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1992-1997 Ford F-150 Repair Manual

Ford F-150 repair manualsThe ninth generation Ford F-150 was introduced in 1992 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). Seven trim levels were available: Custom, XL, XLT, Nite, SVT Lightning, Eddie Bauer and 4×4 Offroad.
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: 116.8 in (2,967 mm) [regular cab 6.75′ box/flareside], 133 in (3,378 mm) [regular cab 8′ box], 138.8 in (3,526 mm) [supercab 6.75′ box/flareside], 155 in (3,937 mm) [supercab 8′ box], 152.2 in (3,866 mm) [crew cab 6.75′ box], 168.4 in (4,277 mm) [crew cab 8′ box]; Length: 197.1 in (5,006 mm) [regular cab 6.75′ box/flareside], 213.3 in (5,418 mm) [regular cab 8′ box], 219.1 in (5,565 mm) [supercab 6.75′ box/flareside], 235.3 in (5,977 mm) [supercab 8′ box], 232.7 in (5,911 mm) [crew cab 6.75′ box], 248.9 in (6,322 mm) [crew cab 8′ box]; Width: 79.0 in (2,007 mm); Height: 70.5-72.5 in (1,790-1,841 mm).

1992-1997 Ford F-150

1992-1997 Ford F-150

3.8L Ford Essex OHV V6 engine

3.8L Ford Essex OHV V6 engine

5.0L Windsor OHV V8 engine

5.0L Windsor OHV V8 engine

7.5L Ford 460 OHV V8 engine

7.5L Ford 460 OHV V8 engine

7.3L International IDI Diesel V8 engine

7.3L International IDI Diesel V8 engine

4-speed 4R70W automatic transmission

4-speed 4R70W automatic transmission

Engines:
3.8L Essex OHV V6 produced 160 hp (119 kW) at 4,000 rpm and 225 lb·ft (305 N·m) at 2,600 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 Truck Six I6 produced 145 hp (108 kW) and 265 lb·ft (359 N·m) [1992-1993], 150 hp (112 kW) and 260 lb·ft (353 N·m) [1994-1997]
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.
5.0L Windsor OHV V8 produced 185 hp (138 kW) at 5,200 rpm and 270 lb·ft (366 N·m) at 4,300 rpm [1992-1993], 195-205 hp (145-153 kW) at 5,200 rpm and 275 lb·ft (373 N·m) at 4,300 rpm [1994-1997]
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 315 lb·ft (427 N·m) [1992], 200 hp (149 kW) and 310 lb·ft (420 N·m) [1993], 240 hp (179 kW) and 340 lb·ft (461 N·m) [1993-1995], 210 hp (157 kW) and 325 lb·ft (441 N·m) [1994-1997]
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 460 OHV V8 produced 230 hp (172 kW) at 5,200 rpm and 390 lb·ft (529 N·m) at 3,400 rpm [1992-1993], 245 hp (183 kW) at 5,200 rpm and 410 lb·ft (556 N·m) at 3,400 rpm [1994-1997]
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.
7.3L International IDI Diesel V8 produced 185 hp (138 kW) at 3,000 rpm and 360 lb·ft (488 N·m) at 1,800 rpm, 190 hp (142 kW) at 3,000 rpm and 390 lb·ft (529 N·m) at 1,800 rpm [turbo]
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.
7.3L Power Stroke V8 produced 215 hp (160 kW) and 425 lb·ft (576 N·m)
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; Fuel type: diesel.
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 4R70W automatic transmission
Gear ratios (overall): I – 2.84:1; II – 1.55:1; III – 1.0:1; IV – 0.7:1; R – 2.32:1
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 NP435E manual transmission
Gear ratios (overall): I – 6.69:1; II – 3.34:1; III – 1.79:1; IV – 1.0:1; R – 8.26:1
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
5-speed ZF S5-47 manual transmission
Gear ratios (overall): I – 5.08:1; II – 2.60:1; III – 1.53:1; IV – 1.0:1; V – 0.77:1; R – 4.66:1
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 1992-1997 Ford F-150 repair manuals are written specifically for the do-it-yourselfer.