Description
Factory Ford Explorer Workshop Manual (1991-1995)
This official factory-level service manual covers the first-generation Ford Explorer (UN46) sold in the US market from 1991 through 1995, delivering step-by-step repair procedures, torque specs, wiring schematics, and scheduled maintenance data for every major system on the truck.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 4.0L Cologne V6 OHV (155-160 hp) |
| Diesel | N/A |
| Transmissions | Mazda M5OD-R1 5-speed manual; A4LD 4-speed automatic |
| Drive | RWD and 4WD (shift-on-the-fly) |
| Model Years | 1991, 1992, 1993, 1994, 1995 |
| Badge Twins | Mazda Navajo (2-door variant, 1991-1994) |
Common Explorer Repairs Covered
| System | Procedures |
|---|---|
| A4LD Automatic Transmission | Band adjustment, fluid and filter service, full overhaul; addresses known slipping and harsh-shift complaints |
| 4.0L V6 Cooling System | Thermostat and water pump replacement, radiator flush, hose inspection; addresses common coolant leak at intake manifold gasket |
| Front Axle & 4WD Engagement | Manual locking hub service, front differential rebuild, vacuum-actuated 4WD engagement diagnosis and repair |
| Brake System | Front disc pad and rotor replacement, rear drum shoe service, ABS sensor diagnosis, brake line inspection |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Does this manual cover the A4LD transmission problems common on early Explorers?
Yes. The A4LD 4-speed automatic was notorious for slipping and harsh engagement on first-generation Explorers. The manual includes complete overhaul procedures, band adjustment specs, fluid capacity figures, and troubleshooting charts to diagnose and resolve these issues correctly.
Is the Mazda Navajo covered by this manual?
The Mazda Navajo (1991-1994) is a badge twin of the 2-door Explorer UN46 and shares the same 4.0L V6, A4LD automatic, and M5OD-R1 manual drivetrain. Most mechanical procedures in this manual apply directly to the Navajo, though Mazda-specific trim references may differ.
Are full wiring diagrams included for the fuel injection and 4WD systems?
Yes. The electrical section contains complete schematics covering EFI engine management, starting and charging circuits, ABS wiring, and the vacuum-actuated 4WD engagement system. Connector pinouts, wire color codes, and ground locations are all documented.
What format is the manual?
The manual is a PDF file delivered via instant download after purchase. It is fully searchable, printable, and compatible with Windows, Mac, iOS, Android, and any device with a PDF reader.
Reviews
There are no reviews yet.