The service and repair manual for the 1991 Ford Explorer — the 4.0L V6 engine, 7 trims. Matched to this exact model year, so the specifications and sequences are the ones Ford published for your car, not figures carried over from a neighbouring year.
01 / FitmentWhat this manual covers
| Model year | 1991 |
|---|---|
| Engines | 4.0L V6 — OHV |
| Trims | Eddie Bauer Sport Utility 4-Door · XL Sport Utility 4-Door · Sport Sport Utility 2-Door · 4x4 Sport Utility 4-Door · XL Sport Utility 2-Door · Base Sport Utility 4-Door +1 |
| Federal record | 10 recalls · 764 complaints · 63 technical service bulletins (refreshed 2026-08-21) |
02 / InsideSample pages from the 1991 Explorer manual
03 / ContentsSections in the manual
- Quick Lookups 65
- Engine Performance 1,044
- Accessories & Equipment 257
- General Information 1,479
- Body & Frame 115
- Heating, Ventilation & A/C (HVAC) 201
- Brakes 172
- Maintenance 135
- Drivelines & Axles 183
- Steering 122
- Electrical 162
- Suspension 74
- Engine Mechanical 102
- Transmission 80
04 / Known issuesRecalls on federal record for the 1991 Explorer
- Structure — body › hatchback/liftgate › support device/strut · 95I007000Vehicle description: multi-purpose passenger vehicles. this is not a safety recall in accordance with federal regulation 573. however, it is deemed a safety improvement campaign.
- Tires — tread/belt · 01X001000This 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.
- Tires — tread/belt · 00T005000Tire 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.
- Visibility — sun/moon roof assembly · 90V098000If sunroof glass is removed and reinstalled by vehicle operator, hinge assemblies can be accidentally improperly mated.
- Structure — body › roof and pillars · 97V235001Vehicle description: multi-purpose passenger vehicles equipped with factory installed sunroof. the sunroof glass panel assembly can separate while the vehicle is moving due to in.
- Seat Belts — front › buckle assembly · 92V113000The rigid mounted safety belt buckles are defective in three ways. first, a fastened safety belt buckle will not unlatch when the release button is depressed. this results from int.
- Structure — body › bumpers · 91V026000Rear bumper reinforcement may be subject to fatigue cracking under extended trailer tow service when using a bumper-mounted trailer hitch ball.
- Fuel System, Gasoline — storage › tank assembly · 91V025000The hot plate weld which attaches the vapor vent valve carrier to the top of the plastic fuel tank may partially fracture, allowing vapor of fuel to escape from the top of the tank.
- Fuel System, Gasoline — storage › tank assembly · 91V024000The front heat shield may contact the front of the plastic fuel tank, causing cuts or other damage to the extent of penetration.
- Service Brakes, Hydraulic — power assist › hydraulic · 96V024001The 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.
Owners have filed 764 complaints and Ford has issued 63 technical service bulletins for the 1991 Explorer. The manual carries the manufacturer's diagnostic and repair procedures behind these systems.
FAQQuestions about the 1991 Explorer manual
Is this manual specific to the 1991 Explorer?
Yes. It is the OEM manual matched to the 1991 model year, covering the 4.0L V6 across the Eddie Bauer Sport Utility 4-Door, XL Sport Utility 4-Door, Sport Sport Utility 2-Door, 4x4 Sport Utility 4-Door, XL Sport Utility 2-Door, Base Sport Utility 4-Door, XLT Sport Utility 4-Door trims. Specifications and procedure sequences are the ones Ford published for this year.
What 1991 Explorer problems does it help with?
10 recalls are on federal record for the 1991 Explorer, covering structure, tires, visibility. The manual carries the manufacturer's diagnostic and repair procedures for those systems; the recall repairs themselves are done free by Ford dealers.
Does it include 1991 Explorer wiring diagrams?
Yes — the complete wiring diagrams for the 1991 build, alongside repair procedures, specifications and diagnostics.
Is it a subscription?
No. $42.99 once and the manual is yours. It is a digital manual — nothing ships; access details arrive by email after checkout and it works on any device.
RelatedOther Explorer years and 1991 Ford models
1997 Explorer · 1996 Explorer · 1995 Explorer · 1994 Explorer · 1993 Explorer · 1992 Explorer · all 34 years
1991 Ford Aerostar · 1991 Ford B-200 · 1991 Ford B-600 · 1991 Ford B-700 · 1991 Ford Bronco · 1991 Ford CF7000 · 1991 Ford CF8000 · 1991 Ford CFT8000 · 1991 Ford CL9000 · 1991 Ford CLT9000 · 1991 Ford Cougar · 1991 Ford Country Squire · every 1991 model