1991 Ford F-800 Service and Repair Manual
This factory service and repair manual for the 1991 Ford F-800 covers four engines on a medium conventional chassis that was built as either a tractor truck or a straight truck, with one Base trim. The diesel choices are a turbocharged 6.6L inline-six and a turbocharged 7.8L inline-six. The gasoline choices are a naturally aspirated 6.1L V8 and a naturally aspirated OHV 7.0L V8, the 7.0L also being offered on LPG (propane). Procedures, specifications, torque values, wiring diagrams and diagnostics follow that split, with each engine handled on its own terms.
Engines covered
- 6.1L V8 (370 cu in) — naturally aspirated, gasoline
- 7.8L inline-six (473 cu in) — turbocharged, diesel
- 7.0L V8 (429 cu in) — OHV, naturally aspirated, LPG (propane) or gasoline
- 6.6L inline-six (401 cu in) — turbocharged, diesel
Body styles covered
- Tractor truck, medium conventional
- Straight truck, medium conventional
Trims covered
- Base
Known issues on the 1991 F-800. A single recall stands on federal record for this year, covering a throttle cable that may have been kinked between the accelerator and the governor assembly during assembly. The kink wears the cable housing lining, and the cable can then fracture, sending the engine to idle, or stick and leave it running at the speed it was at when it jammed. Owners have filed one complaint with NHTSA, on the fuel system. Both the throttle cable and the fuel system fall within the manual's procedures, specifications, torque values, wiring diagrams and diagnostics.
THE THROTTLE CABLE WHICH RUNS FROM THE ACCELERATOR TO THE GOVERNOR ASSEMBLY HOUSING MAY HAVE BEEN KINKED DURING ASSEMBLY, CAUSING EXCESSIVE WEAR OF THE CABLE HOUSING INNER LINING. THIS COULD RESULT IN
VEHICLE WAS STRUCK BEHIND DRIVER DOOR AND IGNITED. TT
