1991 Ford Ranger Service and Repair Manual

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Factory-Grade Data

The 1991 Ford Ranger 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

  • XLT Standard Cab Pickup 2-Door
  • Sport Standard Cab Pickup 2-Door
  • S Standard Cab Pickup 2-Door
  • Sport Extended Cab Pickup 2-Door
  • Custom Standard Cab Pickup 2-Door
  • STX Standard Cab Pickup 2-Door
  • STX Extended Cab Pickup 2-Door
  • XLT Extended Cab Pickup 2-Door
  • Custom Extended Cab Pickup 2-Door

Engines covered

  • 4.0L 245Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.0L 2986CC 182Cu. In. V6 GAS OHV Naturally Aspirated
  • 2.9L 177Cu. In. V6 GAS OHV Naturally Aspirated
  • 2.3L 140Cu. In. l4 GAS SOHC 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 Ranger Recalls & Complaints

NHTSA #06E02600023/03/2006Component: EXTERIOR LIGHTING

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT E

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON AP

NHTSA #01X00100022/05/2001Component: TIRES:TREAD/BELT

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING A

Consequence

SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTI

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVE

NHTSA #00T00500021/08/2000Component: TIRES:TREAD/BELT

TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OP

Consequence

IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEV

NHTSA #98E01000008/04/1998Component: SERVICE BRAKES, AIR:DISC:ROTOR

EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUN

Consequence

LOSS OF BRAKING CAN RESULT.

Remedy

AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLAT

NHTSA #96V02400105/02/1996Component: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC

THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIM

Consequence

IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER CO

Remedy

DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY.

NHTSA #91V18900004/11/1991Component: POWER TRAIN:AUTOMATIC TRANSMISSION

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Consequence

DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED

Remedy

REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

TSB #635982

SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT

TSB #628153

OWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF WILDERNESS AT TIRES. *TT

TSB #627752

SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT

TSB #623944

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

TSB #623988

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

TSB #622665

ON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA AFTER AN ENGINE OIL PAN GASKET REPAIR HAS BEEN PERFORMED. *TT

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

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

19970701Component: SEAT BELTS:FRONT:RETRACTORCrash reported3 injured

WHILE DRIVING 30 MPH, HAD A FRONTAL COLLISION WITH A TRUCK IN WHICH THE DRIVER'S AND PASSENGER'S 3-POINT SEAT BELTS DID NOT RETRACT AND HOLD THE OCCUPANTS BACK, CAUSING INJURIES TO

19950731Component: VEHICLE SPEED CONTROLCrash reported2 injured

CRUISE CONTROL FAILURE, DIFFICULTY DISENGAGING THE CRUISE CONTROL. TT

20001004Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported1 injured

WHILE DRIVING ABOUT 75-80 MH DRIVER NOTICED A TIRE DEFECT. TIRE TREAD BROKE, CAUSING DRIVER TO LOSE BRAKES, AND VEHICLE FLIPPED OVER TWICE. DRIVER WAS CARRYING A CHILD AT THE T

20001004Component: TIRES:TREAD/BELTCrash reported1 injured

WHILE DRIVING ABOUT 75-80 MH DRIVER NOTICED A TIRE DEFECT. TIRE TREAD BROKE, CAUSING DRIVER TO LOSE BRAKES, AND VEHICLE FLIPPED OVER TWICE. DRIVER WAS CARRYING A CHILD AT THE T

Showing the 4 most serious of 145 complaints filed with NHTSA.

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