Manual 5-spd · Rear-Wheel Drive · about $4,800/year to fuel

F250

13mpg combined

City / highway	12 / 16 mpg
Fuel	Regular Gasoline

4.9 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,150/year to fuel

F250

13mpg combined

City / highway	11 / 16 mpg
Fuel	Regular Gasoline

5.8 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,150/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
TiresTread/belt; Sidewall	39	3	0	0	126,881 mi
Engine and engine coolingEngine › Diesel; Engine › Gasoline › Belts and associated pulleys	29	0	4	0	115,772 mi
Power trainAutomatic transmission; Axle hubs	21	3	0	0	—
SteeringGear box (other than rack and pinion); Hydraulic power assist › Pump	18	1	0	0	171,640 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components	17	3	1	4	—
Vehicle speed controlCruise control	16	0	13	0	164,000 mi
SuspensionFront; Front › Springs › Coil springs	14	1	0	1	—
Electrical systemWiring; Starter assembly	14	0	4	0	—
Fuel system, gasolineStorage › Auxillary tank › Selector devices; Storage › Tank assembly	9	0	2	0	106,338 mi
StructureBody › Tailgate; Frame and members	6	0	0	0	—
Seat beltsFront › Buckle assembly; Front › Webbing	5	0	0	0	—
Fuel/propulsion system	5	0	0	0	147,500 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Vehicle speed controlFire
Cruise control switch began smoking, disconnected it and took it to Awesome Ford of Chehalis, WA for recall service sometime in June or July. Service tech found that brake fluid had wicked its way up electrical harness into cruise control servo, necessitating replacement in order to complete recall service. FoMoCo has been unable/unwilling to replace cruise control servo and is instead requiring that I pull one from a wrecking yard in order to complete recall service.
Sep 5, 2023
Fuel/propulsion system
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. ABOUT 5 GALLONS OF FUEL SPILLED OUT OF FILL TUBE.
May 30, 2022
Fuel/propulsion system
FUEL RUNNING OUT FOUNT TANK IN DRIVEWAY WITH SELECTOR ON REAR TANK
Apr 10, 2019 · 17,068 miles
Fuel/propulsion system
EXCESS FUEL FROM REAR TANK IS RETURNED TO FRONT TANK CAUSING FUEL OVERFILL AND FUEL LEAK.
Sep 20, 2017 · 125,000 miles
Fuel/propulsion system
FRONT FUEL TANK STOPPED WORKING. VEHICLE RUNS USING REAR FUEL TANK. IF I TAKE OFF THE FRONT TANK FUEL CAP, GAS POURS OUT SOMETIMES SPRAYS ( ABOUT 8 OUNCES OR SO) . FRONT FUEL TANK SEEMS TO BECOME PRESSURIZED. THIS CAN HAPPEN EVERY TIME YOU DRIVE IT ( IF YOU REMOVE THE FRONT CAP). IN MY OPINION THIS IS A DEFINITE SAFETY HAZARD THAT NEEDS TO BE ADDRESSED. I DID SOME SEARCHES ON THE INTERNET AND THIS PROBLEM IS QUITE COMMON. BIG FIRE HAZARD.
Jan 2, 2016 · 231,000 miles
Tires › Tread/belt
TL* THE CONTACT OWNS A 1996 FORD F-250 EQUIPPED WITH UNIROYAL LAREDO TIRES, SIZE: 265/75R16 (NA). WHILE MAKING A RIGHT TURN AT APPROXIMATELY 50 MPH, THE FRONT PASSENGER SIDE TIRE RUPTURED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS CONFIRMED THAT THE TREAD SEPARATED AND THE TIRE NEEDED TO BE REPLACED. THE TIRE WAS REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 185,000 AND THE TIRE FAILURE MILEAGE WAS 15,000. THE DOT NUMBER WAS UNAVAILABLE.
Jul 10, 2015 · 185,000 miles
Fuel/propulsion system
FUEL SPILLS FROM REAR TANK WHEN FUELING FRONT TANK. ENGINE SPUTTERS AND QUITS WHILE RUNNING DUE TO FUEL PRESSURE FAILURE..
Mar 25, 2015 · 170,000 miles
Steering
THIS IS NOT A COMPLAINT BUT TO LET EVERYONE KNOW WHAT I HAVE FOUND TO BE PART OF THE PROBLEM ON THE STEERING NOT RETURNING AFTER A TURN. THE STEERING COLUMN BEARING IN THE TOP OF THE COLUMN IS BAD. I HAVE HAD TO REPLACE AT LEAST 20 OF THESE FOR THIS COMPLAINT AND FIXED THE PROBLEM. THE LOCKING OF THE STEERING WHEN BREAKING IS A HYDROBOOST PROBLEM NOT A STEERING PROBLEM. FORD NEED TO RESEARCH THIS AND CORRECT IT BEFORE THERE IS A DEATH BECAUSE OF IT. *TR
Dec 25, 2014 · 300,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

ENGINE COMPARTMENT FIRESClosedLed to recall 05V388000
EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED…
EA05005 · opened Mar 22, 2005 · closed Aug 2, 2006
SEPARATED FRONT SUSPENSIONClosed
CONSUMER COMPLAINTS REPORT THAT BOLTS WHICH RETAIN THE AXLE PIVOT BRACKET TO THE FRAME CROSS MEMBER CAN LOOSEN OR FAIL, CAUSING THE INBOARD END OR THE AXLE TO BECOME DETACHED FROM THE VEHICLE.OWNERS ALLEGE THAT THIS COULD RESULT IN LOSS OF STEERING CONTROL, HOWEVER THE COMPLAINT DATA SHOWS ONLY ONE INCIDENT WHERE THE VEHICLE LEFT THE ROADWAY FOLLOWING AXLE SEPARATION, WITH NO DAMAGE TO THE VEHICLE.IN ADDITION TO THE 225 CONSUMER COMPLAINTS, THERE WERE 4,315 WARRANTY CLAIMS RELATED TO THE FRONT SUSPENSION AND MEMBERS, AND 22 VEHICLES WERE REPLACED FOR GOODWILL.DOCUMENTS SUBMITTED BY FORD, UNDER REQUEST FOR CONFIDENTIAL TREATMENT INDICATE THAT THE BOLTS WERE INADEQUATE FOR THE DURABILITY REQUIREMENTS OF THE VEHICLE.ALSO, BOLTS WERE FOUND TO HAVE BEEN INADEQUATELY TORQUED AT ONE OR MORE ASSEMBLY PLANTS.OTHER FACTORS, SUCH AS WAX TREATMENT OF THE FRAME, CONTRIBUTED TO THE PROBLEM.INCREASED…
PE96052 · opened Aug 23, 1996 · closed Jan 27, 1997