1991-2001 Ford Explorer Service and Repair Manual

This 1991-2001 Ford Explorer Service and Repair Manual Covers

Engine and Drivetrain

• Procedures for 4.0L OHV Cologne V6, 4.0L SOHC Cologne V6, and 5.0L High Output (HO) Windsor V8 engines.
• Electronic Fuel Injection (EFI), fuel pressure regulator diagnostics, and distributorless ignition (EDIS) troubleshooting.
• Pushrod, rocker arm, and SOHC timing chain cassette replacement guides.
• Engine cooling system, mechanical fan clutch, water pump, and radiator specifications.
• Exhaust manifold, EGR valve, and catalytic converter repairs.
• Overhaul for 5-speed manual (M5OD-R1), 4-speed automatic (A4LD/4R55E), and 5-speed automatic (5R55E) transmissions.
• Driveshafts, universal joints, transfer cases (Touch Drive, Control Trac, or All-Wheel Drive), and front/rear differential service.

Chassis and Suspension

• Twin I-Beam / Twin Traction Beam (TTB) front suspension repair procedures (1991-1994).
• Independent short-and-long-arm (SLA) front torsion bar suspension servicing (1995-2001).
• Rear leaf spring suspension, shackle pins, and shock absorber replacement.
• Hydraulic power steering pump, steering gear box, and steering rack troubleshooting.
• Wheel alignment specifications including traditional caster, camber, and toe adjustments.
• Front wheel bearing repacking/replacement and integrated rear axle bearing service.

Braking Systems

• ABS module diagnostics, hydraulic control unit, and wheel speed sensor testing.
• Brake master cylinder replacement, vacuum brake booster, and hydraulic line bleeding.
• Dual-piston front brake disc caliper and rear drum brake shoe replacement workflows.
• Rear disc brake assembly configurations (1995-2001 models).
• Mechanical foot-pedal parking brake linkages and cable adjustments.

Electrical and Wiring

• Full factory wiring diagrams, harness routing, and ground terminal locations.
• 12V charging system diagnostics, alternator testing, and starter motor replacement.
• EEC-IV (OBD1) and EEC-V (OBD2) powertrain control module pinout schematics.
• Generic Electronic Module (GEM) and Central Timer Module (CTM) diagnostics.
• Engine bay power distribution box and passenger compartment fuse panel layouts.
• Sealed-beam or composite halogen headlamps, dashboard instrumentation, and power windows.

Air Conditioning and HVAC

• Manual or automatic climate control system diagnostics.
• R-12 (1991-1993) and R-134a (1994-2001) refrigerant servicing and system capacity specifications.
• Blower motor resistor, heater core, and vacuum-operated blend door actuator replacement.
• A/C compressor clutch clearance adjustments and low/high-pressure switch testing.

Body and Interior

• 2-door (Sport) and 4-door interior trim panels, center console, and headliner removal.
• Exterior body panel alignment, door latches, lock cylinders, and liftgate support struts.
• Power door locks, keyless entry remote programming, and factory anti-theft system service.
• Power window motor and manual regulator gear assembly repair.
• Front driver and passenger SRS airbag module, clockspring, and impact sensor service.

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup workflows for OBD2 and code-reading flash sequence guides for OBD1.
• Ford Star tester, New Generation Star (NGS) tester, and standard OBD2 scan tool data workflows.
• Sensor voltage, resistance, and reference signal specifications (MAF, TPS, ECT, O2 sensors).
• Step-by-step troubleshooting workflows for engine cranking but no start, rough idle, or transmission slip.
• Fuel pump relay testing and inertia safety switch reset procedures.

Common Error Codes Covered

This manual provides diagnostic and repair procedures for thousands of manufacturer-specific fault codes and flash counts, including:

Engine Codes

• Code 111 – System Pass (OBD1 EEC-IV Flash Code)
• Code 332 – EGR Valve Opening Insufficient Detected (OBD1 EEC-IV Flash Code)
• P0300 – Random Cylinder Misfire Detected (OBD2 EEC-V Engine Code)
• P0171 – System Too Lean Bank 1 (OBD2 EEC-V Engine Code)
• P0420 – Catalyst Efficiency Below Threshold Bank 1 (OBD2 EEC-V Engine Code)

Transmission Codes

• Code 628 – Excessive Torque Converter Clutch Slippage (OBD1 EEC-IV Flash Code)
• P0715 – Input/Turbine Speed Sensor Circuit Malfunction (OBD2 EEC-V Transmission Code)
• P0751 – Shift Solenoid A Performance or Stuck Off (OBD2 EEC-V Transmission Code)

ABS and Chassis Codes

• Code 22 – Front Left Wheel Speed Sensor Fault (OBD1 Electronic ABS Code)
• C0020 – ABS Pump Motor Control Circuit Malfunction (OBD2 Chassis Code)
• C0031 – Front Wheel Speed Sensor Signal Malfunction (OBD2 Chassis Code)

Network and Electronic Module Codes

• Code 41 – GEM Module Self-Test Fault (Early Electronic Module Diagnostic Code)
• B1311 – Clock Driver Circuit Open (OBD2 Body Control Code)
• B1869 – Airbag Indicator Light Circuit Open or Short to Ground (OBD2 SRS Code)

This manual is ideal for:

• Professional automotive workshops
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Vehicle owners performing DIY repairs
• Automotive training institutions

If you are troubleshooting, maintaining, servicing, or repairing a 1991-2001 Ford Explorer, this is the factory workshop manual you need.

This manual applies to the following model years;

1991 Ford Explorer
1992 Ford Explorer
1993 Ford Explorer
1994 Ford Explorer
1995 Ford Explorer
1996 Ford Explorer
1997 Ford Explorer
1998 Ford Explorer
1999 Ford Explorer
2000 Ford Explorer
2001 Ford Explorer