The Ford Explorer, produced from 1991 to 2001, established itself as a highly popular and versatile mid-size SUV, building on Ford's robust truck and SUV heritage. Available in various trim levels and offering both rear-wheel drive and four-wheel drive configurations, the Explorer was engineered to be capable for families and light off-roading. This generation of Explorer, built on platforms like UN175 and UN105, featured a range of engine options including the 4.0L I6 and the 5.0L V8, paired with reliable automatic or manual transmissions. Its spacious interior, seating up to seven passengers, and significant cargo volume made it a practical choice in a competitive market. This comprehensive Service Repair Manual provides in-depth information essential for the maintenance, diagnosis, and repair of your Ford Explorer. Covering all trim levels and engine variants from 1991-2001, the manual details procedures for powertrain, drivetrain, chassis, electrical systems, and body/interior components. It includes routine maintenance schedules, troubleshooting guides for common issues, detailed repair instructions, and specifications for special tools. This resource is designed to empower owners and technicians, ensuring the longevity and optimal performance of the vehicle through accurate and thorough guidance. 🏷️ Basic Information Identification Make: Ford Model: Explorer Product Name: Ford EXPLORER 1991-2001 Service Repair Manual Generation First Generation Start Year: 1990 Second Generation Start Year: 1994 Codes Vehicle Platform: UN175 (First Gen), UN105 (Second Gen) 👋 Introduction Market Position Segment: Mid-size SUV, highly popular in its era Target Audience: Owners, DIY mechanics, professional repair shops Competitive Analysis Key Competitors: Chevrolet Blazer, Jeep Cherokee (XJ/WJ), Toyota 4Runner, Nissan Pathfinder Key Features Vehicle Appeal: Versatile, capable SUV, often with available 4WD, spacious interior, suitable for families and light off-roading Manual Value Proposition: Provides exhaustive information essential for maintaining and repairing these robust vehicles, empowering owners and saving on service costs. 📋 Manual Details Coverage Areas Covered Years: 1991-2001 Covered Models: All trim levels (e.g., XL, XLT, Eddie Bauer, Sport) Covered Engines: All engine variants offered within the specified years Page Count Estimated Page Count: Varies by specific edition, typically 1500-2500+ pages for comprehensive coverage Manual Type Type: Service Repair Manual (SRM) Language Language: English Format Format: Digital (PDF likely, or bound printed copy) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, emissions control Drivetrain: Automatic transmission, manual transmission, transfer case, front axle, rear axle, driveshafts, CV joints Chassis: Suspension (front and rear), steering system, brake system (front and rear discs/drums), wheels and tires Electrical: Battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, powertrain control modules (PCM) Body And Interior: Body structure, exterior panels, doors, windows, seats, trim, HVAC system, airbags Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, tune-ups, belt and hose inspection/replacement Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, circuit testing Repair: Component removal and installation, overhaul procedures, adjustments, specifications for all major systems Special Tools: Identification of and instructions for using specialized tools required for specific repairs Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine/transmission rebuilds and complex electrical diagnostics 📊 Manual Specifications File Format File Type: Likely PDF, optimized for searchability and printing Print Quality Quality: High resolution for clear diagrams, schematics, and text (assuming quality digital source) Binding Type Binding: N/A for digital; if printed, typically comb, spiral, or perfect bound for durability Paper Type Paper Quality: N/A for digital; if printed, high-quality, durable paper suitable for workshop environments ⚙️ Engine Specifications Primary Engine Engine Codes 1991-1994: 4.0L I6 (Cologne) - #XL, 5.0L V8 (Windsor) - #L Engine Codes 1995-2001: 4.0L I6 (Cologne) - #X, 5.0L V8 (Windsor) - #L (discontinued 1995), 4.0L V6 (Modular - later replaced V8 options) - #E (in 1997-2001 models) Performance 4.0L I6 Hp Approx: 160-170 hp (depending on year and specific tune) 4.0L I6 Torque Approx: 225-235 lb-ft (depending on year and specific tune) 5.0L V8 Hp Approx: 205-210 hp 5.0L V8 Torque Approx: 280-290 lb-ft Fuel System Fuel Delivery Method: Electronic Fuel Injection (EFI) - Sequential Multiport Fuel Injection (SMPI) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type Common: 4-speed Automatic Overdrive (e.g., 4R55E, 4R70W) Optional Transmission Type Optional: 5-speed Manual Transmission (e.g., M5OD-R2) Features Drivetrain Options: Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) - with optional Command-Track or Electronic Shift-On-Demand (ESOF) Transfer Case Types: BorgWarner 1354 manual or electronic transfer cases 📐 Dimensions Exterior Wheelbase 1St Gen: 104.7 inches (2659 mm) Wheelbase 2Nd Gen: 113.7 inches (2888 mm) Interior Seating Capacity: 5-7 passengers (depending on configuration) Cargo Cargo Volume Behind 2Nd Row: Approx. 45-50 cu. ft. (varies by generation) Weights Curb Weight Range: Approx. 3800-4600 lbs (1724-2087 kg) 🛡️ Safety Features Ratings NHTSA Rollover Rating 1St Gen: Often rated 3 or 4 stars (risk of rollover) NHTSA Rollover Rating 2Nd Gen: Often rated 4 or 5 stars (reduced risk of rollover) Active...