1991 Ford Mustang Service And Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Mustang Year: 1991 Codes Chassis Code: Fox Body Platform: Fox 👋 Introduction Market Position Segment: Affordable American Sports Coupe/Convertible Target Audience: Enthusiasts, DIY mechanics, performance modifiers, and owners seeking detailed repair and maintenance information. Competitive Analysis Key Competitors: Chevrolet Camaro, Pontiac Firebird Usp: Iconic styling, accessible performance, strong aftermarket support, and a dedicated enthusiast base. Key Features Engine Options: Durable 2.3L 'Lima' inline-four and the legendary 5.0L (302 cu in) High Output (HO) V8. Handling: Rear-wheel drive chassis with a well-balanced independent front suspension and solid rear axle, providing a classic sporty feel. Design Heritage: Continuation of the successful 'Fox Body' platform, known for its lightweight construction and classic Mustang proportions. Availability: Available as a coupe, convertible, and the high-performance SVT Cobra variant. 📋 Manual Details Coverage Areas Engine Coverage: 2.3L I4, 5.0L V8 (HO) Transmission Coverage: T5 5-speed Manual, AOD 4-speed Automatic Drivetrain Coverage: Rear Wheel Drive (RWD) Body Styles Covered: GTP (Ghia), LX, GT, Cobra (if applicable within VIN range) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Printed Book 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair procedures for both 2.3L I4 and 5.0L V8 engines, including cylinder heads, block, pistons, crankshaft, camshafts, timing, lubrication, cooling systems. Fuel System: EFI systems, fuel pumps, injectors, pressure regulators, lines, EVAP emissions control, fuel tank service. Ignition System: Distributorless Ignition System (DIS) for 2.3L, distributor-based ignition for 5.0L, coil packs, spark plug wires, diagnostic procedures. Emission Control: Catalytic converters, EGR systems, PCV systems, vacuum routing, diagnostic trouble codes (DTCs) related to emissions. Transmission Mechanical: T5 5-speed manual and AOD 4-speed automatic transmission repair, clutch service, linkages, torque converter replacement, internal component overhaul. Drivetrain Components: Driveshaft, U-joints, rear axle assembly (9-inch), differential service, axle bearings, seals. Suspension System: Front MacPherson struts, rear solid axle with control arms and Panhard rod, springs, shock absorbers, bushings, alignment procedures. Steering System: Power steering pump, rack and pinion, steering column, tie rods, universal joints, diagnostic and repair procedures. Brake System: Front disc brakes (Vented for GT/Cobra, solid for others), rear drum brakes, hydraulic system, master cylinder, power booster, ABS (if equipped), bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator), starting system (starter motor), lighting system, accessory circuits, fuses, relays. Climate Control: HVAC system, blower motor, heater core, A/C system (compressor, condenser, evaporator, refrigerant, R-12), controls, ducting. Body And Trim: Exterior panel removal and installation, interior trim, door mechanisms, glass, weatherstripping, bumpers, spoilers. Chassis And Frame: Unibody construction details, structural components, rust prevention measures, jacking and lifting points. Procedures Included Routine Maintenance: Oil changes, fluid checks and replacements, filter changes, spark plug replacement, tune-ups, brake inspections, tire rotations. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation. Major Repairs: Engine rebuilds (short block, long block), transmission overhauls, differential rebuilds, suspension component replacement, steering rack replacement. Electrical Diagnostics: Tracing electrical faults, testing components with multimeters, understanding wiring diagrams, diagnosing sensor and actuator issues. Component Replacement: Step-by-step instructions for replacing key components like alternators, starters, fuel pumps, water pumps, radiators, brake calipers, exhaust systems. Body And Interior Repair: Panel alignment, dent repair, rust repair basics, door lock and window regulator repair, interior trim panel removal and installation. Torque Specifications: Comprehensive list of torque values for all critical fasteners, engine components, chassis parts, and suspension components. Special Tool Identification: Identification and usage guidelines for specialized tools required for specific repair procedures (e.g., timing tools, suspension compressors). Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics and specifications. Diagnostic Capability: Advanced diagnostics for electronic systems, fuel injection, ignition, and emissions control, supported by diagnostic charts and flow diagrams. Rebuild Procedures: Detailed instructions for rebuilding engines, transmissions, differentials, and major suspension components. Wiring Diagrams Quality: High-quality, detailed wiring diagrams for all electrical systems, color-coded and broken down by sub-system. 📊 Manual Specifications File Format Digital Format Compatibility: N/A (Printed Manual) Print Quality Print Type: Professionally printed on durable paper stock. Image Clarity: Clear, high-resolution diagrams, illustrations, and photographs. Binding Type Binding: Professional binding (e.g., perfect bound, spiral bound for ease of use on workbench). Paper Type Paper Quality: Heavyweight paper to withstand shop use and resist grease and oil stains. Usability Navigability: Well-organized with comprehensive table of contents, index, and section tabs for quick access to information. ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.3 Liters (140 cu in) Engine 1 Configuration: Inline-4, SOHC (Single Overhead Cam) Engine 1 Fuel Delivery: Electronic Fuel Injection (EFI) Engine 1 Horsepower: Approx. 105 hp @ 4,200 rpm Engine 1 Torque: Approx. 130 lb-ft @ 2,800 rpm Engine 1 Bore X Stroke: 3.74 in x 3.17 in (95.0 mm x 80.5 mm) Engine...

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Sku: 508552

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Tags: 1991 Car Ford Mustang

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Description

🏷️ Basic Information

Identification

Make:

Model:

Mustang

Year:

Codes

Chassis Code:

Fox Body

Platform:

👋 Introduction

Market Position

Segment:

Affordable American Sports Coupe/Convertible

Target Audience:

Enthusiasts, DIY mechanics, performance modifiers, and owners seeking detailed repair and maintenance information.

Competitive Analysis

Key Competitors:

Chevrolet Camaro, Pontiac Firebird

Iconic styling, accessible performance, strong aftermarket support, and a dedicated enthusiast base.

Key Features

Engine Options:

Durable 2.3L 'Lima' inline-four and the legendary 5.0L (302 cu in) High Output (HO) V8.

Handling:

Rear-wheel drive chassis with a well-balanced independent front suspension and solid rear axle, providing a classic sporty feel.

Design Heritage:

Continuation of the successful 'Fox Body' platform, known for its lightweight construction and classic Mustang proportions.

Availability:

Available as a coupe, convertible, and the high-performance SVT Cobra variant.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.3L I4, 5.0L V8 (HO)

Transmission Coverage:

T5 5-speed Manual, AOD 4-speed Automatic

Drivetrain Coverage:

Rear Wheel Drive (RWD)

Body Styles Covered:

GTP (Ghia), LX, GT, Cobra (if applicable within VIN range)

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Printed Book

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for both 2.3L I4 and 5.0L V8 engines, including cylinder heads, block, pistons, crankshaft, camshafts, timing, lubrication, cooling systems.

Fuel System:

EFI systems, fuel pumps, injectors, pressure regulators, lines, EVAP emissions control, fuel tank service.

Ignition System:

Distributorless Ignition System (DIS) for 2.3L, distributor-based ignition for 5.0L, coil packs, spark plug wires, diagnostic procedures.

Emission Control:

Catalytic converters, EGR systems, PCV systems, vacuum routing, diagnostic trouble codes (DTCs) related to emissions.

Transmission Mechanical:

T5 5-speed manual and AOD 4-speed automatic transmission repair, clutch service, linkages, torque converter replacement, internal component overhaul.

Drivetrain Components:

Driveshaft, U-joints, rear axle assembly (9-inch), differential service, axle bearings, seals.

Suspension System:

Front MacPherson struts, rear solid axle with control arms and Panhard rod, springs, shock absorbers, bushings, alignment procedures.

Steering System:

Power steering pump, rack and pinion, steering column, tie rods, universal joints, diagnostic and repair procedures.

Brake System:

Front disc brakes (Vented for GT/Cobra, solid for others), rear drum brakes, hydraulic system, master cylinder, power booster, ABS (if equipped), bleeding procedures.

Electrical System:

Wiring diagrams, battery, charging system (alternator), starting system (starter motor), lighting system, accessory circuits, fuses, relays.

Climate Control:

HVAC system, blower motor, heater core, A/C system (compressor, condenser, evaporator, refrigerant, R-12), controls, ducting.

Body And Trim:

Exterior panel removal and installation, interior trim, door mechanisms, glass, weatherstripping, bumpers, spoilers.

Chassis And Frame:

Unibody construction details, structural components, rust prevention measures, jacking and lifting points.

Procedures Included

Routine Maintenance:

Oil changes, fluid checks and replacements, filter changes, spark plug replacement, tune-ups, brake inspections, tire rotations.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation.

Major Repairs:

Engine rebuilds (short block, long block), transmission overhauls, differential rebuilds, suspension component replacement, steering rack replacement.

Electrical Diagnostics:

Tracing electrical faults, testing components with multimeters, understanding wiring diagrams, diagnosing sensor and actuator issues.

Component Replacement:

Step-by-step instructions for replacing key components like alternators, starters, fuel pumps, water pumps, radiators, brake calipers, exhaust systems.

Body And Interior Repair:

Panel alignment, dent repair, rust repair basics, door lock and window regulator repair, interior trim panel removal and installation.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners, engine components, chassis parts, and suspension components.

Special Tool Identification:

Identification and usage guidelines for specialized tools required for specific repair procedures (e.g., timing tools, suspension compressors).

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics and specifications.

Diagnostic Capability:

Advanced diagnostics for electronic systems, fuel injection, ignition, and emissions control, supported by diagnostic charts and flow diagrams.

Rebuild Procedures:

Detailed instructions for rebuilding engines, transmissions, differentials, and major suspension components.

Wiring Diagrams Quality:

High-quality, detailed wiring diagrams for all electrical systems, color-coded and broken down by sub-system.

📊 Manual Specifications

File Format

Digital Format Compatibility:

N/A (Printed Manual)

Print Quality

Print Type:

Professionally printed on durable paper stock.

Image Clarity:

Clear, high-resolution diagrams, illustrations, and photographs.

Binding Type

Binding:

Professional binding (e.g., perfect bound, spiral bound for ease of use on workbench).

Paper Type

Paper Quality:

Heavyweight paper to withstand shop use and resist grease and oil stains.

Usability

Navigability:

Well-organized with comprehensive table of contents, index, and section tabs for quick access to information.

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.3 Liters (140 cu in)

Engine 1 Configuration:

Inline-4, SOHC (Single Overhead Cam)

Engine 1 Fuel Delivery:

Electronic Fuel Injection (EFI)

Engine 1 Horsepower:

Approx. 105 hp @ 4,200 rpm

Engine 1 Torque:

Approx. 130 lb-ft @ 2,800 rpm

Engine 1 Bore X Stroke:

3.74 in x 3.17 in (95.0 mm x 80.5 mm)

Engine 1 Compression Ratio:

8.5:1

Engine 1 Cooling System:

Liquid-cooled, pressurized system with radiator and fan.

Engine 2 Variant

Engine 2 Displacement:

5.0 Liters (302 cu in)

Engine 2 Configuration:

V8, Overhead Valve (OHV), Pushrod

Engine 2 Fuel Delivery:

Electronic Fuel Injection (EFI) - Sequential Multi-Port Fuel Injection (SMPI)

Engine 2 Horsepower:

Approx. 225 hp @ 4,000 rpm (GT), 235 hp @ 4,200 rpm (Cobra)

Engine 2 Torque:

Approx. 285 lb-ft @ 3,200 rpm (GT), 300 lb-ft @ 3,200 rpm (Cobra)

Engine 2 Bore X Stroke:

4.00 in x 3.00 in (101.6 mm x 76.2 mm)

Engine 2 Compression Ratio:

9.0:1

Engine 2 Cooling System:

Liquid-cooled, pressurized system with radiator and fan.

Performance

0 60 Mph Gt:

Approx. 6.5-7.0 seconds

Top Speed Gt:

Approx. 130-140 mph

Fuel System

Fuel Type Recommended:

Unleaded gasoline, 87 octane minimum (91 octane recommended for 5.0L HO for optimal performance).

Fuel Tank Capacity:

15.4 gallons (58 L)

🔧 Transmission

Standard

Transmission 1 Type:

T5 Manual Transmission (5-Speed)

Transmission 1 Gear Ratios:

Varies by application, typically around 3.35:1 (1st), 1.93:1 (2nd), 1.29:1 (3rd), 1.00:1 (4th), 0.66:1 (5th OD)

Transmission 1 Fluid Type:

Mercon ATF (Automatic Transmission Fluid) or equivalent

Optional

Transmission 2 Type:

AOD Automatic Transmission (4-Speed with Overdrive)

Transmission 2 Gear Ratios:

Typically 2.46:1 (1st), 1.46:1 (2nd), 1.00:1 (3rd), 0.70:1 (4th OD)

Transmission 2 Fluid Type:

Mercon ATF (Automatic Transmission Fluid) or equivalent

Features

Clutch Type:

Hydraulically actuated single dry plate clutch (for manual transmission)

Driveshaft Material:

Steel

Rear Axle Ratio:

Commonly 2.73:1, 3.08:1, 3.27:1 (GT/Cobra)

📐 Dimensions

Exterior

Wheelbase:

100.4 inches (2548 mm)

Overall Length:

179.0 inches (4547 mm)

Overall Width:

68.3 inches (1735 mm)

Overall Height:

51.5 inches (1308 mm)

Front Track:

57.0 inches (1448 mm)

Rear Track:

56.0 inches (1422 mm)

Ground Clearance:

Approx. 4.5-5.0 inches (114-127 mm)

Wheel Size:

15x7 inch standard, 16x7 inch optional (GT/Cobra)

Tire Size:

205/60VR15 standard, 225/55ZR16 optional (GT/Cobra)

Bolt Pattern:

4 x 4.5 inches (4 x 114.3 mm)

Weights

Curb Weight Coupe 2.3L:

Approx. 2,900 lbs (1315 kg)

Curb Weight Coupe 5.0L:

Approx. 3,150 lbs (1429 kg)

Curb Weight Convertible 5.0L:

Approx. 3,350 lbs (1519 kg)

Cargo

Trunk Volume:

Approx. 11.0 cu ft (311 L)

🛡️ Safety Features

Ratings

NHTSA Driver Side Frontal Impact Rating 1991:

Not explicitly rated by NHTSA for 1991, but considered generally safe for its era.

IIHS Crash Test Results:

No specific IIHS ratings available for this model year.

Active Features

ABS Availability:

Optional on GT and Cobra models.

Passive Features

Airbags:

Driver-side airbag standard.

Seatbelts:

3-point front seatbelts, lap belts for rear occupants.

Rollover Protection:

Convertible models feature reinforced A-pillars and optional factory roll bars.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player, optional premium sound systems with graphic equalizers. CD player was not common in 1991.

Dashboard Design:

Driver-oriented cockpit with analog gauges, including tachometer and speedometer. HVAC controls are manual.

Driver Assistance

Cruise Control:

Optional

Anti Lock Brakes:

Optional (ABS)

Connectivity

Early Electronic Features:

Electronic Fuel Injection (EFI) and Distributorless Ignition System (DIS) for 2.3L were considered advanced for the time.

🔧 Maintenance

Service Intervals

Oil Change Interval Synthetic:

Every 7,500 - 10,000 miles or 6-12 months (with synthetic oil)

Oil Change Interval Conventional:

Every 3,000 - 5,000 miles or 6 months (with conventional oil)

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles or annually

Spark Plug Replacement 2.3L:

Every 30,000 - 60,000 miles

Spark Plug Replacement 5.0L:

Every 30,000 - 60,000 miles (using appropriate plugs)

Transmission Fluid Change Automatic:

Every 30,000 - 60,000 miles (depending on driving conditions)

Transmission Fluid Change Manual:

Every 30,000 - 60,000 miles

Coolant Flush:

Every 2 years or 30,000 miles

Brake Fluid Flush:

Every 2 years or 30,000 miles

Fluid Specifications

Engine Oil 2.3L:

API SF/SG, 5W-30 or 10W-30

Engine Oil 5.0L:

API SF/SG, 5W-30 or 10W-30 (consider 10W-40 for warmer climates or high performance)

Engine Oil Capacity 2.3L:

4.5 quarts (4.3 L) with filter

Engine Oil Capacity 5.0L:

5.0 quarts (4.7 L) with filter

Transmission Fluid Capacity T5:

2.3 quarts (2.2 L)

Transmission Fluid Capacity Aod:

8.0 quarts (7.6 L) dry fill, 5.5 quarts (5.2 L) pan drop and fill

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent, mixed 50/50 with distilled water

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Mercon ATF or compatible fluid

Known Issues

Engine 2.3L Issues:

Head gasket leaks, turbocharger issues (if equipped), oil consumption.

Engine 5.0L Issues:

Oil leaks (rear main seal, valve covers), intake manifold gasket leaks, roller follower wear, occasional timing chain stretch.

Transmission T5 Issues:

Bearing noise, shifter linkage wear, 3rd gear synchro issues.

Transmission Aod Issues:

Slipping, hard shifts, governor issues, seal leaks.

Suspension Issues:

Worn ball joints, tie rod ends, control arm bushings, strut mounts.

Electrical Issues:

Corroded connectors, aging wiring harnesses, faulty sensors (e.g., TPS, MAF, O2 sensors), alternator failure.

Body Issues:

Rust in wheel wells, quarter panels, battery tray area, door bottoms. Headlight motor failure on GT/Cobra.

📚 Vehicle History

Brand Heritage

Ford Legacy:

Ford Motor Company, a global automotive manufacturer with a long history of innovation and popular vehicles.

Model Evolution

Fox Body Era:

The 1991 Mustang is part of the third generation of Mustang, codenamed 'Fox Body', produced from 1979-1993. This generation represented a significant departure from previous models, emphasizing lighter weight and improved aerodynamics.

1991 Updates:

Key updates for 1991 included minor styling tweaks, new wheel designs, and continued refinement of the powertrain and suspension. The 5.0L HO V8 received minor improvements.

Svt Cobra Introduction:

The SVT (Special Vehicle Team) Cobra variant was introduced for the 1993 model year, offering enhanced performance and styling, building upon the 1991 platform.

Production

Manufacturing Location:

Dearborn, Michigan, USA

Production Years For Generation:

1979-1993

Sales Figures 1991:

Over 150,000 units sold for the 1991 model year.

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

The Fox Body Mustang platform consistently received positive reviews for its performance and value throughout its production run. Specific awards for the 1991 model are less common, but it was widely recognized as a benchmark in its segment.

Ratings

Performance Rankings:

Often ranked highly by automotive magazines for its performance-per-dollar, especially the 5.0L V8 models.

Certifications

Manufacturing Quality:

Ford's manufacturing quality for this era was generally considered competitive within the American automotive industry.