1987-1991 Ford F-150 Repair Manual
The eighth generation Ford F-150 was introduced in 1987 in four body styles: 2-door pickup, 2-door extended cab chassis, 2-door chassis cab and 4-door chassis cab (2WD and 4WD submodels). Four trim levels were available: Custom, XL, XLT Lariat and Nite.
General information: Class: full-size pickup truck; Body style: 2-door pickup, 2-door extended cab chassis, 2-door chassis cab, 4-door chassis cab; Layout: front engine, rear-wheel drive or four-wheel drive; Wheelbase: 133.0 in (3,378 mm); Length: 210.2 in (5,339 mm); Width: 79.0 in (2,007 mm); Height: 70.5-72.5 in (1,790-1,841 mm).
 1987-1991 Ford F-150  3.8L Ford Essex OHV V6 engine  4.9L Ford 300 EFI I6 engine  4.9L Windsor OHV V8 engine  7.3L International IDI Diesel V8 engine  5-speed Mazda M5OD manual transmission |
Engines:
3.8L Essex OHV V6 produced 112 hp (84 kW) at 4,200 rpm and 175 lb·ft (237 N·m) at 2,800 rpm
General information: Configuration: V6; Displacement: 232 cu in (3,797 cc); Cylinder bore: 3.8 in (96.8 mm); Piston stroke: 3.4 in (86.0 mm); Cylinder block alloy: Iron; Cylinder head alloy: Aluminum; Valvetrain: OHV [pushrod] (2 Valves Per Cylinder, 12 Valves total); Fuel system: 2-barrel carburetor; Fuel type: gasoline; Cooling system: Liquid-cooled.
4.9L Ford 300 EFI I6 produced 145 hp (108 kW) and 265 lb·ft (359 N·m)
General information: Configuration: I6; Displacement: 300 cu in (4,916 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.98 in (101.1 mm); Fuel system: fuel injection; Fuel type: gasoline.
4.9L 5.0 Windsor OHV V8 produced 185 hp (138 kW) at 5,200 rpm and 270 lb·ft (366 N·m) at 4,300 rpm
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 302 cu in (4,949 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.0 in (76.2 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron ; Valvetrain: pushrod OHV; Compression ratio: 9.0:1; Supercharger: naturally aspirated; Fuel system: EFI; Fuel type: gasoline; Oil system: Wet sump; Cooling system: Jacketed block.
5.8L Windsor OHV V8 produced 210 hp (157 kW) and 305 lb·ft (414 N·m) [1987], 210 hp (157 kW) and 315 lb·ft (427 N·m) [1988-1991]
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 351 cu in (5,752 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.5 in (88.9 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron ; Valvetrain: pushrod OHV; Compression ratio: 8.0:1; Supercharger: naturally aspirated; Fuel system: Carbureted [1987], EFI [1988-1991]; Fuel type: gasoline; Oil system: Wet sump; Cooling system: Jacketed block.
7.5LFord 385 V8 produced 225 hp (168 kW) at 5,200 rpm and 362 lb·ft (491 N·m) at 3,400 rpm [1987], 225 hp (168 kW) at 5,200 rpm and 390 lb·ft (529 N·m) at 3,400 rpm [1988-1991]
General information: Configuration: Naturally aspirated Big-block V8; Displacement: 460 cu in (7,538 cc); Cylinder bore: 4.4 in (110.8 mm); Piston stroke: 3.9 in (97.8 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron ; Valvetrain: OHV 2 valves per cylinder; Compression ratio: 8.0:1; Supercharger: naturally aspirated; Fuel system: Holley 735 CFM 4-barrel carburetor [1987], EFI [1988-1991]; Fuel type: gasoline.
6.9L International IDI Diesel V8 produced 170 hp (127 kW) at 3,300 rpm and 315 lb·ft (427 N·m) at 1,400 rpm
General information: Configuration: V8; Displacement: 420 cu in (6,883 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 4.2 in (106.7 mm); Cylinder block alloy: Iron; Cylinder head alloy: Iron; Valvetrain: OHV; Management: Mechanical; Fuel system: Indirect injection; Fuel type: Indirect injection.
7.3L International IDI Diesel V8 produced 180 hp (134 kW) at 3,000 rpm and 345 lb·ft (468 N·m) at 1,800 rpm
General information: Configuration: V8; Displacement: 444 cu in (7,276 cc); Cylinder bore: 4.1 in (104.1 mm); Piston stroke: 4.2 in (106.7 mm); Cylinder block alloy: Iron; Cylinder head alloy: Iron; Valvetrain: OHV; Management: Mechanical; Fuel system: Indirect injection; Fuel type: Indirect injection.
Repair operations: repair operations possible with the engine in the vehicle; intake manifold: removal and installation; exhaust manifold: removal and installation; valve covers: removal and installation; cylinder head: removal, inspection and installation; engine: removal and installation; engine block: cleaning and inspection; spark plug thread repair; timing chain wear: check; timing cover and timing chain: removal and installation; oil pump: removal, inspection and installation; oil pan: removal, inspection and installation; camshaft and lifters: removal, inspection and installation; crankshaft: inspection, removal and installation etc.
Transmissions:
3-speed Ford C6 automatic transmission
Gear ratios (overall): I – 2.46:1; II – 1.46:1; III – 1.0:1; R – 2.18:1
4-speed Ford AOD automatic transmission
Gear ratios (overall): I – 2.40:1; II – 1.47:1; III – 1.0:1; IV – 0.67:1; R – 2.00:1
4-speed Ford E4OD automatic transmission
Gear ratios (overall): I – 2.71:1; II – 1.54:1; III – 1.0:1; IV – 0.71:1; R – 2.18:1
4-speed Borg-Warner T18 manual transmission
Gear ratios (overall): I – 4.02:1; II – 2.41:1; III – 1.41:1; IV – 1.0:1; R – 4.73:1
4-speed Borg-Warner T19 manual transmission
Gear ratios (overall): I – 4.02:1; II – 2.41:1; III – 1.41:1; IV – 1.0:1; R – 4.42:1
5-speed Mazda M5OD manual transmission
Gear ratios (overall): I – 3.72:1; II – 2.2:1; III – 1.5:1; IV – 1.0:1; V – 0.79:1; R – 3.42:1
5-speed ZF S5-42 manual transmission
Gear ratios (overall): I – 4.14:1; II – 2.37:1; III – 1.42:1; IV – 1.0:1; V – 0.77:1; R – 3.79:1
Repair operations: shift linkage: inspection, removal, installation and adjustment; throttle valve mechanisms: removal, installation and adjustment; kickdown mechanisms: removal, installation and adjustment; vacuum modulator: check and replacement; band adjustment; automatic transmission: removal and installation; manual transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment etc.
Transfer case:
Borg Warner BW 1356 transfer case
General information: Low-range ratio: 2.69:1; Low-range: 1.00:1; Case Material: magnesium, two piece; Shift Type: manual and electric shift versions produced; Fluid Type: MERCON ATF; Fluid Capacity: 2 quarts capacity; Identification: Metal tag stamped with “1356” located on transfer case, typically on the backside. Magnesium, ribbed, two piece transfer case (two part casting bolted together in the center).
Repair operations: transfer case: removal and installation; transfer case: overhaul; front output shaft oil seal: removal and replacement; rear output shaft oil seal: removal and replacement; rear extension housing bushing: removal and replacement; manual shift lever assembly: removal and installation; electronic shift: removal and installation.
Other manuals: cooling, heating and air conditioning systems; fuel and exhaust systems; engine electrical systems; emissions and engine control systems; driveline; brakes; suspension and steering systems; body; chassis electrical system; wiring diagrams. All 1987-1991 Ford F-150 repair manuals are written specifically for the do-it-yourselfer.
