1991 Ford F-150 Service and Repair Manual

This factory service and repair manual for the 1991 Ford F-150 covers two-door standard cab and extended cab pickups in four trims — Custom, XL, XLT and XLT Lariat — with four overhead-valve gasoline engines on the list: the 3.8L V6, the 4.9L inline-six and the 5.0L and 5.8L V8s. Because one chassis carried every one of those combinations, the manual is organized by system instead of by model, with procedures, specifications, torque values, wiring diagrams and diagnostics grouped where a technician looks for them rather than split across separate volumes.

Engines covered

• 3.8L V6 (232 cu in) — OHV, naturally aspirated, gasoline
• 5.8L V8 (351 cu in) — OHV, naturally aspirated, gasoline
• 5.0L V8 (302 cu in) — OHV, naturally aspirated, gasoline
• 4.9L inline-six (300 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door standard cab pickup
• 2-door extended cab pickup

Trims covered

• Custom
• XL
• XLT
• XLT Lariat

Known issues on the 1991 F-150. This model year gathered six recalls on the federal record. Two are Firestone tire campaigns covering Wilderness AT and radial ATX sizes prone to tread separation; another warns that keys hanging from the ignition key ring can lodge in the steering lock receiver and cost the driver steering control. Dual tank fuel cross-flow past the filler cap and an internally shorting ignition switch round out the list. Owners have filed 338 complaints with NHTSA, the fuel system far ahead of the electrical system and the service brakes. Fuel, steering column and ignition work all sit inside the procedures, torque values and wiring diagrams gathered here.