1991 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
1991 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Ford Mustang has 3 documented known issues, with 1 rated critical. The most serious is TFI-IV Ignition Module Heat-Soak Failure (Distributor-Mounted) ($60-$350 repair). Across all issues with published estimates, repair costs range from $40 to $450. DIY maintenance guides at au7o.io.
EXTERIOR LIGHTING:HEADLIGHTS
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
EXTERIOR LIGHTING:HEADLIGHTS
K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
EXTERIOR LIGHTING:HEADLIGHTS
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Ford Mustang has 3 documented issues. The most frequently reported are: TFI-IV Ignition Module Heat-Soak Failure (Distributor-Mounted), Plastic Clutch Quadrant & Clutch Cable Failure (Cable-Clutch Fox Body), 5.0 Spark Plug Wire Melt-Through on Exhaust Manifolds (Misfire). Of these, 1 is rated critical and should be addressed promptly.
The 1991 Ford Mustang has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: TFI-IV Ignition Module Heat-Soak Failure (Distributor-Mounted). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Mustang issues range from $40 to $450, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, TFI-IV Ignition Module Heat-Soak Failure (Distributor-Mounted), typically costs $60-$350 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Fox-body 5.0L Mustangs (1990-1993) mount the Thick Film Ignition (TFI-IV) module directly on the side of the distributor, where it is continuously baked by engine heat. The heat breaks down the module's internal electronics, causing intermittent misfire and stalling once the engi… Repairs typically run $60-$350. Severity: high.
Manual-transmission Fox-body Mustangs (1990-1993) use a cable-actuated clutch with a self-adjusting molded-plastic quadrant (ratcheting sector) on the pedal. The factory quadrant teeth crack, strip, or shatter with age and use, especially with a stiffer aftermarket clutch, often… Repairs typically run $100-$450. Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
EXTERIOR LIGHTING
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
EXTERIOR LIGHTING
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
+ 15 more recalls. Check all on NHTSA.gov
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On 5.0L Mustangs (Fox 1990-1993 and early SN95 1994-1995 GT), the ignition/spark-plug wires route close to the cast-iron exhaust manifolds. Over time the wires sag or, if routed poorly, rest against the hot manifolds, melting the insulation and shorting spark to ground. The resul… Repairs typically run $40-$250. Severity: low.
