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1991 Ford E-150 Econoline CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Ford E-150 Econoline car and truck
repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Ford E-150 Econoline automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-93 Ford Bronco, E-Series, Expedition, F-Series & F-Super Duty
Vehicle: 1991 Ford E-150 Econoline 4.9 L6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
DISC BRAKES, FORD -> General Information -> TROUBLESHOOTING -> BRAKE RATTLE -> BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING -> CALIPER BRAKE FLUID LEAK -> EXCESSIVE PEDAL EFFORT -> EXCESSIVE PEDAL TRAVEL -> HEAVY BRAKE DRAG -> NO BRAKING EFFECT WHEN PEDAL IS DEPRESSED -> PULL, UNEVEN OR GRABBING BRAKES -> REAR BRAKES LOCKING ON APPLICATION
Vehicle: 1991 Ford E-150 Econoline 5.8 V8 GAS
EXCESSIVE PEDAL TRAVEL
- Worn brake lining.
- Shoe and lining knock back after cornering or rough road travel.
- Piston and shoe and lining assembly not properly seated or positioned.
- Air leak or insufficient fluid in system or caliper.
- Loose wheel bearing adjustment.
- Damaged or worn caliper piston seal.
- Improper booster pushrod adjustment.
- Shoe out of flat more than .005 inch.
- Rear brake automatic adjusters inoperative.
- Improperly ground rear brake shoe and lining assemblies.
BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING
- Excessive lateral runout of rotor.
- Rotor excessively out of parallel.
EXCESSIVE P...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1980-92 Econoline w/Gasoline Engine -> Normal Service -> Severe Service
Vehicle: 1991 Ford E-150 Econoline Super 5.0 V8 GAS
Normal Service
S...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1991 Ford E-150 Econoline Club Wagon 5.0 V8 GAS
Single Cardan, Slip Yoke
Disassemble
Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.
- Index-mark the shaft components.
- Remove and discard all four snap rings.
- Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
- If necessary, use a pair of pliers to remove a bearing cup t...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Ford E-150 Econoline Club Wagon 5.8 V8 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly, if required.
- Disconnect wire harness connectors from voltage regulator.
- Remove accessory drive belt.
- Remove alter...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
Ford Motor Co. Trucks -> Low Fuel Level Warning Lamp ->
Vehicle: 1991 Ford E-150 Econoline Club Wagon 5.8 V8 GAS
When fuel level drops below a predetermined level, the CHECK GAUGE indicator should light. The CHECK GAUGE indicator shoul...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
Radiator, Replace
Vehicle: 1991 Ford E-150 Econoline 4.9 L6 GAS
- Disconnect negative battery cable at battery.
- Drain cooling system into a suitable container.
- Remove overflow tube from coolant recovery bottle and detach it from radiator shroud.
- Remove four shroud attaching bolts and position it over fan.
- Remove lower radiator hose and position aside.
- Remove upper radiator hose and p...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford E-150 Econoline AUTOMOBILES
Serpentine Drive Belt, Replace -> Automatic Tension -> Manual Tension
Vehicle: 1991 Ford E-150 Econoline Club Wagon 4.9 L6 GAS
Automatic Tension
- Install suitable 5/16 inch closed end wrench on tensioner pulley bolt, then lift tensioner arm away from belt. Do not use socket and ratchet.
- Remove belt, slowly release tensioner. Do not allow tensioner to snap back, as damage may result.
- Reverse procedure to install.
Manual Tension
- Loosen accessory adjustment bolt and pivot bolt.
- Remove belt.
- Reverse procedure to install, adjust belt tension as follows:
- Lo...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Ford E-150 Econoline AUTOMOBILES
Component location diagrams for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Component Locations Diagram for 1991 Ford E-150 Econoline 5.0 V8 GASComponents on diagram: |
 Instrument Panel Component Locations Diagram for 1991 Ford E-150 Econoline 4.9 L6 GASComponents on diagram: |
CLICK HERE TO GET FULL ACCESS TO 1991 Ford E-150 Econoline PARTS/COMPONENTS LOCATION DIAGRAMS!
WIRING DIAGRAMS FOR 1991 Ford E-150 Econoline AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S.
 1991 Ford E-150 Econoline 4.9 L6 GAS Wiring DiagramComponents on diagram: |
 1991 Ford E-150 Econoline Super 4.9 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Ford E-150 Econoline AUTOMOBILES
OEM TSB listings for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. from 1985+.
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Document: MERCON ATF IS BRING REPLACED BY MERCON V ATF AS A SERVICE FLUID Vehicle: 1991 Ford E-150 Econoline 5.0 V8 GAS Auto Systems: |
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Document: TRANSMISSION - 4R100/E40D - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED Vehicle: 1991 Ford E-150 Econoline 5.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Ford E-150 Econoline AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Ford E-150 Econoline cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
CLICK HERE TO GET FULL ACCESS TO 1991 Ford E-150 Econoline SPECIFICATIONS DATA!
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