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1991 Ford F-250 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- 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 F-250 Pickup 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 F-250 Pickup automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-93 Ford Bronco, E-Series, Expedition, F-Series & F-Super Duty
Vehicle: 1991 Ford F-250 Pickup Super CAB 7.3 V8 DIESEL
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BRAKE SERVICE PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
ANTI-LOCK BRAKE SYSTEM, FORD -> COMPONENT REPLACEMENT -> 1990-91 Models -> COMPUTER MODULE -> EXCITER RING -> REAR ANTI-LOCK BRAKE SYSTEM (RABS) VALVE -> REAR ANTI-LOCK BRAKE SYSTEM SENSOR
Vehicle: 1991 Ford F-250 Pickup 4.9 L6 GAS
All components are serviced as assemblies and should not be disassembled.
COMPUTER MODULE
1990-91 Models
- Disconnect battery ground cable.
- On all models, disconnect wiring harness from RABS module.
- On Bronco II, Ranger and Explorer models, remove module to instrument panel retaining screws behind center of instrument panel.
- On Aerostar models, remove module to instrument panel anti-skid plate retaining screws on lefthand side of engine cover under instrument panel.
- On E-Series models, remove parking brake actuator assembly as follows:
- Loosen adjusting nut at equalizer.
- From inside e...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 1985-94 Diesel 6.9L & 7.3L Engines
Vehicle: 1991 Ford F-250 Pickup Super CAB 7.3 V8 DIESEL
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.
- Discon...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Double Cardan -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1991 Ford F-250 Pickup Super CAB 4.9 L6 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 F-250 Pickup AUTOMOBILES
Starter, Replace
Vehicle: 1991 Ford F-250 Pickup 7.5 V8 GAS
- Disconnect battery ground cable.
- Raise and support vehicle, if required.
- Disconnect electrical connector or solenoid relay wire from starter motor.
- Remove starter motor attach...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
Ford Motor Co. Trucks -> Check Engine Lamp -> 1990-91 EEC-IV
Vehicle: 1991 Ford F-250 Pickup Super CAB 5.8 V8 GAS
This lamp will light when the ignition is turned On. After engine is started the lamp should go off, unless a problem has been detected by the EEC-IV system. After diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are cleared from EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be cleared of stored codes as follows:
- With ignition turned Off, connect a jumper wire between Self Test and Self Test Input (STI) connectors.
- On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender apron...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Ford F-250 Pickup 7.5 V8 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition hose clamp at heater core and remove hose.
- Reposition hose clamp at coolant tube and remove hose.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford F-250 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace -> Automatic Tension -> Manual Tension
Vehicle: 1991 Ford F-250 Pickup 5.0 V8 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 F-250 Pickup AUTOMOBILES
Component location diagrams for most 1991 Ford F-250 Pickup cars and light trucks sold in the U.S. from 1990+.
 Frame Rail Components Diagram for 1991 Ford F-250 Pickup 4.9 L6 GASComponents on diagram: |
 Engine Compartment Components Diagram for 1991 Ford F-250 Pickup 7.3 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Ford F-250 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Ford F-250 Pickup cars and light trucks sold in the U.S.
 1991 Ford F-250 Pickup 7.5 V8 GAS Wiring DiagramComponents on diagram: |
 1991 Ford F-250 Pickup 5.0 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Ford F-250 Pickup AUTOMOBILES
OEM TSB listings for most 1991 Ford F-250 Pickup cars and light trucks sold in the U.S. from 1985+.
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Document: TRANSMISSION - 4R100/E40D - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED Vehicle: 1991 Ford F-250 Pickup 5.0 V8 GAS Auto Systems: |
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Document: WHINING / BUZZING NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER Vehicle: 1991 Ford F-250 Pickup 5.0 V8 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Ford F-250 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Ford F-250 Pickup 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 F-250 Pickup 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 F-250 Pickup 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 F-250 Pickup 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
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