1991 Ford F-350 Service and Repair Manual

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Factory-Grade Data

The 1991 Ford F-350 service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Base Standard Cab Pickup 2-Door
  • XLT Lariat Standard Cab Pickup 2-Door
  • Custom Crew Cab Pickup 4-Door
  • XL Crew Cab Pickup 4-Door
  • XL Cab & Chassis 2-Door
  • XL Standard Cab Pickup 2-Door
  • Custom Extended Cab Pickup 2-Door
  • XLT Lariat Crew Cab Pickup 4-Door
  • XL Extended Cab Pickup 2-Door
  • Custom Standard Cab Pickup 2-Door
  • Custom Cab & Chassis 2-Door
  • XLT Lariat Cab & Chassis 2-Door
  • XLT Lariat Extended Cab Pickup 2-Door

Engines covered

  • 5.0L 302Cu. In. V8 GAS OHV Naturally Aspirated
  • 5.8L 5753CC 351Cu. In. V8 GAS OHV Naturally Aspirated
  • 7.3L 445Cu. In. V8 DIESEL OHV Naturally Aspirated
  • 7.5L 460Cu. In. V8 GAS OHV Naturally Aspirated
  • 4.9L 4917CC 300Cu. In. l6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Ford F-350 Recalls & Complaints

NHTSA #93V06600027/04/1993Component: STEERING: STEERING WHEEL/HANDLE BAR

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 TH

Remedy

A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN

NHTSA #01I00800019/07/2001Component: FUEL SYSTEM, GASOLINE

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 V

Consequence

SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLO

Remedy

FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150

NHTSA #93V12500002/08/1993Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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 TH

Consequence

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.

TSB #623944

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

TSB #623988

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

TSB #616522

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

TSB #608431

INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT

TSB #601010

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

TSB #613350

SERVICE TIP INFORMATION REGARDING THE REVERSE CLUTCH PISTON AND PISTON SEAL USAGE. *TT

TSB #613341

EXPERIENCING FRONT END SHIMMY OCCURRING AT VARIOUS DRIVING SPEEDS AND IS USUALLY INDUCED WHEN HITTING BUMPS SUCH AS LARGE POTHOLES OR ROUGH RAILROAD CROSSINGS. *TT

TSB #612343

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

Showing the 8 most recent of 55 technical service bulletins on file with NHTSA.

20000906Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTSCrash reported

THERE WAS A FACTORY DEFECT WITH BRAKES, IT TOOK SEVERAL YEARS FOR CONSUMER TO FIGURE OUT WHAT THE PROBLEM WAS. BRAKE PEDAL WENT TO THE FLOOR, AND PULLED A TRAILER. IT PULSATED, AND

19961204Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported

ABS BRAKES FAILED, CAUSING LOSS OF CONTROL, RESULTING IN A COLLISION. *AK

19950322Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDALCrash reported

GAS PEDAL STICKS. TT

20030214Component: ENGINE AND ENGINE COOLING:ENGINEFire reported

THE VEHICLE CAUGHT ON FIRE DUE TO MALFUNCTION OF ALTERNATOR IN THE ENGINE COMPARTMENT.*JB *TS

Showing the 4 most serious of 34 complaints filed with NHTSA.

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