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1991 Ford Thunderbird CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
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- 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 Thunderbird 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 Thunderbird automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
A/C & Cooling System Maintenance -> Ford Motor Co. -> 1990-2002 Ford Thunderbird & Mercury Cougar
Vehicle: 1991 Ford Thunderbird LX 3.8 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
POWER BRAKES, FORD MOTOR CO. -> SYSTEM SERVICE -> Assembly -> BENDIX, TEVES & DOUBLE DIAPHRAGM BOOSTER -> Disassembly -> SINGLE DIAPHRAGM BOOSTER
Vehicle: 1991 Ford Thunderbird LX 3.8 V6 GAS
BENDIX, TEVES & DOUBLE DIAPHRAGM BOOSTER
On Bendix, Teves and Double Diaphragm Booster type power brake units, overhaul is not required. If it has been determined that the brake booster is defective, replace power brake unit as an assembly. In some instances, the only service required is replacement of the check valve and grommet and pushrod adjustment.
SINGLE DIAPHRAGM BOOSTER
Disassembly
- Remove brake booster from vehicle.
- Place front shell of booster in a vise.
- Remove clevis from valve rod and plunger assembly.
- Remove dust boot from rear shell,Fig. , then place alignment marks on fron...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
Ford Motor Co. Passenger Cars -> Fuel Filter Replacement -> Except 2002-05 Thunderbird, 2000-06 LS, 1984-87 Escort, Tracer, Tempo & Topaz 2.0L Diesel Engine & 1984-85 Continental & Mark VI 2.4L Diesel Engine
Vehicle: 1991 Ford Thunderbird SC 3.8 V6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
When installing the fuel filter, ensure the flow arrow is facing in the pro...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1991 Ford Thunderbird LX 3.8 V6 GAS
Disassemble
Do not clamp driveshaft in jaws of a vice or a similar holding fixture.
- Place driveshaft on a suitable workbench.
- Mark positions of driveshaft components relative to driveshaft tube. This ensures all components are reassembled in same relationship to maintain correct balance.
- Index driveshaft and driveshaft components.
- Clamp U-Joint Tool in a vise.
- Remove snap rings.
- If bearing cup cannot be pressed all way out, remove it with vise grips.
- Remove driveshaft slip-yoke.
- Position driveshaft in U-Joint Tool.
- Press out a bearing cup.
- Rotate driveshaft 180 degrees.
- Press on...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
Starter, Replace
Vehicle: 1991 Ford Thunderbird SC 3.8 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Disconnect starter cable and relay connector from starter solenoid.
- Remove starter motor mounting bolt...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
Ford Motor Co. Cars -> Check Engine Lamp/Malfunction Indicator Lamp (MIL)/Service Engine Soon Lamp -> 1990-94 Models w/EEC-IV
Vehicle: 1991 Ford Thunderbird LX 3.8 V6 GAS
This lamp should light when the ignition is turned On. After the engine is started, the lamp should go off, unless a fault condition is detected by the EEC-IV system. Following diagnosis and repair, the Check Engine/MIL lamp will automatically reset when the stored codes are cleared from the EEC-IV system memory. After diagnosis and repair, the 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, Fig. . On Crown Victoria, Grand Marquis and Town Car models, the...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
Radiator, Replace
Vehicle: 1991 Ford Thunderbird LX 3.8 V6 GAS
- Disconnect battery ground cable.
- Drain cooling system into a suitable container.
- Disconnect coolant recovery hose at radiator.
- Disconnect upper radiator hose.
- Disconnect lower radiator hose.
- Disconnect transmission oil cooler lines.
- Remove two upper shroud retaining bolts at radiator support.
- Lift fan shroud suffi...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Ford Thunderbird AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Ford Thunderbird 5.0 V8 GAS
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COMPONENT LOCATION DIAGRAMS FOR 1991 Ford Thunderbird AUTOMOBILES
Component location diagrams for most 1991 Ford Thunderbird cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Components Diagram for 1991 Ford Thunderbird 3.8 V6 GASComponents on diagram: |
 Body Components Diagram for 1991 Ford Thunderbird LX 5.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Ford Thunderbird AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Ford Thunderbird cars and light trucks sold in the U.S.
 1991 Ford Thunderbird 3.8 V6 GAS Wiring DiagramComponents on diagram: |
 1991 Ford Thunderbird LX 5.0 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Ford Thunderbird AUTOMOBILES
OEM TSB listings for most 1991 Ford Thunderbird cars and light trucks sold in the U.S. from 1985+.
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Document: MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS Vehicle: 1991 Ford Thunderbird 3.8 V6 GAS Auto Systems: |
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Document: MERCON ATF IS BRING REPLACED BY MERCON V ATF AS A SERVICE FLUID Vehicle: 1991 Ford Thunderbird 3.8 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Ford Thunderbird AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Ford Thunderbird 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 Thunderbird 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 Thunderbird 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 Thunderbird 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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