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Ford Explorer, Maintaince And Repair Manual

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Table of Contents

SENDING UNITS...........................................................................................................................................237

Introduction..........................................................................................................................................237
Coolant Temperature Sender...............................................................................................................237

TESTING......................................................................................................................................237
REMOVAL & INSTALLATION.................................................................................................239

Oil Pressure Sender and Switch...........................................................................................................241

TESTING......................................................................................................................................241
REMOVAL & INSTALLATION.................................................................................................243

Low Oil Level Sensor..........................................................................................................................245

TESTING......................................................................................................................................245
REMOVAL & INSTALLATION.................................................................................................246

SPECIFICATION CHARTS.........................................................................................................................249

ENGINE MECHANICAL..............................................................................................................................251

Engine..................................................................................................................................................251

REMOVAL & INSTALLATION.................................................................................................251

Valve Rocker Arm Cover....................................................................................................................258

REMOVAL & INSTALLATION.................................................................................................258

Rocker Arms........................................................................................................................................269

REMOVAL & INSTALLATION.................................................................................................269

Rocker Arm Shaft Assembly...............................................................................................................271

REMOVAL & INSTALLATION.................................................................................................271
DISASSEMBLY & REASSEMBLY............................................................................................274

Thermostat...........................................................................................................................................274

REMOVAL & INSTALLATION.................................................................................................274

Intake Manifold....................................................................................................................................280

REMOVAL & INSTALLATION.................................................................................................280

Exhaust Manifold.................................................................................................................................305

REMOVAL & INSTALLATION.................................................................................................305

Radiator................................................................................................................................................314

REMOVAL & INSTALLATION.................................................................................................314

Engine Fan...........................................................................................................................................318

REMOVAL & INSTALLATION.................................................................................................318

Water Pump.........................................................................................................................................323

REMOVAL & INSTALLATION.................................................................................................324

Cylinder Head......................................................................................................................................334

REMOVAL & INSTALLATION.................................................................................................334

Oil Pan.................................................................................................................................................356

REMOVAL & INSTALLATION.................................................................................................356

Oil Pump..............................................................................................................................................364

REMOVAL & INSTALLATION.................................................................................................365

Crankshaft Damper..............................................................................................................................370

REMOVAL & INSTALLATION.................................................................................................370

Timing Belt and Cover........................................................................................................................372

TROUBLESHOOTING................................................................................................................372
REMOVAL & INSTALLATION.................................................................................................372

Timing Chain Cover & Oil Seal..........................................................................................................375

REMOVAL & INSTALLATION.................................................................................................375

Timing Chain and Gears......................................................................................................................387

REMOVAL & INSTALLATION.................................................................................................387
TIMING CHAIN DEFLECTION.................................................................................................407

HOW TO USE THIS BOOK

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Summary of Contents for Explorer

Page 1: ...ChiltonDIY Maintaince and Repair Manual Ford Explorer 1991 1999 ...

Page 2: ...ndard and Metric Measurements 21 SERIAL NUMBER IDENTIFICATION 23 Vehicle Identification Number VIN 23 Vehicle Data 25 Safety Compliance Certification Label 28 Emission Calibration Label 29 Engine 30 Transmission 30 Transfer Case 30 Front Drive Axle 30 Rear Axle 30 ROUTINE MAINTENANCE AND TUNE UP 33 Introduction 33 Air Cleaner Element 40 REMOVAL INSTALLATION 40 Fuel Filter 43 REMOVAL INSTALLATION 4...

Page 3: ...N 89 Ignition Timing 90 GENERAL INFORMATION 90 INSPECTION ADJUSTMENT 90 Valve Lash 92 Idle Speed and Mixture Adjustments 92 Air Conditioning System 93 SYSTEM SERVICE REPAIR 93 PREVENTIVE MAINTENANCE 93 SYSTEM INSPECTION 94 Windshield Wipers 94 ELEMENT REFILL CARE REPLACEMENT 95 Tires and Wheels 96 TIRE ROTATION 97 TIRE DESIGN 97 TIRE STORAGE 99 INFLATION INSPECTION 99 FLUIDS AND LUBRICANTS 103 Flu...

Page 4: ...EL CHECK 140 Clutch Master Cylinder 142 FLUID RECOMMENDATIONS 142 LEVEL CHECK 142 Power Steering Pump Reservoir 142 FLUID RECOMMENDATIONS 142 LEVEL CHECK 143 Manual Steering Gear 144 Chassis Greasing 144 Body Lubrication 145 HOOD DOOR LATCH HINGES 145 LOCK CYLINDERS 145 DOOR WEATHERSTRIPPING 145 THROTTLE VALVE TV KICKDOWN LINKAGE 145 Wheel Bearings 145 REPACKING 146 TOWING THE VEHICLE 151 General ...

Page 5: ...General Information 185 SYSTEM OPERATION 185 Diagnosis and Testing 187 SERVICE PRECAUTIONS 187 PRELIMINARY CHECKS 187 GENERAL SYSTEM TEST 187 Ignition Coil Pack s 199 TESTING 199 REMOVAL INSTALLATION 201 Ignition Control Module ICM 207 REMOVAL INSTALLATION 207 Camshaft Position CMP and Crankshaft Position CKP Sensors 209 FIRING ORDERS 211 CHARGING SYSTEM 217 General Information 217 Alternator Prec...

Page 6: ...ION 271 DISASSEMBLY REASSEMBLY 274 Thermostat 274 REMOVAL INSTALLATION 274 Intake Manifold 280 REMOVAL INSTALLATION 280 Exhaust Manifold 305 REMOVAL INSTALLATION 305 Radiator 314 REMOVAL INSTALLATION 314 Engine Fan 318 REMOVAL INSTALLATION 318 Water Pump 323 REMOVAL INSTALLATION 324 Cylinder Head 334 REMOVAL INSTALLATION 334 Oil Pan 356 REMOVAL INSTALLATION 356 Oil Pump 364 REMOVAL INSTALLATION 36...

Page 7: ...SION TEST 443 OIL PRESSURE TEST 444 Buy or Rebuild 445 Engine Overhaul Tips 445 TOOLS 446 OVERHAUL TIPS 446 CLEANING 447 REPAIRING DAMAGED THREADS 449 Engine Preparation 451 Cylinder Head 452 DISASSEMBLY 453 INSPECTION 464 REFINISHING REPAIRING 468 ASSEMBLY 471 Engine Block 471 GENERAL INFORMATION 472 DISASSEMBLY 472 INSPECTION 475 REFINISHING 478 ASSEMBLY 480 Engine Start up and Break in 486 STAR...

Page 8: ... 540 TESTING 540 REMOVAL INSTALLATION 541 Engine Coolant Temperature ECT Sensor 542 OPERATION 542 TESTING 543 REMOVAL INSTALLATION 544 Intake Air Temperature IAT Sensor 545 OPERATION 545 TESTING 545 REMOVAL INSTALLATION 545 Mass Air Flow MAF Sensor 546 OPERATION 546 TESTING 547 REMOVAL INSTALLATION 548 Throttle Position TP Sensor 550 OPERATION 550 TESTING 551 REMOVAL INSTALLATION 552 Camshaft Posi...

Page 9: ...EL LINES AND FITTINGS 603 General Information 603 Hairpin Clip Fitting 603 REMOVAL INSTALLATION 603 Duckbill Clip Fitting 605 REMOVAL INSTALLATION 605 REMOVAL INSTALLATION 607 SEQUENTIAL FUEL INJECTION SFI SYSTEM 609 General Information 609 FUEL SYSTEM SERVICE PRECAUTIONS 610 Relieving Fuel System Pressure 610 Inertia Switch 611 GENERAL INFORMATION 611 RESETTING THE SWITCH 611 Fuel Pump 613 REMOVA...

Page 10: ... MULTIMETERS 658 Troubleshooting Electrical Systems 659 Testing 659 OPEN CIRCUITS 659 SHORT CIRCUITS 660 VOLTAGE 660 VOLTAGE DROP 661 RESISTANCE 661 Wire and Connector Repair 663 BATTERY CABLES 665 AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM 667 SERVICE PRECAUTIONS 668 DISARMING THE SYSTEM 668 ARMING THE SYSTEM 668 HEATING AND AIR CONDITIONING 669 Blower Motor 669 REMOVAL INSTALLATION 669 Blower Motor R...

Page 11: ...OVAL INSTALLATION 705 Fuel Oil Pressure Voltage and Coolant Temperature Gauges 709 REMOVAL INSTALLATION 709 Rear Wiper Switch 711 REMOVAL INSTALLATION 711 Headlight Switch 711 REMOVAL INSTALLATION 712 Back up Light Switch 713 Manual Transmissions 713 LIGHTING 717 Headlights 717 REMOVAL INSTALLATION 717 AIMING THE HEADLIGHTS 721 Signal and Marker Lights 723 REMOVAL INSTALLATION 723 Fog Driving Ligh...

Page 12: ...er 766 REMOVAL INSTALLATION 766 BLEEDING THE SYSTEM 768 Driven Disc and Pressure Plate 768 REMOVAL INSTALLATION 768 AUTOMATIC TRANSMISSION 775 Understanding the Automatic Transmission 775 Identification 775 Neutral Start Switch Back up Switch 775 REMOVAL INSTALLATION 775 ADJUSTMENT 779 Vacuum Diaphragm 779 REMOVAL INSTALLATION 779 Extension Housing Seal 780 REMOVAL INSTALLATION 780 Transmission As...

Page 13: ...ormation 817 Manual Locking Hubs 817 REMOVAL INSTALLATION 817 Automatic Locking Hubs 819 REMOVAL INSTALLATION 819 Vacuum Disconnect Axle Lock 821 REMOVAL INSTALLATION 821 Spindles and Spindle Bearings 823 REMOVAL INSTALLATION 823 Axle Shafts and Seals 824 REMOVAL INSTALLATION 824 Axle Housing 830 REMOVAL INSTALLATION 830 REAR AXLE 837 Determining Axle Ratio 837 Axle Shaft Bearing and Seal 837 REMO...

Page 14: ...STALLATION 876 Upper Control Arm 877 REMOVAL INSTALLATION 877 Lower Control Arm 879 REMOVAL INSTALLATION 879 Front Wheel Bearings 881 REMOVAL INSTALLATION 881 ADJUSTMENT 886 Wheel Alignment 887 CASTER 887 CAMBER 888 TOE 888 4 WHEEL DRIVE FRONT SUSPENSION 891 Introduction 891 Coil Springs 893 REMOVAL INSTALLATION 893 Torsion Bars 894 REMOVAL INSTALLATION 894 RIDE HEIGHT ADJUSTMENT 896 Shock Absorbe...

Page 15: ...ALLATION 939 Combination Switch 945 REMOVAL INSTALLATION 945 Ignition Switch 946 REMOVAL INSTALLATION 946 Ignition Lock Cylinder Assembly 947 REMOVAL INSTALLATION 947 Steering Column 948 REMOVAL INSTALLATION 948 Steering Linkage 950 REMOVAL INSTALLATION 951 Manual Steering Gear 956 ADJUSTMENTS 957 REMOVAL INSTALLATION 958 Power Steering Gear 959 ADJUSTMENTS 959 REMOVAL INSTALLATION 959 Power Rack ...

Page 16: ... Disc 1012 REMOVAL INSTALLATION 1012 INSPECTION 1012 REAR DRUM BRAKES 1015 Introduction 1015 Brake Drums 1017 REMOVAL INSTALLATION 1017 INSPECTION 1018 Brake Shoes 1019 REMOVAL INSTALLATION 1019 ADJUSTMENTS 1029 Wheel Cylinders 1032 REMOVAL INSTALLATION 1032 OVERHAUL 1033 REAR DISC BRAKES 1039 General Information 1039 Brake Pads 1039 REMOVAL INSTALLATION 1039 INSPECTION 1041 Brake Caliper 1041 REM...

Page 17: ...TING 1064 REMOVAL INSTALLATION 1065 Electronic Control Unit 1065 REMOVAL INSTALLATION 1065 Front Wheel Speed Sensor 1066 TESTING 1066 REMOVAL INSTALLATION 1066 Rear Speed Sensor 1066 TESTING 1066 REMOVAL INSTALLATION 1066 Front Speed Sensor Ring 1067 REMOVAL INSTALLATION 1068 Rear Speed Sensor Ring 1068 REMOVAL INSTALLATION 1068 SPECIFICATION CHARTS 1069 EXTERIOR 1071 Doors 1071 REMOVAL INSTALLATI...

Page 18: ...rior Trim Panels 1109 REMOVAL INSTALLATION 1109 Instrument Panel 1114 REMOVAL INSTALLATION 1114 Center Console 1117 REMOVAL INSTALLATION 1117 Headliner 1119 REMOVAL INSTALLATION 1119 Door Locks 1121 REMOVAL INSTALLATION 1121 Door Glass and Regulator 1123 REMOVAL INSTALLATION 1124 Electric Window Motor 1128 REMOVAL INSTALLATION 1128 Windshield and Fixed Glass 1129 REMOVAL INSTALLATION 1129 WINDSHIE...

Page 19: ...stall the new or rebuilt replacement In this way you at least save labor costs Avoiding Trouble Many procedures in this book require you to label and disconnect a group of lines hoses or wires Don t be think you can remember where everything goes you won t If you hook up vacuum or fuel lines incorrectly the vehicle may run poorly if at all If you hook up electrical wiring incorrectly you may insta...

Page 20: ...assembly If a torque figure is not available remember that if you are using the right tool to perform the job you will probably not have to strain yourself to get a fastener tight enough The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you are tightening 2 There are many commercial products available for ensuring th...

Page 21: ...ols Your monetary savings will be far outweighed by frustration and mangled knuckles Begin accumulating those tools that are used most frequently those associated with routine maintenance and tune up In addition to the normal assortment of screwdrivers and pliers you should have the following tools Wrenches sockets and combination open end box end wrenches in sizes from 1 8 3 4 in or 3 19mm as wel...

Page 22: ...n assortment of ratchets and sockets In addition to ratchets a good set of wrenches and hex keys will be necessary A hydraulic floor jack and a set of jackstands are essential for lifting and supporting the vehicle HOW TO USE THIS BOOK 4 Introduction ...

Page 23: ...rtment of pliers grippers and cutters will be handy for old rusted parts and stripped bolt heads Various drivers chisels and prybars are great tools to have in your toolbox HOW TO USE THIS BOOK Introduction 5 ...

Page 24: ...ing a few projects on the vehicle you ll be amazed at the other tools and non tools on your workbench Some useful household items are a large turkey baster or siphon empty coffee cans and ice trays to store parts a ball of twine electrical tape for wiring small rolls of colored tape for tagging lines or hoses markers and pens a note pad golf tees for plugging vacuum lines metal coat hangers or a r...

Page 25: ...A few inexpensive lubrication tools will make maintenance easier Various pullers clamps and separator tools are needed for many larger more complicated repairs HOW TO USE THIS BOOK Introduction 7 ...

Page 26: ...A variety of tools and gauges should be used for spark plug gapping and installation Inductive type timing light HOW TO USE THIS BOOK 8 Introduction ...

Page 27: ...A screw in type compression gauge is recommended for compression testing A vacuum pressure tester is necessary for many testing procedures HOW TO USE THIS BOOK Introduction 9 ...

Page 28: ... always have a Chilton Total Car Care manual handy A more advanced set of tools suitable for tune up work can be drawn up easily While the tools are slightly more sophisticated they need not be outrageously expensive There are several inexpensive tach dwell meters HOW TO USE THIS BOOK 10 Introduction ...

Page 29: ...ng whether or not there is current in a wire These are handy for use if a wire is broken somewhere in a wiring harness As a final note you will probably find a torque wrench necessary for all but the most basic work The beam type models are perfectly adequate although the newer click types breakaway are easier to use The click type torque wrenches tend to be more expensive Also keep in mind that a...

Page 30: ...ent most accidents The rules of safety for mechanics range from don t smoke around gasoline to use the proper tool s for the job The trick to avoiding injuries is to develop safe work habits and to take every possible precaution Screwdrivers should be kept in good condition to prevent injury or damage which could result if the blade slips from the screw SERVICING YOUR VEHICLE SAFELY 13 ...

Page 31: ... undervehicle service Jacks are for raising vehicles jackstands are for making sure the vehicle stays raised until you want it to come down Do use adequate ventilation when working with any chemicals or hazardous materials Like carbon monoxide the asbestos dust resulting from some brake lining wear can be hazardous in sufficient quantities Do disconnect the negative battery cable when working on t...

Page 32: ...under a hat or cap Don t use pockets for toolboxes A fall or bump can drive a screwdriver deep into your body Even a rag hanging from your back pocket can wrap around a spinning shaft or fan Don t smoke when working around gasoline cleaning solvent or other flammable material Don t smoke when working around the battery When the battery is being charged it gives off explosive hydrogen gas Don t use...

Page 33: ...e But you should always inspect the condition of a retainer when it is removed and replace any that show signs of damage Check all threads for rust or corrosion which can increase the torque necessary to achieve the desired clamp load for which that fastener was originally selected Additionally be sure that the driver surface of the fastener has not been compromised by rounding or other damage In ...

Page 34: ... is not too badly damaged you can select a match by finding another bolt which will thread in its place If you find a nut which threads properly onto the damaged bolt then use that nut to help select the replacement bolt WARNING Be aware that when you find a bolt with damaged threads you may also find the nut or drilled hole it was threaded into has also been damaged If this is the case you may ha...

Page 35: ...an be used to assure proper installation of a fastener Torque wrenches come in various designs and most automotive supply stores will carry a variety to suit your needs A torque wrench should be used any time we supply a specific torque value for a fastener Again the general rule of if you are using the right tool for the job you should not have to strain to tighten a fastener applies here Beam Ty...

Page 36: ...wrench driver will have the least effect on the torque reading Avoid any extension that alters the length of the wrench from the handle to the head driving point such as a crow s foot U joint or wobble extensions can greatly affect the readings avoid their use at all times Rigid Case Direct Reading A rigid case or direct reading torque wrench is equipped with a dial indicator to show torque values...

Page 37: ... measuring devices which are available today will have two scales so the Standard or Metric measurements may easily be taken If any of the various measuring tools which are available to you do not contain the same scale as listed in the specifications use the accompanying conversion factors to determine the proper value The conversion factor chart is used by taking the given specification and mult...

Page 38: ... the windshield on the driver s side The VIN number is also found on the Safety Compliance Certification Label which is described below A sample breakdown of the VIN number Click to enlarge VIN plate location The VIN plate as seen through the windshield By looking at the 17 digit VIN number a variety of information about the vehicle can be determined The 1st digit identifies the country of origin ...

Page 39: ...bs C 4 001 5 000 lbs D 5 001 6 000 lbs E 6 001 7 000 lbs F 7 001 8 000 lbs G 8 001 8 500 lbs H 8 500 9 000 lbs J 9 001 10 000 lbs The 5th digits identifies the model or line R Ranger U Explorer Mountaineer The 6th and 7th digits identify chassis and body type The 8th digit identifies the engine A 2 3L 4 cylinder C 2 5L 4 cylinder T 2 9L 6 cylinder U 3 0L 6 cylinder E 4 0L SOHC 6 cylinder X 4 0L 6 ...

Page 40: ...aul MN T Edison NJ U Louisville KY Z Hazlewood MO Digits twelve through seventeen make up the sequential serial and warranty number Digit twelve uses the letter A until the production or sequence of 99 999 units digits thirteen through seventeen is reached Letter A then becomes B for the next production sequence of vehicles Vehicle Data HOW TO USE THIS BOOK Vehicle Data 25 ...

Page 41: ...Vehicle certification labels Click to enlarge HOW TO USE THIS BOOK 26 Vehicle Data ...

Page 42: ...the interior trim seat and body type The transmission installed in the vehicle is identified under TRANS by an alphabetical code A letter and a number or two numbers under AXLE identify the rear axle ratio and when required a letter or number is also stamped after the rear axle code to identify the front axle The letters and or numerals under TAPE designate the external body side tape stripe code ...

Page 43: ...n Label is affixed to the door latch edge on the passenger s side door The label contains the following information name of manufacturer the month and year of manufacture the certification statement and the Vehicle Identification number The label also contains information on Gross Vehicle weight ratings Wheel and tire data and additional vehicle data information codes HOW TO USE THIS BOOK 28 Safet...

Page 44: ...hed to the left side door or the left door post pillar This label plate identifies the engine calibration number engine code number and the revision level These numbers are used to determine if parts are unique to specific engines The engine codes and calibration are necessary for ordering parts and asking questions related to the engine HOW TO USE THIS BOOK Emission Calibration Label 29 ...

Page 45: ...es when the transmission was built it s code letter and model number There were two types of manual transmissions used from 1991 99 the Misubishi 5 speed and the Mazda M5OD The Mitsubishi 5 speed was only used on 1991 92 4X4 Rangers with the 2 9L engine All other applications used the M5OD transmission Transfer Case All vehicles can be equipped with a mechanical or electronic shift transfer case T...

Page 46: ... axle identification code is also stamped on a metal tag hanging from the axle cover to carrier bolt at the 2 o clock position in the cover bolt circle Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK Rear Axle 31 ...

Page 47: ...ROUTINE MAINTENANCE AND TUNE UP Introduction UNDERHOOD MAINTENANCE COMPONENT LOCATIONS Click to enlarge ROUTINE MAINTENANCE AND TUNE UP 33 ...

Page 48: ...UNDERVEHICLE MAINTENANCE COMPONENT LOCATIONS Click to enlarge HOW TO USE THIS BOOK 34 Introduction ...

Page 49: ...Ranger underhood maintenance component locations for the 2 3L engine 2 5L engine similar Click to enlarge HOW TO USE THIS BOOK Introduction 35 ...

Page 50: ...ger underhood maintenance component locations for the 2 9L engine Click to enlarge Ranger underhood maintenance component locations for the 3 0L engine Click to enlarge HOW TO USE THIS BOOK 36 Introduction ...

Page 51: ...ineer underhood maintenance component locations for the 4 0L engine Click to enlarge Ranger Explorer Mountaineer chassis lubrication points for two wheel drive 4x2 models Click to enlarge HOW TO USE THIS BOOK Introduction 37 ...

Page 52: ...h the parts cost you the date and the exact odometer reading at the time Keep all receipts for such items as engine oil and filters so that they may be referred to in case of related problems or to determine operating expenses As a do it yourselfer these receipts are the only proof you have that the required maintenance was performed In the event of a warranty problem these receipts will be invalu...

Page 53: ...rtant maintenance and tune up information can be found on the emission label under the hood There are also several labels which give safety information Click to enlarge HOW TO USE THIS BOOK Introduction 39 ...

Page 54: ...ten if the vehicle is operated under severe dusty conditions and replace it as necessary REMOVAL INSTALLATION The Ranger Explorer and Mountaineer vehicles used two types of air cleaner housings the square panel and the conical or canister type The square panel type retains the housing cover by bolts or on later models bail clips The conical type utilizes a full circumference clamp around the housi...

Page 55: ...Air cleaner assembly for the 3 0L and 4 0L engine 2 9L engine similar Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 41 ...

Page 56: ...mperature sensor electrical connector from the air cleaner housing 2 Some air cleaner assemblies will have enough give in the air inlet pipe and sensor wiring harnesses to allow filter replacement without removing or disconnecting these items Disconnect the hose and inlet tube from the air cleaner 3 Loosen the air cleaner cover retaining screws arrow then gently lift the assembly up enough HOW TO ...

Page 57: ...tainer Spread the two hairpin clip legs about 1 8 in 3mm each to disengage it from the fitting then pull the clip outward Use finger pressure only do not use any tools Push the quick connect fittings onto the filter ends Ford recommends that the retaining clips be replaced whenever removed The fuel tubes used on these fuel systems are manufactured in 5 16 in and 3 8 in diameters Each fuel tube tak...

Page 58: ...uel filter is mounted to the drivers side frame rail by a bracket which also acts as a protective shield Click to enlarge Inertia switch location Click to enlarge HOW TO USE THIS BOOK 44 REMOVAL INSTALLATION ...

Page 59: ...Close up of a 5 16 in push connect fitting Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 45 ...

Page 60: ... follows CAUTION If the fuel filter is being serviced with the rear of the vehicle higher than the front or if the tank is pressurized fuel leakage or siphoning from the tank fuel lines could occur to prevent this condition maintain the vehicle front end at or above the level of the rear of vehicle also relieve tank pressure by loosening the fuel fill cap cap should be tightened after pressure is ...

Page 61: ...bout 15 30 seconds or if the vehicle starts until it runs out of fuel 2 Raise and support the vehicle safely 2 Remove the fuel filter mounting bracket retaining nuts then loosen the filter retaining clamp and slide the bracket assembly back HOW TO USE THIS BOOK REMOVAL INSTALLATION 47 ...

Page 62: ...he old filter 4 Remove the filter from the bracket by loosening the filter retaining clamp enough to allow the filter to pass through 5 The flowdirection arrow should be positioned as installed in the bracket to ensure proper flow of fuel through the replacement filter Install the filter in the bracket ensuring proper direction of flow as noted by arrow Tighten clamp to 15 25 inch lbs 6 Install th...

Page 63: ...is can restore the valve to some level of operating order This should be used only in emergency situations Otherwise the valve should be replaced at least once a year Always check PCV valve hose for wear or cracks during service procedure REMOVAL INSTALLATION Remove the PCV valve by simply disconnecting the vacuum hose from the valve then pulling the valve from the rocker cover grommet Remove the ...

Page 64: ...6km or 10 years of vehicle use No maintenance or service should be required except in the case of damage or malfunction If either condition should exist simply replace that component Battery PRECAUTIONS Always use caution when working on or near the battery Never allow a tool to bridge the gap between the negative and positive battery terminals Also be careful not to allow a tool to provide a grou...

Page 65: ...clear water DO NOT let any of the solution into the filler holes Baking soda neutralizes battery acid and will de activate a battery cell Batteries in vehicles which are not operated on a regular basis can fall victim to parasitic loads small current drains which are constantly drawing current from the battery Normal parasitic loads may drain a battery on a vehicle that is in storage and not used ...

Page 66: ...hecked using the built in hydrometer eye The exact type of eye will vary But most battery manufacturers apply a sticker to the battery itself explaining the readings Although the readings from built in hydrometers will vary a green eye usually indicates a properly charged battery with sufficient fluid level A dark eye is normally an indicator of a battery with sufficient fluid but which is low in ...

Page 67: ...level can be checked by removing the cell caps If the fluid level is low add only distilled water until the level is correct Check the specific gravity of the battery s electrolyte with a hydrometer HOW TO USE THIS BOOK BATTERY FLUID 53 ...

Page 68: ...r charging the specific gravity between any two cells varies more than 50 points 0 50 the battery should be replaced as it can no longer produce sufficient voltage to guarantee proper operation CABLES Once a year or as necessary the battery terminals and the cable clamps should be cleaned Loosen the clamps and remove the cables negative cable first On top post batteries the use of a puller special...

Page 69: ...A special tool is available to pull the clamp from the post The underside of this special battery tool has a wire brush to clean post terminals HOW TO USE THIS BOOK CABLES 55 ...

Page 70: ...Place the tool over the battery posts and twist to clean until the metal is shiny The cable ends should be cleaned as well HOW TO USE THIS BOOK 56 CABLES ...

Page 71: ...installed Deterioration and just plain aging of the battery cables starter motor and associated wires makes the battery s job harder in successive years This makes it prudent to install a new battery with a greater capacity than the old Belts All 1991 92 engines except the 4 0L have manual belt tension adjustment All 1993 99 engines use a serpentine belt with an automatic adjusting belt tensioner ...

Page 72: ...e belt Deep cracks in this belt will cause flex building up heat that will eventually lead to belt failure The cover of this belt is worn exposing the critical reinforcing cords to excessive wear HOW TO USE THIS BOOK 58 INSPECTION ...

Page 73: ...uld give about 1 4 1 2 in If the belt is loose it will slip If the belt is too tight it will damage bearings in the driven unit Those units being driven such as the alternator power steering pump or compressor have a bolt which when loosened allows the unit to move for belt adjustment Sometimes it is necessary to loosen the pivot bolt also to make the adjustment HOW TO USE THIS BOOK ADJUSTMENT 59 ...

Page 74: ...Belt routing and tension adjustments 1991 92 models with the 2 3L engine Click to enlarge HOW TO USE THIS BOOK 60 ADJUSTMENT ...

Page 75: ...Belt routing and tension adjustments 1991 92 Ranger with the 2 9L engine Click to enlarge HOW TO USE THIS BOOK ADJUSTMENT 61 ...

Page 76: ...Belt routing and tension adjustments 1991 92 models with the 3 0L engine and A C Click to enlarge HOW TO USE THIS BOOK 62 ADJUSTMENT ...

Page 77: ...egative battery cable for safety This will help assure that no one mistakenly cranks the engine over with your hands between the pulleys 1 Accessories which can be moved will have a slot in its mounting bracket Some engines utilize a movable idler pulley for tension adjustment Also some may have a 1 2 square hole for using a 1 2 square drive breaker bar to aid in removal and tensioning Loosen the ...

Page 78: ...ive the engine accessories such as the water pump alternator air conditioner compressor air pump etc Because this belt uses a spring loaded tensioner for adjustment belt replacement tends to be somewhat easier than it used to be on engines where accessories were pivoted and bolted in place for tension adjustment Basically all belt replacement involves is to pivot the tensioner to loosen the belt t...

Page 79: ...Belt routing diagram 3 0L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 65 ...

Page 80: ...Belt routing diagram 4 0L engines VIN code X Click to enlarge Belt routing diagram 4 0L SOHC engines VIN code E HOW TO USE THIS BOOK 66 REMOVAL INSTALLATION ...

Page 81: ...es that of the belt routing label or one of the diagrams in this book If for some reason a diagram does not match you may not have the original engine or it may have been modified carefully note the changes on a piece of paper For tensioners equipped with a 1 2 square hole insert the drive end of a large breaker bar into the hole Use the breaker bar to pivot the tensioner away from the drive belt ...

Page 82: ...gnition OFFand check that the belt tensioner arrow is within the proper adjustment range 9 Timing Belts INSPECTION Only the 2 3L and 2 5L OHC engine uses a rubber timing belt All other engines use a timing chain and no periodic inspection is required The 2 3L and 2 5L Ranger engine utilizes a timing belt to drive the camshaft from the crankshaft s turning motion and to maintain proper valve timing...

Page 83: ...l any time the engine timing cover s is are removed you should inspect the belt for premature parting severe cracks or missing teeth Also an access plug is provided in the upper portion of the timing cover so that camshaft timing can be checked without cover removal If timing is found to be off cover removal and further belt inspection or replacement is necessary Do not bend twist or turn the timi...

Page 84: ...if the teeth are cracked or damaged Look for noticeable cracks or wear on the belt face You may only have damage on one side of the belt if so the guide could be the culprit HOW TO USE THIS BOOK 70 INSPECTION ...

Page 85: ...n get in between the teeth and cause damage Inspect the timing belt for cracks fraying glazing or damage of any kind Damage on only one side of the timing belt may indicate a faulty guide HOW TO USE THIS BOOK INSPECTION 71 ...

Page 86: ...ust be rotated one full turn to bring the No 1 piston back to the top and the camshaft around to close the No 1 intake and exhaust valves With the O marks aligned look through the access hole in the cover to assure that the timing mark on the camshaft sprocket aligns with the pointer on the inner belt cover If the belt timing is incorrect the timing cover and belt must be removed for further inspe...

Page 87: ... necessary Run your hand along the length of the hose If a weak or swollen spot is noted when squeezing the hose wall the hose should be replaced The cracks developing along this hose are a result of age related hardening A hose clamp that is too tight can cause older hoses to separate and tear on either side of the clamp HOW TO USE THIS BOOK INSPECTION 73 ...

Page 88: ...ap a thick cloth around the pressure cap and turn it slowly to the stop Step back while the pressure is released from the cooling system When you are sure all the pressure has been released use the cloth to turn and remove the cap Remove the radiator pressure cap 1 Position a clean container under the radiator and or engine draincock or plug then open the drain and allow the cooling system to drai...

Page 89: ...age the neck of the component from which the hose is being removed 4 If the hose is stuck at the connection do not try to insert a screwdriver or other sharp tool under the hose end in an effort to free it as the connection and or hose may become damaged Heater connections especially may be easily damaged by such a procedure If the hose is to be replaced use a single edged razor blade to make a sl...

Page 90: ...l operating temperature BE EXTREMELY CAREFUL not to touch any moving or hot engine parts Once temperature has been reached shut the engine OFF and check for leaks around the hose fittings and connections which were removed earlier CV Boots INSPECTION The Mountaineer and 1995 99 Explorer 4 wheel drive models use an Independent Front Suspension IFS drive axle which utilizes Constant Velocity CV join...

Page 91: ... its tip is just past and parallel to the tip of the center electrode The distance between these two electrodes measured in thousandths of an inch or hundredths of a millimeter is called the spark plug gap The spark plug does not produce a spark but instead provides a gap across which the current can arc The coil produces anywhere from 20 000 to 50 000 volts depending on the type and application w...

Page 92: ...the insulator the closer the electrode is to the block s cooling passages the cooler it will operate A plug that absorbs little heat and remains too cool will quickly accumulate deposits of oil and carbon since it is not hot enough to burn them off This leads to plug fouling and consequently to misfiring A plug that absorbs too much heat will have no deposits but due to the excessive heat the elec...

Page 93: ... Click to enlarge The general rule of thumb for choosing the correct heat range when picking a spark plug is if most of your driving is long distance high speed travel use a colder plug if most of your driving is stop and go use a hotter plug Original equipment plugs are generally a good compromise between the 2 styles and most people never have the need to change their plugs from the factory reco...

Page 94: ...oltage output of modern ignition systems will often allow an engine to run significantly longer on a set of standard spark plugs but keep in mind that efficiency will drop as the gap widens along with fuel economy and power When you re removing spark plugs work on one at a time Don t start by removing the plug wires all at once because unless you number them they may become mixed up Take a minute ...

Page 95: ...ay to the area around the base of the plug and allow it a few minutes to work Using a spark plug socket that is equipped with a rubber insert to properly hold the plug turn the spark plug counterclockwise to loosen and remove the spark plug from the bore 4 Using the proper size spark plug socket loosen the plug by rotating it counterclockwise Once the plug is loose you should be able to remove it ...

Page 96: ... INSPECTION GAPPING Check the plugs for deposits and wear If they are not going to be replaced clean the plugs thoroughly Remember that any kind of deposit will decrease the efficiency of the plug Plugs can be cleaned on a spark plug cleaning machine which can sometimes be found in service stations or you can do an acceptable job of cleaning with a stiff brush If the plugs are cleaned the electrod...

Page 97: ...Checking the spark plug gap with a feeler gauge Adjusting the spark plug gap HOW TO USE THIS BOOK INSPECTION GAPPING 83 ...

Page 98: ...If the standard plug is in good condition the electrode may be filed flat WARNING do not file platinum plugs HOW TO USE THIS BOOK 84 INSPECTION GAPPING ...

Page 99: ...Inspect the spark plug to determine engine running conditions Click to enlarge Spark Plug Wires REMOVAL INSTALLATION HOW TO USE THIS BOOK Spark Plug Wires 85 ...

Page 100: ...each wire in or on the proper terminal of the coil pack or distributor cap Be sure the terminal connector inside the insulator is fully seated The No 1 terminal is identified on the cap 1 Remove wire separators from old wire set and install them on new set in approximately same position 2 Connect wires to proper spark plugs Be certain all wires are fully seated on terminals 3 TESTING Only test one...

Page 101: ...good connection exists between the distributor cap and the spark terminal Never under any circumstances measure resistance by puncturing the spark plug wire If the measured resistance is less than 7000 ohms per foot of wire the wire is good If the measured resistance is greater than 7000 ohms per foot the wire is defective and should be replaced 6 Without Distributor Visually inspect the spark plu...

Page 102: ...g wires with their perspective cylinder number 1 Loosen the cap hold down screws 2 Remove the cap by lifting straight up to prevent damage to the rotor blade and spring 3 If the plug wires do not have enough slack to allow cap removal confirm that they are properly labeled and remove them from the cap Installation is the reverse of the removal procedure Note the position of the square alignment lo...

Page 103: ...r carbon tracks Also inspect the cap terminals for dirt and corrosion 2 Replace the cap if any of the above conditions are observed 3 Distributor Rotor Inspection points for the distributor rotor note the locating boss which fits in the armature Click to enlarge Wash the rotor with soap and water then dry with it compressed air 1 Inspect the rotor for cracks carbon tracks burns or damage to the bl...

Page 104: ...ll traveling up This causes engine ping If the ignition spark is set too far retarded after TDC ATDC the piston will have already passed TDC and started on its way down when the fuel is ignited This will cause the piston to be forced down for only a portion of its travel This will result in poor engine performance and lack of power Timing marks consisting of O marks or scales can be found on the r...

Page 105: ...een reached shut the engine OFF 2 Firmly apply the parking brake and block the drive wheels Place the transmission in P A T or NEUTRAL M T as applicable 3 Make sure heater and A C along with all other accessories are in the OFF position 4 Connect an inductive timing light such as the Rotunda 059 00006 or equivalent to the No 1 spark plug wire according the tool manufacturer s instructions 5 Connec...

Page 106: ...n line connector SPOUT connector near the TFI module 2 Start the engine and measure the voltage at idle from the SPOUT connector to the distributor base The reading should equal battery voltage 3 If the result is okay the problem lies within the EEC IV system 4 If the result was not satisfactory separate the wiring harness connector from the ignition module Check for damage corrosion or dirt Servi...

Page 107: ...ude loss of concentration and drowsiness Generally the limit for exposure is lower for R 134a than it is for R 12 Exceptional care must be practiced when handling R 134a Also some refrigerants can decompose at high temperatures near gas heaters or open flame which may result in hydrofluoric acid hydrochloric acid and phosgene a fatal nerve gas It is usually more economically feasible to have a cer...

Page 108: ...lp maintain the efficiency of the vehicle s A C system Be sure to perform the following The easiest and often most important check for the air conditioning system consists of a visual inspection of the system components Visually inspect the system for refrigerant leaks damaged compressor clutch abnormal compressor drive belt tension and or condition plugged evaporator drain tube blocked condenser ...

Page 109: ...orn they should be replaced immediately Replacement intervals will vary with usage although ozone deterioration usually limits element life to about one year If the wiper pattern is smeared or streaked or if the blade chatters across the glass the elements should be replaced It is easiest and most sensible to replace the elements in pairs If your vehicle is equipped with aftermarket blades there a...

Page 110: ... on tires and will shorten their useful life span For optimum tire life keep the tires properly inflated rotate them often and have the wheel alignment checked periodically Inspect your tires frequently Be especially careful to watch for bubbles in the tread or sidewall deep cuts or underinflation Replace any tires with bubbles in the sidewall If cuts are so deep that they penetrate to the cords d...

Page 111: ... and 5 wheel rotations Click to enlarge Some styled or mag wheels may have different offsets front to rear In these cases the rear wheels must not be used up front and vice versa Furthermore if these wheels are equipped with unidirectional tires they cannot be rotated unless the tire is remounted for the proper direction of rotation The compact or space saver spare is strictly for emergency use It...

Page 112: ...read to provide traction and control The small grooves of a street tire quickly pack with snow and the tire behaves like a billiard ball on a marble floor The more open chunky tread of a snow tire will self clean as the tire turns providing much better grip on snowy surfaces To satisfy municipalities requiring snow tires during weather emergencies most snow tires carry either an M S designation af...

Page 113: ...m away from direct moisture is of paramount importance Tires should not be stored upright but in a flat position INFLATION INSPECTION The importance of proper tire inflation cannot be overemphasized A tire employs air as part of its structure It is designed around the supporting strength of the air at a specified pressure For this reason improper inflation drastically reduces the tire s ability to...

Page 114: ... Consult the owner s manual or the tire pressure sticker for the correct tire pressure Once you ve maintained the correct tire pressures for several weeks you ll be familiar with the vehicle s braking and handling personality Slight adjustments in tire pressures can fine tune these characteristics but never change the cold pressure specification by more than 2 psi A slightly softer tire pressure w...

Page 115: ...pensive gauge or by using a Lincoln head penny Slip the Lincoln penny with Lincoln s head upside down into several tread grooves If you can see the top of Lincoln s head in 2 adjacent grooves the tire has less than 1 16 in 1 5mm tread left and should be replaced You can measure snow tires in the same manner by using the tails side of the Lincoln penny If you can see the top of the Lincoln memorial...

Page 116: ...A penny works well for a quick check of tread depth Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 102 INFLATION INSPECTION ...

Page 117: ...are broken down into multi viscosity and single viscosities Multi viscosity oils are recommended because of their wider range of acceptable temperatures and driving conditions Ford recommends that SAE 5W 30 viscosity engine oil should be used for all climate conditions however SAE 10W 30 is acceptable for vehicles operated in moderate to hot climates When adding oil to the crankcase or changing th...

Page 118: ...ns inside the engine besides their basic lubrication Through a balanced system of metallic detergents and polymeric dispersants the oil prevents high and low temperature deposits and also keeps sludge and dirt particles in suspension Acids particularly sulfuric acid as well as other by products of engine combustion are neutralized by the oil If these acids are allowed to concentrate they can cause...

Page 119: ...FOREIGN COUNTRIES If you plan to drive your truck outside the United States or Canada there is a possibility that fuels will be too low in anti knock quality and could produce engine damage It is wise to consult with local authorities upon arrival in a foreign country to determine the best fuels available Engine OIL LEVEL CHECK Check the engine oil level every time you fill the gas tank The oil le...

Page 120: ...2 Pull out the dipstick and note the oil level It should be between the FULL MAX mark and the ADD MIN mark 3 The level should read below the FULL but above the ADD mark If the level is below the lower mark replace the dipstick and add fresh oil to bring the level within the proper range Do not overfill 4 HOW TO USE THIS BOOK 106 OIL LEVEL CHECK ...

Page 121: ...Y HARD to forget to refill the engine crankcase before you go to start the engine Raise and support the vehicle safely on jackstands Make sure the oil drain plug is at the lowest point on the oil pan If not you may have to raise the vehicle slightly higher on one jackstand side than the other 1 Before you crawl under the car take a look at where you will be working and gather all the necessary too...

Page 122: ...e front plug The best way to assure all oil has been drained is to pull the plugs then remove the jackstands and carefully lower the vehicle make sure your drain pans are properly positioned because the relative positioning of the drain holes will change as the vehicle is lowered Once you are sure the front portion of the oil pan has sufficiently drained raise the vehicle and support it again with...

Page 123: ...t so you can feel when all of the screw threads are out of the hole and so you will keep the oil from seeping past the threads until you are ready to remove the plug You can then remove the plug quickly to avoid having hot oil run down your arm This will also help assure that have the plug in your hand not in the bottom of a pan of hot oil 4 CAUTION Be careful of the oil when at operating temperat...

Page 124: ...urface are not damaged Carefully thread the plug into position and tighten it with a torque wrench to 15 25 ft lbs 20 34 Nm If a torque wrench is not available snug the drain plug and give a slight additional turn You don t want the plug to fall out as you would quickly become stranded but the pan threads are EASILY stripped from overtighening and this can be time consuming and or costly to fix 5 ...

Page 125: ...wrench can be obtained at any auto parts store and is well worth the investment Loosen the filter with the filter wrench With a rag wrapped around the filter unscrew the filter from the boss on the side of the engine Be careful of hot oil that will run down the side of the filter Make sure that your drain pan is under the filter before you start to remove it from the engine should some of the hot ...

Page 126: ...ELY refill the engine crankcase with the proper amount of oil DO NOT WAIT TO DO THIS because if you forget and someone tries to start the car severe engine damage will occur 8 Remove the engine oil fill cap and using a funnel to avoid spills add the proper amount and grade of oil Refill the engine crankcase slowly checking the level often You may notice that it usually takes less than the amount o...

Page 127: ...id level will be indicated If you are going to place the truck on four jackstands this might be the perfect opportunity to rotate the tires as well Remove the filler plug from the side of the transmission case using a 3 8 in drive ratchet and extension The fluid level should be even with the bottom of the filler hole 2 If additional fluid is necessary add it through the filler hole using a siphon ...

Page 128: ...nsmission fluid specifications All transmissions use Mercon automatic transmission fluid DO NOT use improper fluids such as Dexron or gear oil Use of improper fluids could lead to leaks or transmission damage LEVEL CHECK It is very important to maintain the proper fluid level in an automatic transmission If the level is either too high or too low poor shifting operation and internal damage are lik...

Page 129: ...e it with a clean lint free rag and reinsert it until it fully seats 3 With the engine idling in park P remove the Automatic Transmission Fluid ATF level dipstick Withdraw the dipstick and hold it horizontally while noting the fluid level It should be between the upper FULL and the lower ADD marks 4 The level should read between the marks Cold marks holes are for below operating temperature checks...

Page 130: ...mission fluid should not need periodic changing However if a major service is performed to the transmission if transmission fluid becomes burnt or discolored through severe usage or if the vehicle is subjected to constant stop and go driving in hot weather trailer towing long periods of highway use at high speeds fluid should be changed to prevent transmission damage A preventive maintenance chang...

Page 131: ...turns of complete removal then carefully break the gasket seal allowing most of the fluid to drain over the edge of the pan 3 CAUTION DO NOT force the pan while breaking the gasket seal DO NOT allow the pan flange to become bent or otherwise damaged When fluid has drained to the level of the pan flange remove the pan bolts and carefully lower the pan doing your best to drain the rest of the fluid ...

Page 132: ...discard the old gasket and insure that the mating surfaces are clean Inspect this magnet inside of the pan for any large pieces of debris A light gray coating is normal HOW TO USE THIS BOOK 118 DRAIN PAN FILTER SERVICE REFILL ...

Page 133: ...t to air dry Clean the transmission oil pan thoroughly using a safe solvent then allow it to air dry DO NOT use a cloth to dry the pan which might leave behind bits of lint Discard the old pan gasket 5 HOW TO USE THIS BOOK DRAIN PAN FILTER SERVICE REFILL 119 ...

Page 134: ...The transmission filter is secured by a mounting bolt arrow Some models may use two bolts Click to enlarge HOW TO USE THIS BOOK 120 DRAIN PAN FILTER SERVICE REFILL ...

Page 135: ...filter by pulling it down and off of the valve body Make sure any gaskets or seals are removed with the old filter The transmission usually has one round seal and a rectangular gasket 6 Install the new oil filter screen making sure all gaskets or seals are in place then secure using the retaining screws if applicable 7 HOW TO USE THIS BOOK DRAIN PAN FILTER SERVICE REFILL 121 ...

Page 136: ...ing temperature 11 Check the transmission fluid level Add fluid as necessary to obtain the correct level 12 Torque Converter If it is necessary to perform a complete drain and refill it will be necessary to remove the remaining fluid from the torque converter and the cooler lines Remove the converter housing lower cover 1 Rotate the torque converter until the drain plug comes into view 2 Remove th...

Page 137: ...Use Mercon automatic transmission fluid when refilling or adding fluid to the transfer case LEVEL CHECK Position the vehicle on level ground 1 The transfer case fill level check plug is the upper most plug located on the rear of the case HOW TO USE THIS BOOK Transfer Case 123 ...

Page 138: ...e plug using a 3 8 in drive ratchet Remove the transfer case fill plug the upper plug located on the rear of the transfer case The fluid level should be up to the fill hole 2 HOW TO USE THIS BOOK 124 LEVEL CHECK ...

Page 139: ...g Remember that the fluid will likely flow with some force at first arcing outward from the transmission and will not just drip straight downward into the pan Position the drain pan accordingly and move it more directly beneath the drain plug as the flow slows to a trickle 3 To insure that the fill plug is not frozen or rusted in place remove it from the transfer case BEFORE removing the drain plu...

Page 140: ...stead a filler plug is located in the side of the housing or in the side of the cover at a level just barely above the level to which fluid should fill the housing To check the fluid level To check the front drive axle fluid level loosen the fill plug then remove it Fluid should trickle out of the hole If not add the proper grade of lubricant until it does HOW TO USE THIS BOOK 126 LEVEL CHECK ...

Page 141: ...ise and support the vehicle using jackstands at four points to make sure it is completely level Failure to support the vehicle level will prevent from properly checking or filling the drive axle fluid 2 Thoroughly clean the area surrounding the fill plug This will prevent any dirt from entering the housing and contaminating the gear oil 3 To check the rear drive axle fluid level loosen the fill pl...

Page 142: ...any fluid change the oil should be at normal operating temperature to assure the best flow and removal of fluid contaminants Most front and some rear drive axle assemblies do not have a removable cover for fluid draining However these units may have a drain plug instead Drain plug equipped drive axles can be serviced in the same manner as the manual transmission and or transfer case If no drain pl...

Page 143: ... axle 4 Loosen and remove all but two of the cover retaining bolts Don t lose the axle identification tag Loosen and remove all but 2 of the housing cover s upper or side retaining bolts The remaining 2 bolts should then be loosened to within a few turns of complete removal Use a small prytool to carefully break the gasket seal at the base of the cover and allow the lubricant to drain Be VERY care...

Page 144: ...eal and allow the fluid to drain Once most of the fluid has drained remove the remaining bolts and pull the cover from the housing Once most of the fluid has drained remove the final retaining bolts and separate the cover from the housing 6 HOW TO USE THIS BOOK 130 DRAIN REFILL ...

Page 145: ...lt Refill the drive axle housing using the proper grade and quantity of lubricant Install the filler plug operate the vehicle and check for any leaks 9 Cooling System CAUTION Never remove the radiator cap under any conditions while the engine is running Failure to follow these instructions could result in damage to the cooling system and or personal injury To avoid having scalding hot coolant or s...

Page 146: ... of the cooling system using the recovery tank and its markings as a guideline If you top off the system make a note of it to check again soon A coolant level that consistently drops is usually a sign of a small hard to detect leak though in the worst case it could be a sign of an internal engine leak blown head gasket cracked block check the engine oil for coolant contamination In most cases you ...

Page 147: ...components found on all models not shown is the water pump 3 0L equipped ranger shown other models are similar Click to enlarge To add coolant remove the lid from the coolant recovery tank HOW TO USE THIS BOOK INSPECTION 133 ...

Page 148: ...r drive belt s should be inspected and adjusted to the proper tension Refer to the information on drive belts found earlier in this section Finally if everything looks good obtain an antifreeze coolant testing hydrometer in order to check the freeze and boil over protection capabilities of the coolant currently in your engine Old or improperly mixed coolant should be replaced Checking antifreeze p...

Page 149: ...essurized and inspected for leaks If no obvious problems are found use a hydrometer antifreeze coolant tester available at most automotive supply stores to check the condition and concentration of the antifreeze in your cooling system Excessively old coolant or the wrong proportions of water and coolant will hurt the coolant s boiling and freezing points Check the Radiator Cap While you are checki...

Page 150: ...is will prove fatal in sufficient quantity Always drain coolant into a sealable container Coolant may be reused unless it is contaminated or several years old A complete drain and refill of the cooling system at least every 30 000 miles 48 000 km or 3 years will remove the accumulated rust scale and other deposits The recommended coolant for most late model cars is a 50 50 mixture of ethylene glyc...

Page 151: ...To drain the cooling system open the radiator petcock arrow and allow the coolant to drain into a container HOW TO USE THIS BOOK DRAINING FLUSHING REFILLING 137 ...

Page 152: ...o be temporarily removed to drain coolant but they are often hard to get at and it is not really necessary for this procedure 1 Close the petcock or reconnect the hose and install any block drain plugs which may have been removed then fill the system with water 2 Add a can of quality radiator flush 3 Idle the engine until the upper radiator hose gets hot 4 Drain the system again 5 Repeat this proc...

Page 153: ...llows Fill the radiator with coolant until it reaches the radiator filler neck seat 1 Start the engine and allow it to idle until the thermostat opens the upper radiator hose will become hot 2 Turn the engine OFFand refill the radiator until the coolant level is at the filler neck seat 3 Fill the engine coolant overflow tank with coolant to the FULL HOT mark then install the radiator cap 4 9 If av...

Page 154: ...plenty of water When adding fluid to the system ONLY use fresh DOT 3 brake fluid from a sealed container DOT 3 brake fluid will absorb moisture when it is exposed to the atmosphere which will lower its boiling point A container that has been opened once closed and placed on a shelf will allow enough moisture to enter over time to contaminate the fluid within If your brake fluid is contaminated wit...

Page 155: ...his makes checking the level easy and helps reduce the risk of fluid contamination since you don t have to expose the fluid by opening the cap to check the level Fluid should be kept near the FULL line or between the MIN and MAX lines depending on how the reservoir is marked If fluid must be added thoroughly clean the fill cap area then remove the cap and add only fresh clean DOT 3 brake fluid unt...

Page 156: ...eservoir location Click to enlarge The clutch master cylinder reservoir is located under the hood on the left side firewall The fluid in the reservoir will slowly increase or rise as the clutch wears As long as the fluid level is visible at or above the step in the reservoir body top off is not necessary and should not be done to prevent overflow as well as possible contamination of the fluid whil...

Page 157: ... The power steering pump on 1991 95 vehicles requires the use of power steering fluid that meets Ford s specification ESW M2C33 F or an equivalent Type F ATF 1996 99 models require Mercon ATF Warm the fluid to normal operating temperature by driving for at least one mile or start the engine and allow it to idle for five minutes 1 With the engine idling turn the steering wheel back and forth severa...

Page 158: ... HOT range but like most automotive fluids DO NOT overfill 4 When you are finished install the dipstick and be sure it is secure 5 Manual Steering Gear The steering gear is factory filled with steering gear grease Changing of this lubricant should not be performed and the housing should not be drained lubricant is not required for the life of the steering gear Chassis Greasing Chassis greasing sho...

Page 159: ...und the vehicle and give attention to a number of other surfaces which require a variety of lubrication protection HOOD DOOR LATCH HINGES Wipe clean any exposed surfaces of the door hatches and hinges hood latch and auxiliary catch Then treat the surfaces using a multi purpose grease spray that meets Ford s ESR M1C159 A specification LOCK CYLINDERS Should be treated with Ford Lock Lubricant part n...

Page 160: ...his procedure only covers the repacking or greasing of the wheel bearings For the removal procedures see the appropriate Section for you vehicle For 4 wheel drive vehicles see Section 7 For 2 wheel drive vehicles see Section 8 REPACKING Packing the wheel bearings with grease HOW TO USE THIS BOOK 146 Wheel Bearings ...

Page 161: ... mallets Don t handle bearings with dirty or moist hands Do not use gasoline for cleaning use a safe solvent Do not spin dry bearings with compressed air They will be damaged Do not spin unclean bearings Avoid using cotton waste or dirty clothes to wipe bearings Try not to scratch or nick bearing surfaces Do not allow the bearing to come in contact with dirt or rust at any time 4WD vehicles should...

Page 162: ... of the roller cage through the grease with your other hand work as much grease in between the rollers as possible 7 As an alternate method place a large portion of grease and the bearing to be packed into a sealable heavy plastic bag Squeeze the bag to force the grease into the bearing This may reduce the mess usually associated with bearing repacking Apply a thin coat of fresh grease to the new ...

Page 163: ... Place the outer bearing into position on the spindle and into the bearing cup Install the adjusting nut finger tight 10 Adjust the wheel bearings 11 Install any remaining components which were removed 12 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK REPACKING 149 ...

Page 164: ...ou should tow although a numerically higher axle ratio can help compensate for heavier weight Hitch Tongue Weight Calculate the hitch weight in order to select a proper hitch The weight of the hitch is usually 9 11 of the trailer gross weight and should be measured with the trailer loaded Hitches fall into various categories those that mount on the frame and rear bumper the bolt on type or the wel...

Page 165: ...installed in front of the radiator or air conditioning compressor and hooked in line with the transmission cooler tank inlet line Follow the cooler manufacturer s installation instructions Select a cooler of at least adequate capacity based upon the combined gross weights of the vehicle and trailer Cooler manufacturers recommend that you use an aftermarket cooler in addition to and not instead of ...

Page 166: ...ur truck has to be towed backward and is a 4WD model unlock the front axle driving hubs to prevent the front differential from rotating and place the transfer case in Neutral Also clamp the steering wheel on all models in the straight ahead position with a clamping device designed for towing service Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK Towing the...

Page 167: ...so the batteries are connected in a parallel circuit positive terminal to positive terminal negative terminal to negative terminal Hooking the batteries up in parallel circuit increases battery cranking power without increasing total battery voltage output Output remains at 12 volts On the other hand hooking two 12 volt batteries up in a series circuit positive terminal to negative terminal positi...

Page 168: ...attery Try to pick a ground on the engine that is positioned away from the battery in order to minimize the possibility of the 2 clamps touching should one loosen during the procedure DO NOT connect this clamp to the negative terminal of the bad battery 9 CAUTION Be very careful to keep the jumper cables away from moving parts cooling fan belts etc on both engines Check to make sure that the cable...

Page 169: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK Jump Starting Procedure 157 ...

Page 170: ...JACKING Jack positioning 2WD models Click to enlarge Jack positioning 4WD models Click to enlarge JACKING 159 ...

Page 171: ...equipped with limited slip differentials while the vehicle is up on a jack This is because if the drive train is engaged power is transmitted to the wheel with the best traction and the vehicle will drive off the jack resulting in possible damage or injury Lift the front by positioning the jack under the lower front shock absorber mount HOW TO USE THIS BOOK 160 JACKING ...

Page 172: ...arms or spring hangers and the frame Be sure and block the diagonally opposite wheel to prevent the vehicle from moving Place jackstands under the vehicle at the points mentioned above when you are going to work under the vehicle Lift the rear by positioning the jack under the rear spring mount on the axle HOW TO USE THIS BOOK JACKING 161 ...

Page 173: ...ht release from the chassis When raising the vehicle on a hoist position the front end adapters under the center of the lower suspension arm or the spring supports as near to the wheels as practical The rear hoist adapters should be placed under the spring mounting pads or the rear axle housing Be careful not to touch the rear shock absorber mounting brackets Chilton Automotive Information Systems...

Page 174: ...SPECIFICATION CHARTS Standard and Metric Conversion Factors Chart Click to enlarge SPECIFICATION CHARTS 163 ...

Page 175: ...Vehicle Indentification Chart Click to enlarge HOW TO USE THIS BOOK 164 SPECIFICATION CHARTS ...

Page 176: ...Engine Identification Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 165 ...

Page 177: ...General Engine Specifications Click to enlarge HOW TO USE THIS BOOK 166 SPECIFICATION CHARTS ...

Page 178: ...CAPACITIES Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 167 ...

Page 179: ...EDMAINTENANCE INTERVALS Click to enlarge MANUFACTURER RECOMMENDEDSEVERE MAINTENANCE INTERVALS Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 168 SPECIFICATION CHARTS ...

Page 180: ... ICM is mounted on the front fender apron The distributor used by this system is sealed and houses the CMP sensor The distributor does not utilize vacuum or centrifugal advance mechanisms the ignition timing is automatically controlled by the Powertrain Control Module PCM and the ICM Ford calls this electronic ignition the Thick Film Integrated IV TFI IV ignition system The TFI module is also know...

Page 181: ...ed dwell or coil on time when starting the engine During this mode the ICM determines when to turn on the ignition coil based on engine speed information The coil is turned off thereby firing whenever a rising edge of a SPark OUTput SPOUT signal is received The SPOUT signal is generated by the PCM and provides spark timing information to the ICM During the push start mode the SPOUT signal only ind...

Page 182: ...or pushed out pins corrosion loose wires etc Service if required PRELIMINARY CHECKS Visually inspect the engine compartment to ensure that all vacuum lines and spark plug wires are properly routed and securely connected 1 Examine all wiring harness and connectors for insulation damage burned overheated loose or broken conditions Ensure that the ICM is securely fastened to the front fender apron 2 ...

Page 183: ...tarter relay Attach a remote starter switch 2 Turn the ignition switch to theRUNposition 3 Using the remote starter switch crank the engine and check for spark 4 Turn the ignition switchOFF 5 If no spark occurred the problem lies with the wiring harness Inspect the wiring harness for short circuits open circuits and other defects 6 If a spark did occur the problem is not in the ignition system 7 H...

Page 184: ...Secondary coil voltage test 2 chart run mode check Click to enlarge HOW TO USE THIS BOOK TEST PROCEDURES 173 ...

Page 185: ...Wiring harness test 3 chart voltage check Click to enlarge HOW TO USE THIS BOOK 174 TEST PROCEDURES ...

Page 186: ...he ICM terminals as shown below GND PIP IN should be greater than 500 ohms 1 PIP PWR PIP IN should be less than 2 000 ohms 2 PIP PWR TFI PWR should be less than 200 ohms 3 GND IGN GND should be less than 2 ohms 4 PIP IN PIP should be less than 200 ohms 5 2 If any of these checks failed replace the ICM with a new one 3 HOW TO USE THIS BOOK TEST PROCEDURES 175 ...

Page 187: ...If okay the problem is not in the ignition system 4 If no spark occurs check the voltage at the positive terminal of the ignition coil with the ignition switch in RUN 5 If the reading is not within battery voltage check for a worn or damaged ignition switch 6 If the reading is within battery voltage check for faults in the wiring between the coil and TFI module terminal No 2 or any additional wiri...

Page 188: ... satisfactory separate the wiring harness connector from the ignition module Check for damage corrosion or dirt Service as necessary 5 Measure the resistance between terminal No 5 and the pin in line connector This test is done at the ignition module connector only The reading should be less than 5 ohms 6 If the reading is okay replace the TFI module 7 If the result was not satisfactory service th...

Page 189: ... Attach the negative lead from a Volt ohmmeter to the distributor base 2 Measure the battery voltage 3 Turn the ignition switch to the RUNposition 4 Measure the voltage at the positive terminal of the ignition coil If the reading is at least 90 of battery voltage check the ignition coil connector for dirt corrosion and damage Check the ignition coil terminals for dirt corrosion and damage if no pr...

Page 190: ...reading is between 0 3 1 0 ohms the ignition coil is OK continue on to the Ignition Coil Secondary Resistance Test If the reading is less than 0 3 ohms or greater than 1 0 ohms replace the ignition coil 4 Ignition Coil Secondary Resistance Test Use an ohmmeter to measure the resistance between the negative terminal to the high voltage terminal of the ignition coil 1 If the reading is between 6 500...

Page 191: ... removed from the ignition coil 4 To install If necessary install the radio interference capacitor onto the ignition coil Tighten the mounting bolt to 25 35 inch lbs 2 8 4 0 Nm 5 Position the ignition coil onto the mounting bracket then install and tighten the mounting bolts to 25 35 inch lbs 2 8 4 0 Nm 6 Attach all wiring to the ignition coil then connect the negative battery cable 7 Ignition Con...

Page 192: ...battery cable 8 Distributor Mounted Module Disconnect the negative battery cable 1 Remove the distributor assembly from the engine 2 Place the distributor on the workbench and remove the module retaining screws Pull the right side of the module down the distributor mounting flange and back up to disengage the module terminal from the connector in the distributor base The module may be pulled towar...

Page 193: ... 6 Install the distributor into the engine Install the cap and wires 7 Reconnect the negative battery cable 8 Recheck the initial timing Adjust if necessary 9 Distributor REMOVAL INSTALLATION Exploded view of the distributor mounted ICM distributor Click to enlarge HOW TO USE THIS BOOK 182 Distributor ...

Page 194: ...istributor hold down bolt and clamp 5 Some engines may be equipped with a security type distributor hold down bolt If this is the case use distributor wrench T82L 12270 A or equivalent to remove the retaining bolt and clamp Remove the distributor assembly from the engine Be sure not to rotate the engine while the distributor is removed 6 To install Make sure that the engine is still with the No 1 ...

Page 195: ...ugh to just disengage the distributor gear from the camshaft gear Rotate the rotor enough to engage the distributor gear on another tooth of the camshaft gear Repeat Step 9 if necessary Install the distributor hold down clamp and bolt s tighten them slightly 10 Attach the vehicle wiring harness connector to the distributor 11 Install the cap and wires Install the No 1 spark plug if removed 12 Rech...

Page 196: ...le reluctance sensor mounted near the crankshaft damper and pulley The crankshaft damper has a 36 minus 1 tooth wheel data wheel mounted on it When this wheel rotates the magnetic field reluctance of the CKP sensor changes in relationship with the passing of the teeth on the data wheel This change in the magnetic field is called the CKP signal The base ignition timing is set at 10 plus or minus 2 ...

Page 197: ... signals are calculated the ICM determines the proper ON and OFF timing for the ignition coils The 4 0L engine utilizes one ignition coil pack which contains three separate ignition coils Each ignition coil fires two spark plugs simultaneously One of the two plugs being fired is on the compression stroke this plug uses most of the voltage and the other plug is on the exhaust stroke this plug uses ...

Page 198: ... of the voltage Since these two plugs are connected in series the firing voltage of one plug is negative with respect to ground and the other plug is positive Diagnosis and Testing SERVICE PRECAUTIONS Always turn the ignition key OFFand isolate both ends of a circuit whenever testing for shorts or continuity Never measure voltage or resistance directly at the processor connector Always disconnect ...

Page 199: ...lay different voltage readings depending on whether the DVOM is first turned on and then the test leads are attached or if the leads are attached first then the DVOM is turned on Also they may not auto range to the same range during each test and some show different values depending on the range selected Test A no start part 1 Click to enlarge HOW TO USE THIS BOOK 188 GENERAL SYSTEM TEST ...

Page 200: ...Test A no start part 2 Click to enlarge HOW TO USE THIS BOOK GENERAL SYSTEM TEST 189 ...

Page 201: ...Test A no start part 3 Click to enlarge HOW TO USE THIS BOOK 190 GENERAL SYSTEM TEST ...

Page 202: ...Test A no start part 4 Click to enlarge HOW TO USE THIS BOOK GENERAL SYSTEM TEST 191 ...

Page 203: ...Test A no start part 5 Click to enlarge HOW TO USE THIS BOOK 192 GENERAL SYSTEM TEST ...

Page 204: ...Test A no start part 6 Click to enlarge HOW TO USE THIS BOOK GENERAL SYSTEM TEST 193 ...

Page 205: ...Test A no start part 7 Click to enlarge HOW TO USE THIS BOOK 194 GENERAL SYSTEM TEST ...

Page 206: ...Test B code 16 memory code 18 and or Check Engine Light On IDM failure Click to enlarge HOW TO USE THIS BOOK GENERAL SYSTEM TEST 195 ...

Page 207: ...Test C memory code 45 and or Check Engine Light On coil failure part 1 Click to enlarge HOW TO USE THIS BOOK 196 GENERAL SYSTEM TEST ...

Page 208: ...Test C memory code 45 and or Check Engine Light On coil failure part 2 Click to enlarge HOW TO USE THIS BOOK GENERAL SYSTEM TEST 197 ...

Page 209: ...Test D engine running with code 18 SAW failure part 1 Click to enlarge HOW TO USE THIS BOOK 198 GENERAL SYSTEM TEST ...

Page 210: ...ness connector from the ignition coil to be tested 1 Check for dirt corrosion or damage on the terminals 2 PRIMARY RESISTANCE Use an ohmmeter to measure the resistance between the following terminals on the ignition coil and note the resistance 1 Except 2 3L 2 5L and 5 0L engines B to Coil 1 B to Coil 2 B to Coil 3 2 3L 2 5L and 5 0L engines B to Coil 1 B to Coil 2 or HOW TO USE THIS BOOK Ignition...

Page 211: ... 2 5L and 5 0L engines Click to enlarge Measure using the ohmmeter and note the resistance between each corresponding coil terminal and the two spark plug wire towers on the ignition coil The coil terminals and plug wires towers are grouped as follows 1 Except 2 3L 2 5L and 5 0L engines Terminal 3 coil 1 spark plugs 1 and 5 Terminal 2 coil 3 spark plugs 2 and 6 Terminal 1 coil 2 spark plugs 3 and ...

Page 212: ...e for all of the readings was between 6 500 11 500 ohms the ignition coils are OK If any of the readings was less than 6 500 ohms or more than 11 500 ohms replace the corresponding coil pack On 2 3L 2 5L and 5 0L engines if one coil pack is found to be defective the other pack does not need to be replaced REMOVAL INSTALLATION All engines except the 2 3L 2 5L and 5 0L engines utilizes one coil pack...

Page 213: ...1991 ignition coil mounting for the 2 3L engine Click to enlarge HOW TO USE THIS BOOK 202 REMOVAL INSTALLATION ...

Page 214: ...1992 99 ignition coil mounting for the 2 3L 2 5L engine Click to enlarge Ignition coil mounting for the 3 0L engine Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 203 ...

Page 215: ...Ignition coil mounting for the 4 0L engine Click to enlarge HOW TO USE THIS BOOK 204 REMOVAL INSTALLATION ...

Page 216: ...Click to enlarge Disconnect the negative battery cable 1 To remove the coil pack unplug the electrical harness connector from it Unplug the electrical harness connector from the ignition coil pack 2 HOW TO USE THIS BOOK REMOVAL INSTALLATION 205 ...

Page 217: ... from the coil by squeezing the lock tabs arrows and pulling straight up Label and remove the spark plug wires from the ignition coil terminal towers by squeezing the locking tabs to release the coil boot retainers 3 Remove the coil retaining screws HOW TO USE THIS BOOK 206 REMOVAL INSTALLATION ...

Page 218: ...onnect the negative battery cable 7 Ignition Control Module ICM REMOVAL INSTALLATION Only the EEC IV ignition systems use an external ICM EEC V systems have incorperated the ICM into the Power Control Module PCM Disconnect the negative battery cable 1 Detach the wiring harness connector s from the ICM 2 Remove the mounting bolts then remove the ICM 3 To install Position the ICM onto the inner fend...

Page 219: ...nition control module and mounting location on the 2 3L 2 5L engine Click to enlarge Ignition control module used on all EEC IV systems except the 2 3L engine HOW TO USE THIS BOOK 208 REMOVAL INSTALLATION ...

Page 220: ...amshaft Position CMP and Crankshaft Position CKP Sensors For procedures on these sensors please refer to Section 4 in this manual Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK Camshaft Position CMP and Crankshaft Position CKP Sensors 209 ...

Page 221: ...e correct firing order but could change the relative placement of the plug towers in relation to the engine For this reason it is imperative that you label all wires before disconnecting any of them Also before removal compare the current wiring with the accompanying illustrations If the current wiring does not match make notes in your book to reflect how your engine is wired 1991 94 2 9L and 3 0L...

Page 222: ...2 3L 2 5L Engines Distributorless ignition Click to enlarge HOW TO USE THIS BOOK 212 FIRING ORDERS ...

Page 223: ...1995 99 3 0L Engines Distributorless ignition Click to enlarge HOW TO USE THIS BOOK FIRING ORDERS 213 ...

Page 224: ...4 0L Engines Distributorless ignition Click to enlarge HOW TO USE THIS BOOK 214 FIRING ORDERS ...

Page 225: ...1996 99 5 0L Engines Distributorless ignition Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK FIRING ORDERS 215 ...

Page 226: ...arge the battery and power the rest of the electrical system When the ignition key is turned ON current flows from the battery through the charging system indicator light on the instrument panel to the voltage regulator and to the alternator Since the alternator is not producing any current the alternator warning light comes on When the engine is started the alternator begins to produce current an...

Page 227: ...following precautions should be taken when working with the electrical system Never reverse the battery connections Booster batteries for starting must be connected properly positive to positive and negative to ground Disconnect the battery cables before using a fast charger the charger has a tendency to force current through the diodes in the opposite direction for which they were designed This b...

Page 228: ...good condition and adjusted to the proper tension 2 All connections in the system are clean and tight 3 In order for the current indicator to give a valid reading the vehicle must be equipped with battery cables which are of the same gauge size and quality as original equipment battery cables Before commencing with the following tests turn off all electrical components on the vehicle Make sure the...

Page 229: ...urrent probe to the B terminal on the alternator 3 Start the engine and have an assistant run the engine at 2000 rpm Adjust the tester load bank to determine the output of the alternator Alternator output should be within ten percent of the alternator s output rating if so continue with the Alternator No Load test If the output is not within ten percent of the alternator s output rating there is a...

Page 230: ...ingle wire connector then the multi wire connector from the back of the alternator integral regulator units lack the single wire If the push on connectors are difficult to remove use a small pick to disengage the connector latch HOW TO USE THIS BOOK REMOVAL INSTALLATION 221 ...

Page 231: ...e alternator To disconnect push on type terminals disengage the lock tab and pull straight off 3 Remove the alternator bolts then remove the alternator from the engine 4 then remove the alternator mounting bolts Remove the alternator from its mounting bracket To install HOW TO USE THIS BOOK 222 REMOVAL INSTALLATION ...

Page 232: ... bracket and bolts Tighten the bolts to 71 106 inch lbs 8 12 Nm 7 Install the accessory drive belt Ensure that the drive belt is properly installed on the pulleys before starting the engine 8 Attach all engine wiring harness connectors to the alternator 9 Connect the negative battery cable 10 Voltage Regulator REMOVAL INSTALLATION 1991 95 models with non integral type regulator The regulator is at...

Page 233: ... the regulator in one hand and pry off the cap covering the Aterminal screw head with a small prybar 3 Holding the regulator in one hand break off the tab covering the A screw to expose the brush holder retaining screws Click to enlarge Remove 2 Torx head screws retaining the regulator to the brush holder Separate the regulator from the brush holder 4 HOW TO USE THIS BOOK 224 REMOVAL INSTALLATION ...

Page 234: ...ivalent tool through both the location hole in the regulator and through the holes in the brushes 7 Install the regulator brush holder assembly and remove the paper clip Install the attaching screws and tighten to 20 30 inch lbs 2 3 3 4 Nm 8 Connect the negative battery cable 9 1995 99 models with integral type regulator The internal voltage regulator used on alternators used with these vehicles i...

Page 235: ...Example of the integral type regulator atlernator Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 226 REMOVAL INSTALLATION ...

Page 236: ... with a solenoid actuated drive Battery Remote control starter switch part of the ignition switch Park Neutral Position PNP or Manual Lever Position MLP switch on 1994 automatic transmission models or Transmission Range TR sensor on 1995 99 automatic transmission models Clutch Pedal Position CPP switch on manual transmission models Starter relay Heavy circuit wiring Exploded view of the coil type ...

Page 237: ... The amount of damage evident may even prevent the starter motor from rotating the engine at all Vehicles equipped with a manual transmission are equipped with a Clutch Pedal Position CPP switch in the starter circuit which is designed to prevent the starter motor from operating unless the clutch pedal is depressed Vehicles equipped with automatic transmissions are equipped with either a Park Neut...

Page 238: ...ating the crankshaft and starting the engine An overrunning clutch in the starter drive assembly protects the starter motor from excessive speed when the engine starts Starter TESTING Use the charts to help locate and diagnose starting system problems Remember that the starter uses large amounts of current during operation so use all appropriate precautions during testing Starter system inspection...

Page 239: ... enlarge REMOVAL INSTALLATION Disconnect the negative battery cable 1 Raise the front of the vehicle and install jackstands beneath the frame Firmly apply the parking brake and place blocks in back of the rear wheels 2 HOW TO USE THIS BOOK 230 TESTING ...

Page 240: ... hardshell connector at the S terminal grasp the plastic shell to pull it off Do not pull on the wire itself Ensure to pull the connector straight off to prevent damage to the connector and S terminal If any part of the connector is damaged replace the damaged component Some starters use a self threading bolt to hold the starter cable HOW TO USE THIS BOOK REMOVAL INSTALLATION 231 ...

Page 241: ...olenoid connector by pushing it straight on Ensure that the connector locks in position with a notable click 6 Install the starter cable nut to the starter solenoid B terminal Tighten the nut to 80 123 inch lbs 9 14 Nm Connect any remaining wiring to the starter motor 7 Lower the front of the vehicle and remove the wheel blocks 8 Connect the negative battery cable 9 RELAY REPLACEMENT Disconnect th...

Page 242: ... Also remove any protective caps Remove the push on connectors by pulling them straight off Disconnect the positive battery cable from the battery terminal 3 Remove the nut securing the positive battery cable to the relay 4 HOW TO USE THIS BOOK RELAY REPLACEMENT 233 ...

Page 243: ...ny other wiring under that cable 5 then remove all of the cables from the relay Label and remove the push on wires from the front of the relay 6 Remove the nut and disconnect the cable from the starter side of the relay 7 HOW TO USE THIS BOOK 234 RELAY REPLACEMENT ...

Page 244: ...l the relay and mounting bolts Tighten the mounting bolts until snug 9 Attach all wiring to the relay 10 If equipped install the power distribution box cover 11 Connect the positive cable to the battery 12 Connect the negative cable to the battery 13 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK RELAY REPLACEMENT 235 ...

Page 245: ...ture and use variable resistance to control the current flow back to the indicating device Both types of sending units are connected in series by a wire to the battery through the ignition switch When the ignition is turned ON current flows from the battery through the indicating device and on to the sending unit Coolant Temperature Sender The coolant temperature sender is located in the following...

Page 246: ...Temperature gauge diagnostic chart Click to enlarge HOW TO USE THIS BOOK 238 TESTING ...

Page 247: ...d 3 Measure and note the resistance 4 Slowly heat the pot up on the stove to 190 210 F 88 99 C and observe the resistance of the sender unit The resistance should evenly and steadily decrease as the water temperature increases The resistance should not jump drastically or decrease erratically 5 If the sender unit did not function as described replace the sender unit with a new one 6 REMOVAL INSTAL...

Page 248: ...sender with Teflon tape or electrically conductive sealer then install the sender Tighten the sender to 107 143 inch lbs 12 16 Nm 5 Attach the wiring to the sender and connect the negative battery cable 6 If necessary add antifreeze to replace any lost coolant then install the radiator cap 7 Water temperature and oil pressure sending units on the 2 3L 2 5L engine Click to enlarge HOW TO USE THIS B...

Page 249: ...ed as follows 2 3L 2 5L engine Left side rear of the engine in the cylinder head 3 0L engine Behind the right cylinder head in the engine block 2 9L and 4 0L engines Left side front of the engine below the cylinder head in the engine block 5 0L engines Left hand front of the engine below the rocker arm cover TESTING Oil pressure sender and gauge wiring schematic Click to enlarge HOW TO USE THIS BO...

Page 250: ...her end of the jumper wire to a good engine ground any bare metal engine surface Have an assistant observe the instrument gauge cluster while you do this and tell you if the low oil warning lamp illuminates or not the low oil warning lamp should illuminate If the lamp does not illuminate skip to Step 3 1 If the lamp does illuminate replace the switch with a new one 2 2 Before jumping to any bad co...

Page 251: ...lly starting the engine Observe the other lights on the instrument cluster If all of the other lights illuminate when turning the ignition switch ON the oil pressure switch is defective and must be replaced 1 If none of the other lights illuminate there is a problem with power supply to the instrument cluster and gauges 2 4 REMOVAL INSTALLATION Oil pressure and level switches used on the 2 9L and ...

Page 252: ...ender switch 2 Remove the oil pressure sender switch from the engine 3 To install Coat the threads with electrically conductive sealer and thread the unit into place Tighten the sender switch to 10 18 ft lbs 13 24 Nm 4 Attach the wiring to the sender switch and connect the negative battery cable 5 HOW TO USE THIS BOOK 244 REMOVAL INSTALLATION ...

Page 253: ...agnostic chart to help pinpoint low oil level sensor malfunctioning The ignition switch should be turned OFFfor a minimum of 5 minutes between checks to ensure that the electronic relay which has a 5 minute timer has reset Low oil level indicator diagnostic chart Click to enlarge HOW TO USE THIS BOOK Low Oil Level Sensor 245 ...

Page 254: ...ront of the vehicle and install jackstands beneath the frame Firmly apply the parking brake and place blocks in back of the rear wheels 2 Typical low oil level sensor mounting note the sensor is constantly submerged in oil therefore drain some oil out of the engine before removing it Drain at least 2 quarts 1 9 liters of engine oil out of the pan 3 HOW TO USE THIS BOOK 246 TESTING ...

Page 255: ... words panside should face the oil pan Install the sensor and gasket assembly into the oil pan Tighten the sensor to 13 20 ft lbs 17 27 Nm 7 Connect the electrical wire to the sensor 8 Lower the front of the vehicle and remove the wheel blocks 9 Refill the crankcase to the proper level 10 Start the engine and check for leaks 11 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HO...

Page 256: ...SPECIFICATION CHARTS Troubleshooting Basic Starting System Problems Click to enlarge SPECIFICATION CHARTS 249 ...

Page 257: ...Troubleshooting Basic Charging System Problems Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 250 SPECIFICATION CHARTS ...

Page 258: ...nts always make sure the engine is properly supported When removing the engine make sure that any lifting devices are properly attached to the engine It is recommended that if your engine is supplied with lifting hooks your lifting apparatus be attached to them Lift the engine from its compartment slowly checking that no hoses wires or other components are still connected After the engine is clear...

Page 259: ...hen disconnect the fuel supply and return lines from the engine 12 Remove any remaining mounting brackets and or drive belt tensioners 13 Raise the vehicle and safely support it on jackstands 14 CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective ...

Page 260: ...Engine mounting points for 2 3L and 2 5L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 253 ...

Page 261: ...Engine mounting points for 3 0L engines Click to enlarge HOW TO USE THIS BOOK 254 REMOVAL INSTALLATION ...

Page 262: ...Engine mounting points 4 0L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 255 ...

Page 263: ...Engine mounting points 5 0L engines Click to enlarge HOW TO USE THIS BOOK 256 REMOVAL INSTALLATION ...

Page 264: ...he engine out of the vehicle Be sure to lift the engine slowly and check often that nothing such as wires hoses etc will cause the engine to hang up on the vehicle 26 At this point the engine can be installed on an engine stand 27 To install Lightly oil all bolts and stud threads except those specifying special sealant prior to installation Using the hoist or engine crane slowly and carefully posi...

Page 265: ...rmal operating temperature then check for leaks 39 Stop the engine and check all fluid levels 40 Install the hood aligning the marks that were made during removal 41 If equipped have the A C system properly leak tested evacuated and charged by a MVAC trained EPA certified automotive technician 42 Valve Rocker Arm Cover REMOVAL INSTALLATION 2 3L and 2 5L Engines To service the valve cover on the 2 ...

Page 266: ...on the cover and the cylinder head 4 Install a new gasket to the valve cover 5 Place the valve cover onto the cylinder head and install all of the retaining bolts finger tight 6 Alternately tighten the bolts to the proper specification 7 If removed install the EGR supply tube 8 Install any electrical connections which were removed 9 HOW TO USE THIS BOOK REMOVAL INSTALLATION 259 ...

Page 267: ...nd the load distribution washers patch pieces Be sure the washers are installed in their original position 4 Detach the transmission fluid level indicator tube and bracket from the valve cover 5 Disconnect the vacuum line at the canister purge solenoid and disconnect the line routed from the canister to the purge solenoid disconnect the power brake booster hose if so equipped 6 With a light plasti...

Page 268: ...way 2 If the left hand cover is being removed remove the throttle body assembly the PCV valve and fuel injector harness stand offs If the right hand cover is being removed remove the engine harness connectors fuel injector harness stand offs and air cleaner closure hose from the oil fill adapter 3 Using caution slide a sharp thin blade knife between the cylinder head gasket surface and the valve c...

Page 269: ...eces will result in oil leaks Disconnect the negative battery cable Tag and remove the spark plug wires 1 Disconnect and remove the fuel supply and return lines See Section 5 2 For left valve cover removal remove the upper intake manifold 3 For right valve cover removal remove the air inlet duct and hose to oil fill tube and the alternator Drain the cooling system and remove the upper radiator hos...

Page 270: ...alve cover first disconnect the crankcase breather vent tube Label and unplug any electrical connections as well as vacuum fittings which will inhibit valve cover removal HOW TO USE THIS BOOK REMOVAL INSTALLATION 263 ...

Page 271: ...e valve cover bolts and load distribution pieces The washers must be installed in their original positions so keep track of them 5 Remove the valve cover It will probably be necessary to tap the cover loose with a plastic or rubber mallet 6 Remove the valve cover gaskets 7 HOW TO USE THIS BOOK 264 REMOVAL INSTALLATION ...

Page 272: ...move the cover from the engine A slight tap with a soft faced hammer helps to break the seal Remove the old valve cover gasket and discard To install Clean all gasket material from the cover and head 3 HOW TO USE THIS BOOK REMOVAL INSTALLATION 265 ...

Page 273: ...the upper intake manifold 2 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several yea...

Page 274: ...unted to the valve cover 5 Label and detach the two vacuum lines connected to the DPFE transducer 6 Disconnect the engine electrical multi plug and remove it from the valve cover 7 Detach the wire harness connections on the coil pack 8 Label and remove the spark plug cables from the coil pack 9 Remove the valve cover hold down bolts and remove the valve cover Discard the old valve cover gasket 10 ...

Page 275: ...ral years old Drain the cooling system until the coolant level is below the intake manifold 2 Remove the upper intake manifold 3 Label and remove the spark plug wires from the coil packs 4 Detach the coil pack electrical connections and remove them from the engine 5 Remove any remaining wires or lines which will interfere with valve cover removal 6 Remove the valve cover hold down bolts and remove...

Page 276: ...and the spark plug wires to the coils 6 Install the upper intake manifold 7 Refill the cooling system 8 Connect the negative battery cable 9 Allow the engine to reach normal operating temperature upper radiator hose hot and check for leaks 10 Rocker Arms REMOVAL INSTALLATION 2 3L 2 5L and 4 0L SOHC VIN E Engines A special tool is required to compress the valve spring Remove the valve cover and ass...

Page 277: ... 4 0L engines or equivalent depress the valve spring as necessary a000nd slide the cam follower over the lash adjuster and out from under the camshaft 3 Install the cam follower in the reverse order of removal Lubricate the followers with SAE 50W engine oil meeting Ford specification WSE M2C908 A1 and API SG prior to installing 4 3 0L and 5 0L Engines Remove the rocker arm covers 1 Remove the sing...

Page 278: ... seated into the cylinder head 3 0L engines or the fulcrum guide 5 0L engines Tighten the rocker arm fulcrum bolts to specifications 4 Rocker Arm Shaft Assembly REMOVAL INSTALLATION This procedure applies only to 2 9L and 4 0L VIN X engines Remove the valve rocker arm covers 1 Remove the rocker arm shaft stand attaching bolts by loosening the bolts two turns at a time in sequence from the end of s...

Page 279: ...sen the shaft retaining bolts and remove the assembly from the cylinder head To install If equipped loosen the valve lash adjusting screws a few turns Apply engine oil to the assembly to provide the initial lubrication 4 HOW TO USE THIS BOOK 272 REMOVAL INSTALLATION ...

Page 280: ...Rocker arm shaft assembly installation on the 2 9L engine Rocker arm shaft installation on the 4 0L engine HOW TO USE THIS BOOK REMOVAL INSTALLATION 273 ...

Page 281: ...the remaining plug 3 The oil holes in the rocker arm shaft must point down when the shaft is installed This position of the shaft can be recognized by a notch on the front face of the shaft 4 If the plugs were removed from the shaft use a blunt tool and install a plug cup side out in each end of the shaft 5 Install a spring washer and pin on one end of the shaft coat the rocker arm shaft with heav...

Page 282: ...nside the elbow connection and turn it clockwise to lock it in position with the bridge against the flats cast into the elbow connection 7 Position the elbow connection onto the mounting surface of the outlet so that the thermostat flange is resting on the gasket and install the retaining bolts 8 Connect the heater hose to the thermostat housing 9 Fill the radiator and operate the engine until it ...

Page 283: ... 26 Nm 9 Install the hose fill and bleed the cooling system connect the battery ground cable and start the engine Check for leaks 10 2 9L and 4 0L Engines Drain the cooling system 1 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This wi...

Page 284: ...e thermostat housing for the 4 0L engine 2 9L engine is similar Click to enlarge To remove the thermostat first remove the upper radiator hose then the three attaching screws HOW TO USE THIS BOOK REMOVAL INSTALLATION 277 ...

Page 285: ...roperly seated Install the thermostat with the release valve facing upwards Remove the 3 thermostat housing attaching bolts 5 Remove the thermostat housing You may have to tap it loose with a plastic mallet or your hand 6 Pull the thermostat from the intake manifold 7 HOW TO USE THIS BOOK 278 REMOVAL INSTALLATION ...

Page 286: ...ing system 1 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years old Disconne...

Page 287: ...ler Position the new gasket on the engine and place the housing on the engine Tighten the bolts to specifications 9 Intake Manifold The engines covered by this manual utilize an upper and lower intake manifold assembly If necessary only the upper intake manifold may be removed by following the intake manifold procedure up to that point Obviously installation would also begin at the upper intake st...

Page 288: ...for the fuel injectors are machined to prevent both air and fuel leakage The following procedure is for the removal of the intake manifold with the fuel charging assembly attached Make sure the ignition is off then drain the coolant from the radiator engine cold 1 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to d...

Page 289: ... removed 4 Linkage and hose location on the 2 3L and 2 5L engine Click to enlarge Disconnect the EGR valve supply tube Click to enlarge Tag and disconnect the vacuum lines at the upper intake manifold vacuum tree at the EGR valve and at the fuel pressure regulator and canister purge line as necessary 5 Remove the throttle linkage shield and disconnect the throttle linkage and speed control cable i...

Page 290: ...r intake manifold removal on the 2 3L and 2 5L engine Click to enlarge Remove the upper intake manifold retaining nuts Remove the upper intake manifold and throttle body assembly 11 If you only need to remove the upper intake manifold stop at this point Otherwise continue with the procedure to also remove the lower intake manifold HOW TO USE THIS BOOK REMOVAL INSTALLATION 283 ...

Page 291: ...the bolts are removed remove the lower intake manifold 15 Clean and inspect the mounting faces of the lower intake manifold and cylinder head Both surfaces must be clean and flat If the intake manifold upper or lower section is being replaced it will be necessary to transfer components from the old to the new part 16 To install To install first clean and oil the manifold bolt threads Install a new...

Page 292: ...ion a new gasket on the fuel charging assembly air throttle body mounting flange Install the air throttle body to the fuel charging assembly Install two retaining nuts and two bolts and tighten to 15 6 ft lbs 9 Connect the accelerator and speed control cable if equipped then install the throttle linkage shield 10 Reconnect any electrical harness plugs which were removed 11 Connect the air intake h...

Page 293: ...1 Remove intake manifold attaching bolts and nuts Note length of manifold attaching bolts during removal so that they may be installed in their original positions Tap manifold lightly with a plastic mallet to break gasket seal Lift off manifold 12 Remove all old gasket material and sealing compound 13 To install Apply sealing compound to the joining surfaces Place the intake manifold gasket in pos...

Page 294: ... in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years old Disconnect the battery ground cable 2 Depressurize the fuel system and remove the air intake throttle body as outlined in Section 5 3 Disconnect the fuel return and supply lines...

Page 295: ...ting surfaces should be clean and free of old silicone rubber sealer Use a suitable solvent to clean these areas 14 Silicone sealer and intake end seal application for the 3 0L engine Click to enlarge Intake manifold gasket positioning for the 3 0L Click to enlarge HOW TO USE THIS BOOK 288 REMOVAL INSTALLATION ...

Page 296: ...ated first to 11 ft lbs then to 18 ft lbs 20 If installing a new manifold install fuel supply rail and injectors Refer to the necessary service procedures 21 Install 3 cylinder intake valve pushrod Apply oil to pushrod and fulcrum prior to installation Rotate the crankshaft to place the lifter on the heel position or base circle of camshaft Tighten to 8 ft lbs to seat fulcrum in cylinder head Fina...

Page 297: ...nifold is a 4 piece assembly consisting of the upper intake manifold the throttle body the fuel supply manifold and the lower intake manifold Disconnect the battery ground cable 1 Begin the intake removal by unbolting the throttle linkage weather shield then remove the air intake duct from the throttle body HOW TO USE THIS BOOK 290 REMOVAL INSTALLATION ...

Page 298: ...racket Remove the weather shield 2 Remove the air cleaner intake duct 3 Disconnect the throttle cable and bracket 4 Label all of the electrical and vacuum connections on the intake manifold then disconnect the vacuum lines HOW TO USE THIS BOOK REMOVAL INSTALLATION 291 ...

Page 299: ...nnect all electrical wires attached to the upper manifold assembly 6 Relieve the fuel system pressure 7 Also ensure that any brackets which are bolted to the manifold are unfastened Tag and remove the spark plug wires 8 Remove the EDIS ignition coil and bracket 9 HOW TO USE THIS BOOK 292 REMOVAL INSTALLATION ...

Page 300: ... then remove the old upper intake gasket use care when scraping Remove the 6 attaching nuts and lift off the upper manifold 10 If you only need to remove the upper intake manifold stop at this point Otherwise continue with the procedure to also remove the lower intake manifold HOW TO USE THIS BOOK REMOVAL INSTALLATION 293 ...

Page 301: ...n the lower intake manifold then disconnect them Next remove the valve covers Disconnect the fuel supply and return lines from the injector fuel rail 11 Label and disconnect all of the electrical connections on the lower manifold assembly 12 Remove the valve covers 13 HOW TO USE THIS BOOK 294 REMOVAL INSTALLATION ...

Page 302: ...m the engine Remove the lower intake manifold bolts Tap the manifold lightly with a plastic mallet and remove it 14 Remove the old intake gasket from the cylinder heads and engine block Clean all surfaces of old gasket material 15 HOW TO USE THIS BOOK REMOVAL INSTALLATION 295 ...

Page 303: ...s of the heads and manifold 16 This material will set within 15 minutes so work quickly Install new manifold gaskets and again apply the RTV material 17 Intake manifold and gasket installation for the 4 0L Click to enlarge HOW TO USE THIS BOOK 296 REMOVAL INSTALLATION ...

Page 304: ...nnect the negative battery cable 1 Remove the air cleaner to intake tube 2 Remove the accelerator splash shield 3 Disconnect the accelerator and if equipped with cruise control speed control cables from the throttle control cam 4 Remove the accelerator cable retaining bracket from the upper intake manifold 5 Label and disconnect all vacuum and electrical connections on the intake manifold 6 Remove...

Page 305: ...ove the CMP the fuel injectors will not remain timed to the engine and the vehicle will not run Disconnect the negative battery cable 1 Drain the cooling system 2 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in s...

Page 306: ...manifold stop at this point Otherwise continue with the procedure to also remove the lower intake manifold CAUTION Fuel lines on fuel injected vehicles will remain pressurized after the engine is shut off Fuel pressure must be relieved before servicing the fuel system Properly relieve the fuel system pressure then disconnect the fuel supply and return lines from the fuel supply manifold 16 HOW TO ...

Page 307: ...any electrical components sensors or vacuum lines connected to the lower manifold 18 Disconnect the upper radiator hose from the water outlet 19 Loosen the water pump bypass hose clamp at the pump 20 Remove the rear engine ground strap 21 Remove the camshaft synchronizer with the Camshaft Position CMP sensor installed Refer to Section 4 22 HOW TO USE THIS BOOK 300 REMOVAL INSTALLATION ...

Page 308: ... bolts in the sequence given 4 Remove the lower manifold and its gasket from the engine 5 To install Ensure that all of the gasket mating surfaces are clean and free or grease oil or dirt Also ensure that the EGR passages in the manifolds and heads are clear 6 HOW TO USE THIS BOOK REMOVAL INSTALLATION 301 ...

Page 309: ...ke sure the holes in the gaskets are aligned with the holes in the cylinder heads 8 Apply a 1 16 in 1 6mm bead of sealer to the outer end of each intake manifold seal for the full width of the seal Make sure the silicone sealer will not fall into the engine and possibly block oil passages 9 Using guide pins to ease installation carefully lower the intake manifold into position on the cylinder bloc...

Page 310: ...Install the upper radiator hose to the water outlet 15 Connect any electrical components or vacuum lines which were removed from the lower manifold 16 Install the hot water tube to the engine and connect the heater hose to the tube 17 Connect the fuel lines then temporarily connect the negative battery cable Cycle the ignition to pressurize the fuel system and check for leaks Turn the ignition key...

Page 311: ... spark plug wires to them 40 If equipped install the EGR spacer throttle body coolant hoses 41 Install the accelerator cable brackets and cables to the intake and throttle shaft 42 Connect any electrical components or vacuum lines removed from the upper manifold 43 Install the throttle body shield 44 Install the air cleaner outlet tube to the throttle body 45 Refill and bleed the cooling system 46...

Page 312: ...n and remove the EGR valve to exhaust manifold tube 3 Exploded view of the 2 3L and 2 5L engine exhaust manifold Click to enlarge Disconnect the exhaust pipe from the exhaust manifold 4 Remove the two nuts securing the lifting bracket transducer mount and remove the bracket 5 Remove the exhaust manifold mounting bolts nuts and remove the manifold 6 Install the exhaust manifold in the reverse order...

Page 313: ...lick to enlarge Lift the manifold from the cylinder head 3 To install Position the manifold on the heads and install and tighten the attaching bolts to specification 4 Install and tighten the inlet pipe attaching nuts 5 3 0L Engine Disconnect the negative battery cable Raise and safely support the vehicle as necessary 1 Remove the spark plugs 2 HOW TO USE THIS BOOK 306 REMOVAL INSTALLATION ...

Page 314: ...t hand exhaust manifolds on the 3 0L engine Click to enlarge Remove the manifold to exhaust pipe attaching nuts then separate the exhaust pipe from the manifold 4 Remove the exhaust manifold attaching bolts and the manifold 5 To install Clean all gasket mating surfaces 6 Lightly oil all bolt and stud threads before installation If a new manifold is being installed the oxygen sensor will have to be...

Page 315: ...E 9 If installing the left side manifold install the oil tube dipstick assembly apply sealer to the tube as necessary Also reattach the EGR tube and components if removed 10 Install the spark plugs 11 Connect the negative battery cable Start the engine and check for leaks 12 4 0L Engine VIN X Disconnect the negative battery cable Remove the oil level indicator tube bracket 1 Exploded view of the l...

Page 316: ...Exploded view of the right hand exhaust manifold on the 4 0L engine Click to enlarge Raise and safely support the vehicle 2 HOW TO USE THIS BOOK REMOVAL INSTALLATION 309 ...

Page 317: ...st pipe to manifold bolts from underneath Remove the exhaust pipe to manifold bolts 3 Lower the vehicle 4 Unbolt the hot air intake shroud which wraps around the manifold and covers some of the attaching bolts HOW TO USE THIS BOOK 310 REMOVAL INSTALLATION ...

Page 318: ...ld disconnect the power steering pump hoses 5 If removing the right hand manifold remove the hot air intake shroud which is bolted around the manifold 6 then unbolt the manifold and lift it from the engine HOW TO USE THIS BOOK REMOVAL INSTALLATION 311 ...

Page 319: ... from the Differential Pressure Feedback EGR DPFE transducer which is mounted to the valve cover 1 Disconnect the EGR tube from the manifold and the valve and remove the tube The 4 0L SOHC engine exhaust manifold is retained by six nuts Always use new nuts when installing the manifold 2 5 Remove the six manifold to engine attaching nuts 6 Remove the manifold and the gasket Discard the old gasket 7...

Page 320: ...lick to enlarge Remove A C compressor bolts and position it off to the side 1 Remove the oil level indicator tube nut and tube 2 Raise and safely support the vehicle 5 Remove the exhaust inlet pipe to manifold bolts 6 Lower vehicle to a suitable height to access the manifold to engine attaching bolts 7 Access to the manifold to engine bolts is through the wheel well opening Remove the pushpins sec...

Page 321: ... lbs 35 44 Nm 18 Connect the spark plug wires to the plugs 19 Install the fender apron and its pushpins 20 Raise and safely support the vehicle to allow access to the exhaust inlet to manifold pipe fasteners 21 Install the inlet pipe bolts to the exhaust manifold and tighten to 26 33 ft lbs 34 46 Nm 22 Lower the vehicle 23 If installing the left hand manifold install the oil level indicator tube a...

Page 322: ...Exploded view of the 2 3L and 2 5L engine radiator and related components Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 315 ...

Page 323: ...iator and related components 2 9L and 3 0L engines are similar Click to enlarge Remove the retaining bolts at the top of the shroud and position the shroud over the fan clear of the radiator 3 HOW TO USE THIS BOOK 316 REMOVAL INSTALLATION ...

Page 324: ... 0L engine remove the engine fan and the radiator shroud from the vehicle 4 If equipped with an automatic transmission disconnect the transmission cooling lines from the bottom of the radiator 5 Disconnect the upper and lower hoses from the radiator Remove the radiator retaining bolts HOW TO USE THIS BOOK REMOVAL INSTALLATION 317 ...

Page 325: ...level Correct as needed 8 Engine Fan REMOVAL INSTALLATION Refer to exploded view illustration before starting this service procedure WARNING The following procedures for removing the fan clutch gives the factory recommended loosening and tightening directions for the fan hub nut However it has been our experience that certain aftermarket parts manufacturers have changed this to enable use of unive...

Page 326: ...shroud remove the mounting screws and lift the shroud off the brackets Place the shroud behind the fan 2 Remove the 4 clutch fan assembly to pulley screws and remove the clutch fan assembly Vehicles equipped with A C should remove the clutch fan and shroud together 3 If necessary remove the fan to clutch bolts to separate the fan from the clutch 4 Installation is the reverse of removal Torque the ...

Page 327: ...flow hose is routed through the fan shroud remove it from the shroud 3 Lift up on the fan shroud to disengage the lower mounting clips 4 Remove the fan clutch assembly and the fan shroud together 5 If necessary remove the fan to clutch bolts to separate the fan from the clutch 6 To install Installation is the reverse of removal Torque the fan to clutch bolts to 55 70 inch lbs 6 8 Nm the hub nut to...

Page 328: ...w of the engine fan for the 4 0L engine Click to enlarge Before attempting to unfasten the engine fan check the fan shroud for indications of normal or reverse threads HOW TO USE THIS BOOK REMOVAL INSTALLATION 321 ...

Page 329: ...r equivalents loosen the large nut attaching the clutch to the water pump hub 2 Using the special tools loosen the fan clutch nut in the direction indicated on the shroud Some models have enough room between the shroud and the engine to remove the fan without unbolting the shroud Remove the two upper fan shroud retaining bolts If the overflow hose is routed through the fan shroud remove it from th...

Page 330: ... engine loosen the large nut attaching the clutch to the water pump hub 2 WARNING The manufacturer does not specify a loosening or tightening direction Using extreme care try loosening the nut in one direction first If it does not move change directions Applying too much force to the end of the water pump will break it Remove the two upper fan shroud retaining bolts If the overflow hose is routed ...

Page 331: ...e Disconnect the negative battery cable 1 Drain the cooling system 2 CAUTION When draining engine coolant keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in HOW TO USE THIS BOOK 324 REMOVAL INSTALLATION ...

Page 332: ...nd This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years old Using Tools T83T 6312 A and B remove the fan and clutch assembly from the front of the water pump 2 See the engine fan removal procedure in this section Loosen the alternator mounting bolts and remove the alternator belt 3 Remove...

Page 333: ...the way 10 Remove the water pump attaching bolts Note their location for installation 11 Remove the pump and discard the gasket 12 Thoroughly clean the pump and engine mating surfaces 13 To install Using an adhesive type sealer position a new gasket on the timing cover 14 Position the water pump and start the bolts When all the bolts are started torque them to specifications Refer to the necessary...

Page 334: ...Connect the battery ground cable Run the engine and check for leaks 23 4 0L Engine VIN X Disconnect the negative battery cable 1 Drain the cooling system 2 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficie...

Page 335: ...drain the cooling system then remove the engine fan clutch and the fan shroud from the vehicle Remove the fan and fan clutch assembly 3 See the engine fan removal procedure in this section HOW TO USE THIS BOOK 328 REMOVAL INSTALLATION ...

Page 336: ...ing the accessory drive belt Loosen the water pump pulley attaching bolts 6 Except 1997 99 Explorer Mountaineer models loosen the alternator mounting bolts and remove the belt On vehicles with air conditioning remove the tensioner pulley alternator and bracket 7 Except 1997 99 Explorer Mountaineer models remove the A C compressor and power steering pump mounting bracket without disconnecting the l...

Page 337: ...h removing the water pump pulley Remove the water pump pulley 9 Disconnect the heater hose at the pump 10 Remove the heater hose connection at the water pump Remove all of the water pump attaching bolts HOW TO USE THIS BOOK 330 REMOVAL INSTALLATION ...

Page 338: ...mp on the cover and install the bolts finger tight When all bolts are in place torque them to 72 108 inch lbs 8 5 12 Nm 14 Install the pulley 15 On vehicles with air conditioning install the alternator bracket and tensioner pulley 16 Install the A C compressor and power steering pump mounting bracket 17 Install and adjust the drive belt 18 Connect the hoses and tighten the clamps 19 Install the fa...

Page 339: ...both sides of a new gasket and place the gasket on the pump 14 Position the pump on the cover while connecting the bypass hose to the pump and install the bolts finger tight When all bolts are in place torque them to 72 108 inch lbs 6 9 ft lbs or 8 5 12 Nm 15 Position the bypass hose clamp back to its original position 16 Install the water pump pulley and its attaching bolts Snug the bolts 17 Conn...

Page 340: ... To install Clean the mounting surfaces of the pump and front cover thoroughly Remove all traces of gasket material 13 Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump 14 Install the lower radiator hose to the water pump 15 Position the pump on the cover and install the bolts finger tight When all bolts are in place torque them to 15 21 ft lbs 20 28 Nm 16...

Page 341: ...sor at the exhaust manifold 8 Disconnect required vacuum hoses 9 Remove dipstick tube and bracket 10 Remove rocker retaining bolts and remove cover 11 Remove intake manifold retaining bolts 12 Loosen alternator retaining bolts and remove belt from the pulley Remove mounting bracket retaining bolts to the head 13 Disconnect the upper radiator hose at both ends and remove from the vehicle 14 Remove ...

Page 342: ... Position cylinder head to block 32 Install cylinder head retaining bolts and tighten to specifications 33 Fig 1 2 3L and 2 5L cylinder head bolt tightening sequence Click to enlarge Connect oil sending unit lead wires 34 Install the timing belt idler spring stop to the cylinder head 35 HOW TO USE THIS BOOK REMOVAL INSTALLATION 335 ...

Page 343: ... plug wires 55 Install the heater hose to valve cover retaining screws 56 Fill and bleed the cooling system 57 Install the air cleaner 58 Connect the negative battery cable 59 Start the engine and check for leaks 60 2 9L Engines According to the manufacturer you must use new cylinder head bolts when installing the heads Disconnect the battery ground cable 1 Drain the radiator coolant 2 CAUTION Whe...

Page 344: ...s and rocker arms 19 Install the distributor 20 Adjust the valves as described in Section 1 under Valve Lash adjustment 21 Install the rocker arm covers 22 Connect the fuel line to the fuel rail 23 Install the distributor cap with spark plug wires attached Coat the inside of each spark plug boot with silicone lubricant and install them on the spark plug 24 Install the throttle linkage and air clea...

Page 345: ...der head 3 11 If the right hand head is being removed Disconnect alternator electrical harnesses 1 Remove belt tensioner assembly 2 Remove the alternator and bracket 3 Remove hose from valve cover to oil fill adapter 4 12 Remove the spark plugs 13 Remove the exhaust manifold s 14 Remove the rocker arm covers as previously described 15 Loosen rocker arm fulcrum retaining bolts enough to allow the r...

Page 346: ...Cylinder head gasket positioning for the 3 0L Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 339 ...

Page 347: ...Cylinder head installation bolt torque sequence for the 3 0L Click to enlarge HOW TO USE THIS BOOK 340 REMOVAL INSTALLATION ...

Page 348: ...o 11 ft lbs 22 Install intake manifold as outlined 23 Dip each pushrod in heavy engine oil then install the pushrods in their original locations 24 For each valve rotate the crankshaft until the tappet rests on the heel base circle of the camshaft lobe before tightening the fulcrum attaching bolts Position the rocker arms over the pushrods Install the fulcrums tighten to 8 ft lbs to seat fulcrum a...

Page 349: ...ioner assembly 3 Reconnect alternator electrical harnesses 4 36 Install the accessory drive belt 37 Connect fuel lines Install fuel line safety clips 38 Install all radiator hoses Connect vacuum lines 39 Drain and change engine oil 40 CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your...

Page 350: ...connect the hoses Tie the assembly out of the way 3 Remove the spark plugs After removing the intake manifold loosen the accessory mounting bracket bolts then remove the bracket and accessory 4 6 If the right head is being removed Remove the accessory drive belt 1 Remove the alternator and bracket 2 Remove the EDIS ignition coil and bracket 3 Remove the spark plugs 4 7 Remove the exhaust manifold ...

Page 351: ...ve the rocker shaft assembly 9 Remove the pushrods keeping them in order so they may be installed in their original locations 10 Loosen and remove the cylinder head attaching bolts then lift the cylinder head from the engine HOW TO USE THIS BOOK 344 REMOVAL INSTALLATION ...

Page 352: ... cover and cylinder block gasket surfaces of all traces of old gasket material and or sealer Refer to the following overhaul procedures for cylinder head component removal valve replacement resurfacing etc 14 With rags placed in the cylinder bores scrape the gasket mating surfaces clean Lightly oil all bolt and stud bolt threads except those specifying special sealant Position the new head gasket ...

Page 353: ...e Fig 15 Cylinder head torque sequence for the 4 0L engine The cylinder head s and intake manifold are torqued alternately and in sequence to assure a correct fit and gasket crush Position the cylinder head s on the block 16 HOW TO USE THIS BOOK 346 REMOVAL INSTALLATION ...

Page 354: ...all the valve covers using new gaskets coated with sealer Torque the bolts to 36 6 inch lbs After 2 minutes re torque the cover bolts 27 Install the upper intake manifold Torque the nuts to 15 18 ft lbs 28 Install the exhaust manifold s 29 Install the spark plugs and wires 30 If the left head was removed install the power steering pump compressor and drive belt 31 If the right head was removed ins...

Page 355: ... disconnect the complete engine wire harness including injectors sensors etc from the engine and position it out of the way 9 Disconnect the EGR valve supply tube then remove the valve 10 Remove the heater hose bracket from the engine and disconnect the transmission dipstick tube 11 Disconnect both heater hoses from the engine 12 Remove the thermostat housing bypass hose 13 Remove the thermostat h...

Page 356: ...ft sprocket bolt 25 Remove the LH cassette chain guide retaining bolt 26 Remove the eight 12 mm and two 8 mm bolts in sequence from the LH cylinder head 27 Remove the cylinder head and discard the old gasket 28 WARNING The RH exhaust manifold must be removed before the RH cylinder head to avoid breaking the camshaft cassette HOW TO USE THIS BOOK REMOVAL INSTALLATION 349 ...

Page 357: ...lic chain tensioner Access to the tensioner is through the RH fender well 30 WARNING The RH camshaft sprocket bolt uses left hand threads Use the cam gear torque adapter tool to remove the RH camshaft sprocket bolt 31 Fig 20 Remove the RH cassette retaining bolt arrow Remove the RH cassette retaining bolt 32 WARNING HOW TO USE THIS BOOK 350 REMOVAL INSTALLATION ...

Page 358: ...eight 12mm and two 8mm bolts in sequence from the RH cylinder head 34 Remove the cylinder head and discard the old gasket 35 To install Thoroughly clean all gasket mating surfaces Remove all traces of old gasket material oil grease or dirt 36 Fig 22 Cylinder head bolt loosening and tightening sequence for the 4 0L SOHC engine Insure that the rubber band is holding the RH chain to the cassette 37 I...

Page 359: ...cond rotate 90 third rotate an additional 90 42 Install the RH camshaft sprocket in the cassette 43 Loosely install the RH camshaft sprocket bolt 44 The camshaft sprocket must turn freely on the camshaft DO NOT tighten the bolt Install the RH cassette retaining bolt 45 Loosely install the LH camshaft sprocket bolt 46 The camshaft sprocket must turn freely on the camshaft DO NOT tighten the bolt In...

Page 360: ...k 3 Position the camshaft timing slots to properly fit the camshaft holding tool and position the toll on the LH cylinder head The camshaft timing slots are off center and below the center line of the camshaft 4 Install the camshaft gear positioning holding tool on the LH cylinder head 5 Ensure that the bolts on the camshaft gear positioning holding tool are tight then tighten the LH camshaft spro...

Page 361: ...the engine oil dipstick and tube 92 Install the crankcase vent separator and the spring clip 91 Lubricate the injector o rings with SAE 50W oil and install them 90 Install both valve covers 89 Install the fuel injection supply manifold 88 Tighten the upper fuel line bracket 87 Install the spark plug wires to the plugs 86 Install the thermostat housing assembly 85 Install the thermostat bypass hose...

Page 362: ...2 Position a new cylinder head gasket to the engine block then install the cylinder head 13 Fig 27 Cylinder head bolt tightening sequence for the 5 0L engine Install new cylinder head bolts and tighten in three steps Tighten all bolts in sequence to 25 37 ft lbs 34 47 Nm 1 Tighten all bolts in sequence to 45 1 ft lbs 7 18 Nm 2 Tighten all bolts an additional 85 95 1 4 turn 3 14 Ensure that the oil...

Page 363: ...attached Sludge and debris in the oil pan will fall into the cylinders pistons and connecting rods possibly causing rapid wear Sludge may also plug the engine oil pickup screen Mount the engine assembly on an engine stand with the engine mounted in the upright position 3 Remove the oil pan mounting bolts 4 Remove the oil pan from the engine 5 Remove and discard the oil pan gasket Thoroughly clean ...

Page 364: ...o the cross member 6 Remove the engine oil dipstick tube 7 Raise the truck on a hoist and support with jackstands 8 Drain the engine crankcase and remove the oil filter 9 CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn wh...

Page 365: ...Oil pan gasket positioning on the 2 9L engine Click to enlarge Oil pan bolt torque sequence on the 2 9L engine Click to enlarge HOW TO USE THIS BOOK 358 REMOVAL INSTALLATION ...

Page 366: ...n areas as soon as possible after exposure to used engine oil Soap and water or waterless hand cleaner should be used Remove the starter motor from the engine 8 Remove the transmission inspection cover 9 Remove the right hand axle I Beam The brake caliper must be removed and secured out of the way Refer to the necessary service procedures 10 Remove the oil pan attaching bolts using a suitable lift...

Page 367: ...crankcase with the correct amount of new engine oil Start engine and check for leaks 22 If equipped with distributor ignition check the base ignition timing 23 4 0L Engine VIN X Review the complete service procedure before starting this repair Disconnect the negative battery cable Remove the complete engine assembly from the vehicle Refer to the necessary service procedures in this section 1 Mount...

Page 368: ...shaft rear main bearing cap wedge seal The seal should fit snugly into the sides of the rear main bearing cap 6 Oil pan installation on the 4 0L engine VIN X Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 361 ...

Page 369: ... machined mating surface of the rear of the block extending over the oil pan to transmission mounting surface 1 Using a feeler gauge measure the gap between the oil pan mounting pad and the straightedge 2 Repeat the procedure for the other side 3 Select the spacers as follows Gap 0 011 0 020 in spacer 0 010 in Gap 0 021 0 029 in spacer 0 020 in Gap 0 030 0 039 in spacer 0 030 in 4 9 Failure to use...

Page 370: ...rt the vehicle 2 Drain the engine oil 3 Exploded view of the 4 0L SOHC engine oil pan assembly Remove the ten oil pan bolts and remove the pan 4 Installation is the reverse of removal Clean the gasket mating surfaces and install a new gasket Tighten the pan bolts to 6 7 4 ft lbs 8 10 Nm Refill the engine with clean oil 5 5 0L Engine The oil pan cannot be removed with the engine in the vehicle Remo...

Page 371: ...ve the oil pan and gasket 4 Installation is the reverse of removal Use RTV sealer at the four corners of the block and pan Tighten the four oil pan end attaching bolts to 12 18 ft lbs 16 25 Nm and the 18 oil pan bolts to 110 144 inch lbs 13 16 Nm 5 Oil Pump HOW TO USE THIS BOOK 364 Oil Pump ...

Page 372: ...4 Install the pump and tighten the mounting bolts to 14 21 ft lbs 19 29 Nm on 17 7 2 3L engines 6 10 ft lbs 8 14 Nm on 2 9L engines 30 40 ft lbs 41 54 Nm on 3 0L engines 13 15 ft lbs 18 20 Nm on 4 0L engines 5 WARNING Do not force the oil pump if it does not seat readily The oil pump driveshaft may be misaligned with the distributor or shaft assembly If the pump is tightened down with the drivesha...

Page 373: ...Oil pump installation on the 1991 94 2 3L engine Click to enlarge Oil pump installation on the 3 0L engines Click to enlarge HOW TO USE THIS BOOK 366 REMOVAL INSTALLATION ...

Page 374: ...rocket 4 Use a prybar or drift through one of the holes in the pump sprocket to keep it from turning while loosening the bolt Unbolt the camshaft position sensor 5 Remove the four bolts retaining the oil pump to the engine block 6 Remove the oil pump from the front of the engine and discard the pump to block gasket 7 Inspect the oil pump and O rings and replace as necessary Clean all gasket mating...

Page 375: ...4 0L SOHC VIN E and 5 0L Engines The oil pump cannot be removed with the engine in the vehicle Remove the engine 1 Remove the oil pan 2 Remove the two oil pick up attaching bolts arrows 4 0L engine shown On the 4 0L engine remove the eight ladder frame bolts in the oil pan area Unbolt the oil pick up tube 3 On the 4 0L engine remove the eight ladder frame bolts which were under the oil pan 4 On th...

Page 376: ...f the side ladder frame bolts arrow on the 4 0L engine On the 4 0L engine remove the seven LH and the eight RH ladder frame bolts 6 On the 4 0L engine lift the ladder frame from the engine 7 Remove the two oil pump attaching bolts and the pump 8 HOW TO USE THIS BOOK REMOVAL INSTALLATION 369 ...

Page 377: ... to prime it Tighten the pump attaching bolts to 13 15 ft lbs 17 21 Nm for the 4 0L engine and 23 31 ft lbs 30 43 Nm for the 5 0L engine 9 Crankshaft Damper REMOVAL INSTALLATION Disconnect the negative battery cable for safety 1 Remove the engine fan clutch assembly and shroud 2 Remove the accessory drive belt 3 If equipped unbolt the crankshaft pulley from the damper 4 HOW TO USE THIS BOOK 370 Cr...

Page 378: ...he crankshaft Assemble a puller to the damper then tighten the center bolt to remove the damper from the crankshaft Remove the damper to crankshaft snout attaching bolt 5 Assemble a puller to the damper and remove it 6 To install HOW TO USE THIS BOOK REMOVAL INSTALLATION 371 ...

Page 379: ...pplies to the 2 3L and 2 5L engine only TROUBLESHOOTING Should the camshaft drive belt timing belt jump timing by a tooth or two the engine could still run but very poorly To visually check for correct timing of the crankshaft auxiliary shaft and the camshaft follow this procedure There is an access plug provided in the cam drive belt cover so that the camshaft timing cam be checked without moving...

Page 380: ...Timing belt cover on the 2 3L and 2 5L engine Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 373 ...

Page 381: ...ft pulleys An access plug is provided in the cam belt cover so that the camshaft timing can be checked without removal of the cover or any other parts Set the crankshaft to TDC by aligning the timing mark on the crank pulley with the TDC mark on the belt cover Look through the access hole in the belt cover to make sure that the timing mark on the cam drive sprocket is lined up with the pointer on ...

Page 382: ...stall the new belt over the crankshaft sprocket and then counterclockwise over the auxiliary and camshaft sprockets making sure the lugs on the belt properly engage the sprocket teeth on the pulleys Be careful not to rotate the pulleys when installing the belt 8 Release the timing belt tensioner pulley allowing the tensioner to take up the belt slack If the spring does not have enough tension to m...

Page 383: ...large Installing the front seal cover installed on the 2 9L engine Front cover alignment tool on the 2 9L engine Disconnect the negative battery cable 1 Remove the oil pan as described under Oil Pan removal and installation 2 HOW TO USE THIS BOOK 376 REMOVAL INSTALLATION ...

Page 384: ...all Clean the front cover mating surfaces of gasket material Apply sealer to the gasket surfaces on the cylinder block and back side of the front cover plate Install the guide sleeves with new seal rings with the chamfered end toward the front cover if removed Position the gasket and the front cover plate on the cylinder block Temporarily install the four front cover screws to position the gasket ...

Page 385: ...otor mount retaining nuts Remove the A C compressor upper bolts then remove the front cover front nuts on vehicles with automatic transmission and A C 6 Raise the vehicle Remove the A C compressor bolts and bracket if so equipped and position the assembly aside 7 Remove the crankshaft pulley and damper assembly Remove the oil pan Refer to the necessary service procedures in this section 8 Accordin...

Page 386: ...Front cover removal 3 0L Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 379 ...

Page 387: ...nstall retaining bolts with pipe sealant and tighten as outlined Refer to the necessary illustration 14 If the front seal needs to be replaced proceed as follows Using Front Cover Seal Removal Tool T70P 6B070 A or its equivalent remove the front seal 1 Lubricate the engine front cover and oil seal lip inner lip with engine oil 2 Using Crankshaft Seal Replacer Cover Aligner T82L 6316 A or its equiv...

Page 388: ...ining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years old To remove the front cover remove the ...

Page 389: ...DO NOT disconnect the hoses 5 Remove the alternator 6 Remove the water pump 7 Remove the drive pulley damper from the crankshaft 8 Remove the crankshaft timing sensor 9 Front cover mounting 4 0L engine Click to enlarge HOW TO USE THIS BOOK 382 REMOVAL INSTALLATION ...

Page 390: ... cover attaching bolts Remove the front cover attaching bolts It may be necessary to tap the cover loose with a plastic mallet 10 Inspect the oil seal If the seal needs replacing follow the procedures under installation 11 To install HOW TO USE THIS BOOK REMOVAL INSTALLATION 383 ...

Page 391: ...seal out of the cover using a hammer and punch Use an ordinary seal driver and seat a new seal into the cover at the same position as the old one Install the front cover and attaching bolts Refer to the necessary illustration 13 If the front seal needs to be replaced proceed as follows Using Front Cover Seal Removal Tool T74P 6700 A or its equivalent remove the front seal 1 Lubricate the engine fr...

Page 392: ...stall Thoroughly clean all gasket mating surfaces Use new gaskets and coat them with a sealer adhesive 7 Install the front cover and tighten all of the bolts 8 If the front seal needs to be replaced proceed as follows Using Front Cover Seal Removal Tool T74P 6700 A or its equivalent remove the front seal 1 Lubricate the engine front cover and oil seal inner lip with engine oil 2 Using Crankshaft S...

Page 393: ...sealer adhesive 8 Install the front cover water pump assembly and tighten all of the bolts 9 View of the front cover seal removal tool Using the seal replacer tool to install a new front seal If the front seal needs to be replaced proceed as follows Using Front Cover Seal Removal Tool T70P 6B070 B or its equivalent remove the front seal 1 Lubricate the engine front cover and oil seal lip inner lip...

Page 394: ...the spacer 4 Feed the timing chain around the crankshaft sprocket and then around the camshaft sprocket Install the camshaft sprocket together with timing chain as an assembly Align all necessary timing marks Check the camshaft end play Refer to checking camshaft If not within specifications replace the thrust plate 5 Align the keyway in the crankshaft gear with key in the crankshaft and align the...

Page 395: ...k alignment 3 0L engine Click to enlarge Timing chain mounting 3 0L engine Click to enlarge Rotate crankshaft until No 1 piston is at TDC and timing marks are aligned in the correct position 4 HOW TO USE THIS BOOK 388 REMOVAL INSTALLATION ...

Page 396: ...en as outlined 9 Refill and bleed cooling system Connect the negative battery cable Start engine check for coolant oil and exhaust leaks 10 4 0L Engine VIN X Review the complete service procedure before starting this repair Refer to the necessary service procedures in this section Disconnect the negative battery cable 1 Drain the cooling system 2 CAUTION When draining the coolant keep in mind that...

Page 397: ...iming chain mounting 4 0L engine Click to enlarge Rotate the engine by hand until the No 1 cylinder is at TDC compression and the timing marks are aligned 5 HOW TO USE THIS BOOK 390 REMOVAL INSTALLATION ...

Page 398: ...Remove the tensioner lower attaching bolt HOW TO USE THIS BOOK REMOVAL INSTALLATION 391 ...

Page 399: ... and install a holding clip in the bolt hole and the slot on the rubbing block HOW TO USE THIS BOOK 392 REMOVAL INSTALLATION ...

Page 400: ...Unbolt and remove the tensioner HOW TO USE THIS BOOK REMOVAL INSTALLATION 393 ...

Page 401: ...A close up view of a homemade holding clip HOW TO USE THIS BOOK 394 REMOVAL INSTALLATION ...

Page 402: ...ove the lower tensioner bolt and install a holding clip in the bolt hole and the slot on the rubbing block 6 Unbolt and remove the tensioner Remove the camshaft sprocket bolt and sprocket retaining key 7 HOW TO USE THIS BOOK REMOVAL INSTALLATION 395 ...

Page 403: ...Loosen the camshaft sprocket bolt HOW TO USE THIS BOOK 396 REMOVAL INSTALLATION ...

Page 404: ... then remove it HOW TO USE THIS BOOK REMOVAL INSTALLATION 397 ...

Page 405: ...move the camshaft sprocket and chain Remove the camshaft and crankshaft sprockets with the timing chain 8 If necessary unbolt the chain guide attaching bolts HOW TO USE THIS BOOK 398 REMOVAL INSTALLATION ...

Page 406: ...remove the guide from the engine To remove the crankshaft sprocket use a chisel to loosen the keyway then remove the keyway from the crankshaft Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 399 ...

Page 407: ...Using a jawed puller tighten the center bolt HOW TO USE THIS BOOK 400 REMOVAL INSTALLATION ...

Page 408: ... To install Install the timing chain guide Make sure the pin of the guide is in the hole in the block Tighten the bolts to 84 96 inch lbs 10 Align the timing marks on the crankshaft and camshaft sprockets and install the sprockets and chain 11 HOW TO USE THIS BOOK REMOVAL INSTALLATION 401 ...

Page 409: ...dtest the vehicle for proper operation 22 4 0L SOHC Engine VIN E On the 4 0L SOHC engine there are four chains which are used to time the camshafts and balance the engine There is a jackshaft mounted in the middle of the engine block The two camshafts are connected to the jackshaft by two chains The jackshaft is connected to the crankshaft by a third chain Also a balance shaft assembly is chain dr...

Page 410: ...vehicle 1 Remove the oil pan and ladder frame 2 For ladder frame removal procedures refer to the oil pump removal and installation procedure in this section Remove the front cover attaching bolts and remove the cover 3 Remove the cylinder heads 4 Install a pin into the jackshaft chain tensioner arrow HOW TO USE THIS BOOK REMOVAL INSTALLATION 403 ...

Page 411: ...ion 5 Loosen and remove the jackshaft sprocket bolt 6 Remove the jackshaft sprocket and chain assembly 7 View of the left hand front cassette retaining bolt arrow Remove the left hand front cassette retaining bolt and remove the cassette chain and tensioner assembly 8 HOW TO USE THIS BOOK 404 REMOVAL INSTALLATION ...

Page 412: ...t be removed from the back of the engine block View of the right hand rear cassette retaining bolt Remove the rear jackshaft plug from the back of the engine block 10 Remove the right hand rear cassette retaining bolt and spacer 11 Remove the rear jackshaft sprocket retaining bolt arrow HOW TO USE THIS BOOK REMOVAL INSTALLATION 405 ...

Page 413: ...procket bolt and tighten in two stages Stage 1 32 35 ft lbs 43 47 Nm 1 Stage 2 Turn an additional 65 75 2 20 Install the cylinder heads Time the chains as outlined in the cylinder head procedure 21 Install the front cover and tighten all of the bolts 22 Install the ladder frame and oil pan 23 Install the engine into the vehicle 24 Run the engine and check for leaks 25 5 0L Engine Remove the engine...

Page 414: ...point of the chain Measure from this point to the chain 3 Rotate the crankshaft in the opposite direction to take up the slack on the right hand side of the chain Force the left hand side of the chain out with your fingers and measure the distance between the reference point and the chain The deflection is the difference between the two measurements 4 If the deflection measurement exceeds specific...

Page 415: ...llow Steps 7 9 then skip to Step 12 Drain the cooling system Remove the air cleaner assembly and disconnect the negative battery cable 1 CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always ...

Page 416: ...g installing tool is on hand the cylinder head must be removed for new bearings to be installed by a machine shop 13 Exploded view of the camshaft mounting 2 3L and 2 5L engine Click to enlarge Camshaft installation is in the reverse order of service removal procedure Coat the camshaft with a heavy SF or better grade oil before sliding it into the cylinder head Install a new front seal Apply a coa...

Page 417: ...ssembly 5 Disconnect the distributor wiring harness and remove the distributor 6 Remove the alternator 7 Remove the intake manifold as described earlier 8 Remove the rocker arm covers and rocker arm and shaft assemblies as described in this section Label and remove the push rods and the tappets so they can be reinstalled in the same location 9 Remove the oil pan as described in this section 10 Rem...

Page 418: ...on 24 Position the tappets in their original locations Apply Lubriplate or equivalent to both ends of the push rods 25 Install the push rods in same location as removed Install the intake manifold as described earlier 26 Install the oil baffles and rocker arm and shaft assemblies Tighten the rocker arm stand bolts to 43 50 ft lbs Adjust the valves and install the valve rocker arm covers 27 Install...

Page 419: ...13 Remove the throttle body See Section 5 14 Remove the fuel injection harness See Section 5 15 Drain the engine oil into a suitable container and dispose of it properly 16 CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn ...

Page 420: ...0W Install the spacer ring with the chamfered side toward the camshaft then insert the camshaft key 33 Install the camshaft in the block using caution to avoid any damage to the camshaft bearings 34 Install the thrust plate Tighten the attaching screws to 84 inch lbs 35 Rotate the camshaft and crankshaft as necessary to align the timing marks Install the camshaft gear and chain Tighten the attachi...

Page 421: ...aust No 4 intake No 5 exhaust 40 Rotate the engine until the camshaft timing mark is at the bottom of the sprocket and the crankshaft timing mark is at the top of the sprocket and both are aligned Tighten the following fulcrum bolts to 18 ft lbs No 1 exhaust No 2 intake No 3 intake and exhaust No 4 exhaust No 5 intake No 6 intake and exhaust 41 Now tighten all the bolts to 24 ft lbs 42 Turn the en...

Page 422: ...umber of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing the oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil Soap and water or waterless hand cleaner should be used Drain the cooling system 3 CAUTION When draining the coolant keep in mi...

Page 423: ...eck the camshaft end play If excessive you ll have to replace the thrust plate 24 Remove the camshaft gear attaching bolt and washer then slide the gear off the camshaft 25 Remove the camshaft thrust plate 26 Carefully slide the camshaft out of the engine block using caution to avoid any damage to the camshaft bearings 27 To install Oil the camshaft journals and cam lobes with a heavy 50W SG grade...

Page 424: ...Camshaft installation 4 0L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 417 ...

Page 425: ...f the pushrods Install the pushrods in their original locations 37 Install the upper and lower intake manifolds 38 Install the rocker shaft assemblies 39 Install the valve covers 40 Install the fan and clutch 41 Install the fuel lines 42 Install the oil pump drive 43 Install the alternator 44 Install the EDIS coil and plug wires Coat the inside of each wire boot with silicone lubricant 45 Install ...

Page 426: ...s Using the Valve Spring Compressor Tool ST150 A or its equivalent remove the camshaft roller followers 5 Remove the camshaft bearing cap bolts and the oil rail 6 Remove the camshaft 7 To install Lubricate all of the moving parts with SAE 50W engine oil 8 Install the camshaft onto the cylinder head 9 Position the oil rail and install the bearing caps and bolts Tighten the bolts in two stages Stage...

Page 427: ...Install the camshaft onto the cylinder head 9 Position the oil rail and install the bearing caps and bolts Tighten the bolts in two stages Stage 1 53 5 inch lbs 6 Nm 1 Stage 2 11 12 5 ft lbs 15 17 Nm 2 10 Install the camshaft followers in the same manner as removal 11 Install the camshaft sprocket bolt Do not tighten the bolt 12 Refer to the steps in the cylinder head removal and installation proc...

Page 428: ...ighten to 9 12 ft lbs 13 16 Nm 14 Apply SAE 50W engine oil to the valve tappets and install them If reusing the old lifters place them in their original positions 15 Install the pushrods to their original positions 16 Reposition the rocker arms and tighten them as outlined earlier in this Section 17 Install the valve covers the lower and the upper intake manifolds 18 Install the camshaft sprocket ...

Page 429: ...ach lobe in consecutive order and make a note of the reading Camshaft assembly specifications are sometimes modify by Ford after production Refer to a local reputable machine shop as necessary Remove the fresh air inlet tube and the air cleaner Remove the heater hose and crankcase ventilation hoses Remove valve rocker arm cover s 1 Remove the rocker arm stud nut or fulcrum bolts fulcrum seat and r...

Page 430: ...all the valve rocker arm covers and the air cleaner 9 Camshaft End Play 2 3L and 2 5L ENGINES Camshaft thrust plate installation 2 3L and 2 5L engines Remove the camshaft drive belt cover Push the camshaft toward the rear of the engine Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw or gear hub Zero the dial indicator Position a prybar between the c...

Page 431: ...e service limit is 0 009 inch 0 007 inch on 3 0L engine Camshaft specifications are sometimes modified by Ford after production 2 If the end play is excessive check the spacer for correct installation before it is removed If the spacer is correctly installed replace the thrust plate 3 The spacer ring and thrust plate are available in two thicknesses to permit adjusting the end play Remove the dial...

Page 432: ...e the head and place it on a work stand 1 Remove the camshaft 2 Using a tool such as Bearing Replacer T71P 6250 A remove the bearings 3 Coat the new bearings with clean 50W engine oil and install them with the tool 4 2 9L Engines HOW TO USE THIS BOOK BEARING REMOVAL INSTALLATION 425 ...

Page 433: ...ivalents remove the bearings 5 To remove the front and rear bearings use the special adapter tube T72C 6250 or equivalent 6 To install Following the instructions in the tool kit install the bearings Make sure that you follow the instructions carefully Failure to use the correct expanding collets can cause severe bearing damage 7 Make sure that the oil holes in the bearings and block are aligned In...

Page 434: ...e sure that you follow the instructions carefully Failure to use the correct expanding collets can cause severe bearing damage 7 Make sure that the oil holes in the bearings and block are aligned Make sure that the front bearing is installed 0 51 0 89mm below the face of the block Install a new bearing bore plug coated with sealer 8 Install the camshaft 9 Install the flywheel 10 Install the engine...

Page 435: ...ove the auxiliary shaft cover and thrust plate 4 Withdraw the auxiliary shaft from block 5 The distributor drive gear and the fuel pump eccentric on the auxiliary shaft must not be allowed to touch the auxiliary shaft bearings during removal and installation Completely coat the shaft with oil before sliding it into place Slide the auxiliary shaft into the housing and insert the thrust plate to hol...

Page 436: ...y shaft cover Fit a new gasket into the fuel pump and install the pump 8 Insert the distributor and install the auxiliary shaft sprocket 9 Align the timing marks and install the drive belt 10 Install the drive belt cover 11 Check the ignition timing 12 Rear Main Oil Seal REMOVAL INSTALLATION Rear main seal installation for the 2 3L and 2 5L engines Click to enlarge HOW TO USE THIS BOOK Rear Main O...

Page 437: ...nction with a rear main bearing replacement the engine must be removed from the vehicle and installed on a work stand Remove the starter 1 Remove the transmission from the vehicle following the procedures in Section 7 2 On a manual shift transmission remove the pressure plate and cover assembly and the clutch disc following the procedure in Section 7 3 Remove the flywheel attaching bolts and remov...

Page 438: ...e oil Start the seal in the recess with the seal lip facing forward and install it with a seal driver Keep the tool T82L 6701 A 4 cyl engines or T72C 6165 6 cyl engine straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface Remove the tool and inspect the seal to be sure it was not damaged during installation 7 Install the engine rear ...

Page 439: ...Clutch pilot bearing removal HOW TO USE THIS BOOK 432 REMOVAL INSTALLATION ...

Page 440: ...nlarge Remove the transmission following procedures in Section 7 1 On a manual shift transmission remove the clutch pressure plate and cover assembly and clutch disc following the procedures in Section 7 2 HOW TO USE THIS BOOK REMOVAL INSTALLATION 433 ...

Page 441: ... then remove the flywheel from the crankshaft To install Position the flywheel on the crankshaft flange Coat the threads of the flywheel attaching bolts with Loctite or equivalent and install the bolts Tighten the bolts in sequence across from each other to specifications 4 HOW TO USE THIS BOOK 434 REMOVAL INSTALLATION ...

Page 442: ...transmission install the clutch disc and pressure plate and cover assembly following the procedures in Section 7 5 Install the transmission following the procedure in Section 7 6 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK REMOVAL INSTALLATION 435 ...

Page 443: ... a nuisance and could injure your eye CAUTION DO NOT perform exhaust repairs or inspection with the engine or exhaust hot Allow the system to cool completely Exhaust systems are noted for sharp edges flaking metal and rusted bolts Gloves and eye protection are required A healthy supply of penetrating oil and rags is highly recommended Cracks in the muffler are a guaranteed leak EXHAUST SYSTEM 437 ...

Page 444: ...s loose connections or other deterioration which could permit exhaust fumes to seep into the passenger compartment Inspect all mounting brackets and hangers for deterioration some may have rubber O rings that can become overstretched and non supportive and should be replaced if worn Many technicians use a pointed tool to poke up into the exhaust system at rust spots to see whether or not they crum...

Page 445: ...Make sure the exhaust does contact the body or suspension Check for overstretched or torn exhaust hangers HOW TO USE THIS BOOK EXHAUST SYSTEM 439 ...

Page 446: ...ip joint type These components slip into one another using clamps to retain them together CAUTION Allow the exhaust system to cool sufficiently before spraying a solvent exhaust fasteners Some solvents are highly flammable and could ignite when sprayed on hot exhaust components Before removing any component of the exhaust system ALWAYS squirt a liquid rust dissolving agent onto the fasteners for e...

Page 447: ... NOT perform exhaust repairs or inspection with the engine or exhaust hot Allow the system to cool Exhaust systems are noted for sharp edges flaking metal and rusted bolts Gloves and eye protection are required Example of a flange type exhaust system joint HOW TO USE THIS BOOK REPLACEMENT 441 ...

Page 448: ...e manifold itself On slip joint components remove the mounting U bolts from around the exhaust pipe you are extracting from the vehicle Don t be surprised if the U bolts break while removing the nuts 4 Loosen the exhaust pipe from any mounting brackets retaining it to the floor pan and separate the components Slight twisting and turning may be required to remove the component completely from the v...

Page 449: ...il consumption evidence of oil in the engine air intake area and or bluish smoke from the tailpipe may indicate worn piston rings worn valve guides and or valve seals As a general rule an engine that uses no more than one quart of oil every 1000 miles is in good condition Engines that use one quart of oil or more in less than 1000 miles should first be checked for oil leaks If any oil leaks are pr...

Page 450: ...13 psi 779 kPa 11 If a cylinder exhibits an unusually low compression reading pour a tablespoon of clean engine oil into the cylinder through the spark plug hole and repeat the compression test If the compression rises after adding oil it means that the cylinder s piston rings and or cylinder bore are damaged or worn If the pressure remains low the valves may not be seating properly a valve job is...

Page 451: ...her car If you have considered all these matters and have still decided to rebuild the engine then it is time to decide how you will rebuild it The editors at Chilton feel that most engine machining should be performed by a professional machine shop Think of it as an assurance that the job has been done right the first time There are many expensive and specialized tools required to perform such ta...

Page 452: ...he use of most of these tools is illustrated in this section Many can be rented for a one time use from a local parts jobber or tool supply house specializing in automotive work Occasionally the use of special tools is called for See the information on Special Tools and the Safety Notice in the front of this book before substituting another tool OVERHAUL TIPS Aluminum has become extremely popular ...

Page 453: ...l and varnish or sludge can usually be removed using a scraper and or cleaning solvent Extremely stubborn deposits may require the use of a power drill with a wire brush If using a wire brush use extreme care around any critical machined surfaces such as the gasket surfaces bearing saddles cylinder bores etc Use of a wire brush is NOT RECOMMENDED on any aluminum components Always follow any safety...

Page 454: ...basket and allowed to soak Use pipe cleaner type brushes and clean all passageways in the components Use a ring expander and remove the rings from the pistons Clean the piston ring grooves with a special tool or a piece of broken ring Scrape the carbon off of the top of the piston You should never use a wire brush on the pistons After preparing all of the piston assemblies in this manner wash and ...

Page 455: ...r head valve seats A mistake or slip may cost you a new seat When cleaning the cylinder head remove carbon from the combustion chamber with the valves installed This will avoid damaging the valve seats REPAIRING DAMAGED THREADS Damaged bolt hole threads can be replaced with thread repair inserts HOW TO USE THIS BOOK REPAIRING DAMAGED THREADS 449 ...

Page 456: ...h the specified size bit Be sure to drill completely through the hole or to the bottom of a blind hole Using the kit tap the hole in order to receive the thread insert Keep the tap well oiled and back it out frequently to avoid clogging the threads HOW TO USE THIS BOOK 450 REPAIRING DAMAGED THREADS ...

Page 457: ...nserts usually differ because they require a tap equipped with pilot threads and a combined reamer tap section Most manufacturers also supply blister packed thread repair inserts separately in addition to a master kit containing a variety of taps and inserts plus installation tools Before attempting to repair a threaded hole remove any snapped broken or damaged bolts or studs Penetrating oil can b...

Page 458: ...ny vehicles Whether made from aluminum or iron all cylinder heads have valves and seats Some use two valves per cylinder while the more hi tech engines will utilize a multi valve configuration using 3 4 and even 5 valves per cylinder When the valve contacts the seat it does so on precision machined surfaces which seals the combustion chamber All cylinder heads have a valve guide for each valve The...

Page 459: ...nized will aid in assembly and reduce confusion Where possible try to maintain a components original location this is especially important if there is not going to be any machine work performed on the components If you haven t already removed the rocker arms and or shafts do so now 1 Position the head so that the springs are easily accessed 2 When removing an OHV valve spring use a compressor tool...

Page 460: ... Be careful not to lose the small valve locks keepers Remove the valve locks from the valve tip and or retainer A small magnet may help in removing the locks 4 Lift the valve spring tool and all off of the valve stem 5 HOW TO USE THIS BOOK 454 DISASSEMBLY ...

Page 461: ...shown Removing an umbrella positive type seal If equipped remove the valve seal If the seal is difficult to remove with the valve in place try removing the valve first then the seal Follow the steps below for valve removal 6 HOW TO USE THIS BOOK DISASSEMBLY 455 ...

Page 462: ...til all of the valves have been removed 10 2 3L 2 5L and 4 0L SOHC VIN E Engines Whether it is a single or dual overhead camshaft cylinder head the disassembly procedure is relatively unchanged One aspect to pay attention to is careful labeling of the parts on the dual camshaft cylinder head There will be an intake camshaft and followers as well as an exhaust camshaft and followers and they must b...

Page 463: ...Exploded view of a valve seal spring retainer and locks from an OHC cylinder head HOW TO USE THIS BOOK DISASSEMBLY 457 ...

Page 464: ...of a multi valve cylinder head Note how it has 2 intake and 2 exhaust valve ports C clamp type spring compressor and an OHC spring removal tool center for cup type followers HOW TO USE THIS BOOK 458 DISASSEMBLY ...

Page 465: ...t followers are easily disassembled using a standard valve spring compressor However certain models may not have enough open space around the spring for the standard tool and may require you to use a C clamp style compressor tool instead Example of the shaft mounted rocker arms on some OHC heads HOW TO USE THIS BOOK DISASSEMBLY 459 ...

Page 466: ...mshaft If not already removed remove the rocker arms and or shafts and the camshaft If applicable also remove the hydraulic lash adjusters Mark their positions for assembly 1 Before the camshaft can be removed all of the followers must first be removed HOW TO USE THIS BOOK 460 DISASSEMBLY ...

Page 467: ...nder head to allow access to the valve spring 2 Use a valve spring compressor tool to relieve the spring tension from the retainer 3 Compress the valve spring Due to engine varnish the retainer may stick to the valve locks A gentle tap with a hammer may help to break it loose HOW TO USE THIS BOOK DISASSEMBLY 461 ...

Page 468: ...oving the small locks 4 Lift the valve spring tool and all off of the valve stem 5 Remove the valve spring and retainer from the cylinder head If equipped remove the valve seal If the seal is difficult to remove with the valve in place try removing the valve first then the seal Follow the steps below for valve removal 6 HOW TO USE THIS BOOK 462 DISASSEMBLY ...

Page 469: ...f the valve If this has happened use a metal file to carefully remove the high spots around the lock grooves and or tip Only file it enough to allow removal Remove the valve from the cylinder head 8 All aluminum and some cast iron heads will have these valve spring shims Remove all of them as well If equipped remove the valve spring shim A small magnetic tool or screwdriver will aid in removal 9 R...

Page 470: ...enter of the head and will usually not occur to all of the valves All of the heads should look the same any that seem dished more than others are probably bad Next inspect the valve lock grooves and valve tips Check for any burrs around the lock grooves especially if you had to file them to remove the valve Valve tips should appear flat although slight rounding with high mileage engines is normal ...

Page 471: ...pecifications chart Check the readings against the specifications given Any springs that fail these inspections should be replaced The spring retainers rarely need replacing however they should still be checked as a precaution Inspect the spring mating surface and the valve lock retention area for any signs of excessive wear Also check for any signs of cracking Replace any retainers that are quest...

Page 472: ... If any seem lower or higher from another the guide has moved Mount a dial indicator onto the spring side of the cylinder head Lightly oil the valve stem and insert it into the cylinder head Position the dial indicator against the valve stem near the tip and zero the gauge Grasp the valve stem and wiggle towards and away from the dial indicator and observe the readings Mount the dial indicator 90 ...

Page 473: ...rely worn or recessed seat may need to be replaced All cracked seats must be replaced A seat concentricity gauge if available should be used to check the seat run out If run out exceeds specifications the seat must be machined if no specification is available given use 0 002 in or 0 051mm CYLINDER HEAD SURFACE FLATNESS After you have cleaned the gasket surface of the cylinder head of any old gaske...

Page 474: ...it is not there Some more reliable methods for inspecting for cracks include Magnaflux a magnetic process or Zyglo a dye penetrant Magnaflux is used only on ferrous metal cast iron heads Zyglo uses a spray on fluorescent mixture along with a black light to reveal the cracks It is strongly recommended to have your cylinder head checked professionally for cracks especially if the engine was known to...

Page 475: ...e valve on the valve seat and lifting the tool often to prevent grooving 5 Lap the valve until a smooth polished circle is evident on the valve and seat 6 Remove the tool and the valve Wipe away all traces of the grinding compound and store the valve to maintain its lapped location 7 WARNING Do not get the valves out of order after they have been lapped They must be put back with the same valve se...

Page 476: ...mer and a stepped drift or punch may be used to install and remove the guides Before removing the guides measure the protrusion on the spring side of the head and record it for installation Use the stepped drift to hammer out the old guide from the combustion chamber side of the head When installing determine whether or not the guide also seals a water jacket in the head and if it does use the rec...

Page 477: ...ce the valve spring and retainer over the stem 4 Position the spring compressor tool and compress the spring 5 Assemble the valve locks to the stem 6 Relieve the spring pressure slowly and insure that neither valve lock becomes dislodged by the retainer 7 Remove the spring compressor tool 8 Repeat Steps 2 through 8 until all of the springs have been installed 9 2 3L 2 5L and 4 0L SOHC VIN E Engine...

Page 478: ...ble to forego this step However some ridges may actually prevent the assemblies from being removed necessitating its removal There are several different types of ridge reamers on the market none of which are inexpensive Unless a great deal of engine rebuilding is anticipated borrow or rent a reamer Turn the crankshaft until the piston is at the bottom of its travel 1 Cover the head of the piston w...

Page 479: ... engine is always number 1 However depending on the engine placement the front of the engine could either be the flywheel or damper pulley end Generally the front of the engine faces the front of the vehicle Use a number punch or scribe and also mark the main bearing caps from front to rear with the front most cap being number 1 if there are five caps mark them 1 through 5 front to rear Place rubb...

Page 480: ...he piston and rod by hand put the upper half of the bearing insert back into the rod install the cap with its bearing insert installed and hand tighten the cap fasteners If the parts are kept in order in this manner they will not get lost and you will be able to tell which bearings came form what cylinder if any problems are discovered and diagnosis is necessary Remove all the other piston assembl...

Page 481: ...in bearing saddles and caps for damage burrs or high spots If damage is found and it is caused from a spun main bearing the block will need to be align bored or if severe enough replacement Any burrs or high spots should be carefully removed with a metal file Place a straightedge on the bearing saddles in the engine block along the centerline of the crankshaft If any clearance exists between the s...

Page 482: ... top of the cylinder bore then proceed to the middle and finally the bottom making a total of six measurements Hold the gauge square in the bore 90 degrees from the crankshaft centerline and gently tighten the lock Tilt the gauge back to remove it from the bore 2 Measure the gauge with the micrometer and record the reading 3 Again hold the gauge square in the bore this time parallel to the cranksh...

Page 483: ...sive wear on the skirts The wrist pin attaches the piston to the connecting rod The piston should move freely on the wrist pin both sliding and pivoting Grasp the connecting rod securely or mount it in a vise and try to rock the piston back and forth along the centerline of the wrist pin There should not be any excessive play evident between the piston and the pin If there are C clips retaining th...

Page 484: ...r pits If the bearing is severely worn scored pitted or heat blued then the bearing and the components that use it should be brought to a machine shop for inspection Full circle bearings used on most camshafts auxiliary shafts balance shafts etc require specialized tools for removal and installation and should be brought to a machine shop for service Oil Pump The oil pump is responsible for provid...

Page 485: ...istons will have a mark indicating the direction to the front of the engine and the must be installed into the engine in that manner Usually it is a notch or arrow on the top of the piston or it may be the letter F cast or stamped into the piston Most pistons are marked to indicate positioning in the engine usually a mark means the side facing the front C CLIP TYPE PISTONS Note the location of the...

Page 486: ...d spray the entire assembly down with an anti rust solution such as WD 40 or similar product Take a clean lint free rag and wipe up any excess anti rust solution from the bores bearing saddles etc Repeat the final cleaning process on the crankshaft Replace any freeze or oil galley plugs which were removed during disassembly Crankshaft Remove the main bearing inserts from the block and bearing caps...

Page 487: ...l cap and tighten bolts to specifications Do not turn crankshaft while Plastigage is in place 2 Remove the cap Using the supplied Plastigage scale check width of Plastigage at widest point to get maximum clearance Difference between readings is taper of journal 3 HOW TO USE THIS BOOK ASSEMBLY 481 ...

Page 488: ...and bearings Install the rear main bearing cap Install all bearing caps except the thrust bearing cap Be sure that main bearing caps are installed in original locations Tighten the bearing cap bolts to specifications 8 Install the thrust bearing cap with bolts finger tight 9 Pry the crankshaft forward against the thrust surface of upper half of bearing 10 Hold the crankshaft forward and pry the th...

Page 489: ...d journal to the bottom of its stroke 15 Pistons and Connecting Rods Before installing the piston connecting rod assembly oil the pistons piston rings and the cylinder walls with light engine oil Install connecting rod bolt protectors or rubber hose onto the connecting rod bolts studs Also perform the following Select the proper ring set for the size cylinder bore 1 Position the ring in the bore i...

Page 490: ...ng and its lower land according to specification The gauge should slide freely around the entire ring circumference without binding Any wear that occurs will form a step at the inner portion of the lower land If the lower lands have high steps the piston should be replaced The notch on the side of the bearing cap matches the tang on the bearing insert 6 HOW TO USE THIS BOOK 484 ASSEMBLY ...

Page 491: ...are marked to show which side of the ring should face up when installed to the piston Install the rings to the pistons Install the oil control ring first then the second compression ring and finally the top compression ring Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage 4 Install the piston and rod assembly into the block using a ring compressor an...

Page 492: ... lifters followers into their bores 2 Install the timing gears chain assembly 3 CYLINDER HEAD S Install the cylinder head s using new gaskets 1 Assemble the rest of the valve train pushrods and rocker arms and or shafts 2 2 3L 2 5L and 4 0L SOHC VIN E Engines CYLINDER HEAD S Install the cylinder head s using new gaskets 1 Install the timing sprockets gears and the belt chain assemblies 2 Engine Co...

Page 493: ...he speed but do not accelerate hard Most importantly do not lug the engine and avoid sustained high speeds until at least 100 miles Check the engine oil and coolant levels frequently Expect the engine to use a little oil until the rings seat Change the oil and filter at 500 miles 1500 miles then every 3000 miles past that KEEP IT MAINTAINED Now that you have just gone through all of that hard work...

Page 494: ...SPECIFICATION CHARTS Engine Specifications 2 3L Engine Click to enlarge SPECIFICATION CHARTS 489 ...

Page 495: ...Engine Specifications 2 3L Engine Click to enlarge HOW TO USE THIS BOOK 490 SPECIFICATION CHARTS ...

Page 496: ...Engine Specifications 2 5L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 491 ...

Page 497: ...Engine Specifications 2 5L Engine Click to enlarge HOW TO USE THIS BOOK 492 SPECIFICATION CHARTS ...

Page 498: ...Engine Specifications 2 9L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 493 ...

Page 499: ...Engine Specifications 2 9L Engine Click to enlarge HOW TO USE THIS BOOK 494 SPECIFICATION CHARTS ...

Page 500: ...Engine Specifications 3 0L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 495 ...

Page 501: ...Engine Specifications 3 0L Engine Click to enlarge HOW TO USE THIS BOOK 496 SPECIFICATION CHARTS ...

Page 502: ...Engine Specifications 4 0L VIN E Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 497 ...

Page 503: ...Engine Specifications 4 0L VIN E Engine Click to enlarge HOW TO USE THIS BOOK 498 SPECIFICATION CHARTS ...

Page 504: ...Engine Specifications 4 0L VIN X Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 499 ...

Page 505: ...Engine Specifications 4 0L VIN X Engine Click to enlarge HOW TO USE THIS BOOK 500 SPECIFICATION CHARTS ...

Page 506: ...Engine Specifications 5 0L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 501 ...

Page 507: ...Engine Specifications 5 0L Engine Click to enlarge HOW TO USE THIS BOOK 502 SPECIFICATION CHARTS ...

Page 508: ...Torque Specifications 2 3L Engine Click to enlarge Torque Specifications 2 3L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 503 ...

Page 509: ...Torque Specifications 2 5L Engine Click to enlarge HOW TO USE THIS BOOK 504 SPECIFICATION CHARTS ...

Page 510: ...Torque Specifications 2 9L Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 505 ...

Page 511: ...Torque Specifications 3 0L Engine Click to enlarge HOW TO USE THIS BOOK 506 SPECIFICATION CHARTS ...

Page 512: ...Torque Specifications 4 0L VIN X Engine Click to enlarge HOW TO USE THIS BOOK SPECIFICATION CHARTS 507 ...

Page 513: ...Torque Specifications 4 0 VIN E Engine Click to enlarge Torque Specifications 4 0 VIN E Engine Click to enlarge HOW TO USE THIS BOOK 508 SPECIFICATION CHARTS ...

Page 514: ...Torque Specifications 5 0L Engine Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK SPECIFICATION CHARTS 509 ...

Page 515: ...s a check valve by preventing air flow from entering the crankcase in the opposite direction The PCV valve also prevents combustion backfiring from entering the crankcase in order to prevent detonation of the accumulated crankcase gases TESTING Remove the PCV valve from the valve cover or engine block mounting grommet The PCV valve for the 5 5L and 5 5L engine is mounted in the crankcase oil vent ...

Page 516: ...paper over the hose end and wait 1 minute If vacuum holds the paper in place the system is OK reconnect the hose 1 If the paper is not held in place check for loose hose connections vacuum leaks or blockage Correct as necessary 2 6 REMOVAL INSTALLATION Disconnect the vacuum hose from the PCV valve 1 Remove the PCV valve from its mounting grommet 2 HOW TO USE THIS BOOK 512 TESTING ...

Page 517: ...PCV system hose routing for the 2 3L and 2 5L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 513 ...

Page 518: ...PCV system hose routing for the 3 0L engine 2 9L engine is similar Click to enlarge HOW TO USE THIS BOOK 514 REMOVAL INSTALLATION ...

Page 519: ... to the carbon canister for storage until they are purged to the engine for burning Purging the carbon canister removes the fuel vapor stored in the carbon canister The fuel vapor is purged via a CANister Purge CANP solenoid or vacuum controlled purge valve Purging occurs when the engine is at normal operating temperature and off idle The evaporative emission control system consists of the followi...

Page 520: ...the carbon canister The vapor space also allows for thermal expansion of the fuel CANP Solenoid The CANP solenoid is inline with the carbon canister and controls the flow of fuel vapors out of the canister It is normally closed When the engine is shut OFF the vapors from the fuel tank flow into the canister After the engine is started the solenoid is engaged and opens purging the vapors into the e...

Page 521: ...Evaporative canister and hose routing on the 2 3L and 2 1L engine Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 517 ...

Page 522: ...Evaporative canister and hose routing on the 3 0L engine 2 4L engine similar Click to enlarge HOW TO USE THIS BOOK 518 COMPONENT TESTING ...

Page 523: ...Evaporative canister and hose routing on the 4 0L engine Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 519 ...

Page 524: ...EVAP canister mounting for the 1 0L engine Click to enlarge HOW TO USE THIS BOOK 520 COMPONENT TESTING ...

Page 525: ...Fuel vapor management valve mounting 1 0L engine shown others similar Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 521 ...

Page 526: ...y the intensity of the fuel odor from the canister These methods are unreliable and inhaling gasoline fumes can be toxic CANP Solenoid 1441 1444 MODELS Remove the CANP solenoid 1 Using an external voltage source apply 4 14 DC volts to the CANP solenoid electrical terminals Then use a hand held vacuum pump and apply 16 in Hg 13 kPa vacuum to the manifold side nipple of the CANP solenoid If the sole...

Page 527: ...does not open and the vacuum remains replace the solenoid with a new one 2 4 REMOVAL INSTALLATION Fuel Vapor Canister The fuel vapor canister is referred to as the evaporative emissions canister on 1441 44 models Disconnect the vapor hoses from the canister 1 Remove the mounting screws then remove the canister 2 To install Position the canister in place then install the mounting screws 3 Attach al...

Page 528: ...as Recirculation EGR system is designed to reintroduce exhaust gas into the combustion chambers thereby lowering combustion temperatures and reducing the formation of Oxides of Nitrogen NOx The amount of exhaust gas that is reintroduced into the combustion cycle is determined by several factors such as engine speed engine vacuum exhaust system backpressure coolant temperature throttle position All...

Page 529: ...Typical EGR system schematic Click to enlarge COMPONENT TESTING HOW TO USE THIS BOOK OPERATION 525 ...

Page 530: ...Exploded view of the EGR system and related components for the 2 3L and 2 5L engine Click to enlarge HOW TO USE THIS BOOK 526 COMPONENT TESTING ...

Page 531: ...Exploded view of the EGR system and related components for the 3 0L engine Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 527 ...

Page 532: ...a small vacuum signal however it should be less than 1 0 in Hg 3 4 kPa of vacuum Start the engine and allow it to run until normal operating temperature is reached With the engine running at idle detach the vacuum supply hose from the EGR valve and install a vacuum gauge to the hose The vacuum reading should be less than 1 0 in Hg 3 4 kPa of vacuum If the vacuum is greater than that specified the ...

Page 533: ...ass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak Do not allow the idle speed to exceed typical idle rpm Some EGR valves may be tested using a vacuum pump by watching for diaphragm movement Using a hand held vacuum pump slowly apply 5 10 in Hg 17 34 kPa of vacuum to the EGR valve nipple If the idle speed drops more than 100 rpm with the vacuum applied an...

Page 534: ...tery cable 1 Label and detach the wiring harness connector from the EVR solenoid 2 Detach the main emission vacuum control connector from the solenoid 3 Remove the retaining nuts then separate the solenoid from the mounting bracket 4 To install Position the solenoid on its mounting bracket and install the retaining nuts 5 Attach the main emission vacuum control connector and the wiring harness con...

Page 535: ...Cutaway view of a base entry type EGR valve Click to enlarge Cutaway view of a side entry type EGR valve Click to enlarge To install HOW TO USE THIS BOOK REMOVAL INSTALLATION 531 ...

Page 536: ... inch lbs 1 18 Nm on 5 0L engines 8 Connect the EGR valve to exhaust manifold tube to the valve then tighten the tube nut to 30 ft lbs 41 Nm 9 Connect all wiring or hoses to the EGR valve 10 Install the air inlet tube 11 Connect the negative battery cable 12 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 532 REMOVAL INSTALLATION ...

Page 537: ...IAT sensor a sensor in the area of the MAF sensor measures the temperature of the incoming air and transmits a corresponding electrical signal Another temperature sensor the ECT sensor inserted in the engine coolant tells if the engine is cold or warmed up The TP sensor a switch that senses throttle plate position produces electrical signals that tell the PCM when the throttle is closed or wide op...

Page 538: ... The module automatically senses and compensates for any changes in altitude when driving your vehicle REMOVAL INSTALLATION Typical PCM module 491 92 Models Disconnect the negative battery cable 1 Remove the inside lower cowl trim panel from the passenger s side of the vehicle to expose the PCM 2 Disengage the wiring harness connector from the PCM by loosening the connector retaining bolt then pul...

Page 539: ... the connector retaining bolt 6 Install the right cowl trim panel 7 Connect the negative battery cable 8 493 99 Models The module is mounted under the hood on the firewall On 493 94 models it is mounted low on the firewall near the left hand fender drivers side On 495 99 models it is mounted high on the firewall offset to the right hand side of center HOW TO USE THIS BOOK REMOVAL INSTALLATION 535 ...

Page 540: ...ing the connector retaining bolt then pulling the connector from the module 2 Remove the two nuts and the PCM cover 3 Remove the PCM from the bracket by pulling the unit outward 4 To install Install the PCM in the mounting bracket 5 Install the PCM cover and tighten the two nuts 6 Attach the wiring harness connector to the module then tighten the connector retaining bolt 7 Connect the negative bat...

Page 541: ... indicates too much oxygen in the exhaust lean condition and conversely a high voltage signal indicates too little oxygen in the exhaust rich condition Typical Heated Oxygen Sensor H2OS most vehicles are equipped with multiple sensors The oxygen sensors are threaded into the exhaust manifold and or exhaust pipes on all vehicles Heated oxygen sensors are used on all models to allow the engine to re...

Page 542: ...nnect the HO2S 1 Measure the resistance between PWR and GND terminals of the sensor If the reading is approximately 6 ohms at 68 F 1 C the sensor s heater element is in good condition 2 With the HO2S connected and engine running measure the voltage with a Digital Volt Ohmmeter DVOM between terminals HO2Sand SIG RTN GND of the oxygen sensor connector If the voltage readings are swinging rapidly bet...

Page 543: ...nifold and the other in the dual converter Y pipe 1991 95 2 3L engines use only one sensor Disconnect the negative battery cable 1 Raise and safely support the vehicle on jackstands 2 From underneath locate the oxygen sensor arrow which is screwed into an exhaust component Disconnect the HO2S from the engine control sensor wiring 3 If excessive force is needed to remove the sensors lubricate the s...

Page 544: ...mined by the Powertrain Control Module PCM and controlled by a duty cycle signal to bypass the throttle plate in order to maintain the proper idle speed Typical Idle Air Control IAC valve which is mounted to the throttle body cutaway view shows air bypass direction Click to enlarge TESTING Turn the ignition switch to the OFFposition 1 Disengage the wiring harness connector from the IAC valve 2 Usi...

Page 545: ... enlarge REMOVAL INSTALLATION Disconnect the negative battery cable 1 To remove the IAC valve first disconnect the negative battery cable then the IAC wire harness plug Next remove the two IAC valve attaching bolts HOW TO USE THIS BOOK TESTING 541 ...

Page 546: ...sing a new gasket position the IAC valve on the throttle body Install and tighten the retaining screws to 71 106 inch lbs 8 12 Nm 5 Attach the wiring harness connector to the IAC valve 6 Connect the negative battery cable 7 Engine Coolant Temperature ECT Sensor OPERATION The engine coolant temperature sensor resistance changes in response to engine coolant temperature The sensor resistance decreas...

Page 547: ...ach the engine wiring harness connector to the sensor 3 Start the engine and allow the engine to warm up to normal operating temperature 4 Once the engine has reached normal operating temperature turn the engine OFF 5 Once again detach the engine wiring harness connector from the ECT sensor 6 Measure and note the ECT sensor resistance then compare the cold and hot ECT sensor resistance measurement...

Page 548: ...le 2 Most ECT sensors arrow can be found on the intake manifold near the water outlet housing Detach the wiring harness connector from the ECT sensor 3 Using an open end wrench remove the coolant temperature sensor from the intake manifold 4 To install Thread the sensor into the intake manifold by hand then tighten it securely 5 Connect the negative battery cable 6 HOW TO USE THIS BOOK 544 TESTING...

Page 549: ... cleaner to throttle body supply tube However some earlier engines have it mounted to the upper intake manifold TESTING Turn the ignition switch OFF Disengage the wiring harness connector from the IAT sensor 1 Using a Digital Volt Ohmmeter DVOM measure the resistance between the two sensor terminals 2 Compare the resistance reading with the accompanying chart If the reading for a given temperature...

Page 550: ... sensor mounting boss to clean the sensor area of all dirt and grime 4 Install the sensor into the air cleaner outlet tube securely 5 Attach the wiring harness connector to the IAT sensor 6 Connect the negative battery cable 7 Mass Air Flow MAF Sensor OPERATION The Mass Air Flow MAF sensor directly measures the amount of the air flowing into the engine The sensor is mounted between the air cleaner...

Page 551: ...F sensor is mounted to the air cleaner housing The sensing element hot wire is a1 thin platinum wire wound on a ceramic bobbin and coated with glass This hot wire is maintained at 392 F 200 C above the ambient temperature as measured by a constant cold wire TESTING With the engine running at idle use a DVOM to verify there is at least 10 5 volts between terminals Aand Bof the MAF sensor connector ...

Page 552: ... The mass air flow sensor hot wire sensing element and housing are calibrated as a unit and must be serviced as a complete assembly Do not damage the sensing element or possible failure of the sensor may occur Disconnect the negative battery cable 1 HOW TO USE THIS BOOK 548 TESTING ...

Page 553: ... harness connector from the MAF sensor and if necessary the IAT sensor 2 Loosen the engine air cleaner outlet tube clamps then remove the tube from the engine 3 Remove the MAF sensor from the air cleaner assembly by disengaging the retaining clips 4 Remove the four MAF sensor attaching screws HOW TO USE THIS BOOK REMOVAL INSTALLATION 549 ...

Page 554: ...The Throttle Position TP sensor is a potentiometer that provides a signal to the PCM that is directly proportional to the throttle plate position The TP sensor is mounted on the side of the throttle body and is connected to the throttle plate shaft The TP sensor monitors throttle plate movement and position and transmits an appropriate electrical signal to the PCM These signals are used by the PCM...

Page 555: ...ning sensor 4 Reconnect the negative battery cable 5 Turn the DVOM to the voltmeter setting 6 WARNING Ensuring the DVOM is on the voltmeter function is vitally important because if you measure circuit resistance ohmmeter function with the battery cable connected your DVOM will be destroyed Detach the wiring harness connector from the PCM located behind the lower right hand kick panel in the passen...

Page 556: ...ct the wire harness plug from the sensor If the mounting holes of the sensor are slotted mark its position Note factory sensors are not slotted Disengage the wiring harness connector from the TP sensor 2 Remove the two TP sensor mounting screws then pull the TP sensor out of the throttle body housing 3 HOW TO USE THIS BOOK 552 TESTING ...

Page 557: ...ainst the throttle body slide the sensor straight onto the housing 4 Install and tighten the sensor mounting screws until snug 5 Attach the wiring harness connector to the sensor then connect the negative battery cable 6 The TP sensor is not adjustable Camshaft Position CMP Sensor OPERATION The CMP sensor provides the camshaft position information called the CMP signal which is used by the Powertr...

Page 558: ...haft drive sprocket On the 1991 94 2 9L and 3 0L engine the distributor stator is the Camshaft Position CMP sensor and it is a Hall effect magnetic switch On the 1995 99 3 0L engine the CMP is mounted on the oil pump drive assembly located towards the rear of the block it is also a single hall effect magnetic switch and it is activated by a single vane and is driven by the camshaft Camshaft Positi...

Page 559: ... TESTING Three Wire Sensors With the ignition OFF disconnect the CMP sensor With the ignition ONand the engine OFF measure the voltage between sensor harness connector VPWRand PWR GNDterminals refer to the accompanying illustration If the reading is greater than 10 5 volts the power circuit to the sensor is okay 1 With the ignition OFF install break out box between the CMP sensor and the PCM Using...

Page 560: ...ocedure Have your A C system refrigerant reclaimed by an MVAC certified repair shop However there may be enough flex or slack in the A C lines to allow you to support the compressor off to the side without disconnecting the lines Disconnect the negative battery cable 1 Remove the accessory drive belt 2 Remove the four bolts securing the A C compressor to the mounting bracket and set aside 3 Remove...

Page 561: ... procedure may result in improper stator alignment This will result in the fuel system being out of time with the engine possibly causing engine damage Disconnect the negative battery cable 1 Remove the ignition coil radio capacitor and ignition coil bracket 2 Disengage the wiring harness connector from the CMP sensor 3 Prior to removing the camshaft position sensor set the No 1 cylinder to 10 Aft...

Page 562: ... synchro positioning tool such as Ford Tool T89P 12200 A or equivalent To do so perform the following Engage the sensor housing vane into the radial slot of the tool 1 Rotate the tool on the camshaft sensor housing until the tool boss engages the notch in the sensor housing The cover tool should be square and in contact with the entire top surface of the camshaft position sensor housing 2 8 HOW TO...

Page 563: ...Attach the CMP synchro positioning tool to the housing CMP sensor positioning for the 3 0L 75 and 4 0L 60 engines Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 559 ...

Page 564: ...UTION If the sensor connector is positioned correctly DO NOT reposition the connector by rotating the sensor housing This will result in the fuel system being out of time with the engine This could possibly cause engine damage Remove the sensor housing and repeat the installation procedure beginning with step one Install the sensor and retaining screws tighten the screws to 22 8 inch lbs 2 4 Nm 13...

Page 565: ...t pulley is used to determine crankshaft position and crankshaft rpm The CKP sensor is a reluctance sensor which senses the passing of teeth on a sensor ring because the teeth disrupt the magnetic field of the sensor This disruption creates a voltage fluctuation which is monitored by the PCM The CKP sensor A is triggered by the teeth which are machined into the crankshaft damper B TESTING Using a ...

Page 566: ...L VIN X and E engines Click to enlarge REMOVAL INSTALLATION Disconnect the negative battery cable 1 To remove the CKP sensor first disconnect the wire harness plug Disengage the wiring harness connector from the CKP sensor 2 Loosen the CKP sensor mounting stud bolts then separate the sensor form the engine front cover 3 HOW TO USE THIS BOOK 562 TESTING ...

Page 567: ...mall rub tabs which wear off and allow the sensor to be perfectly spaced from the damper Position the sensor against the engine front cover then install the mounting stud bolts Tighten them until snug 4 Install the CKP sensor cover and retaining nuts tighten the nuts until snug 5 Reattach the wiring harness connector to the CKP sensor 6 Connect the negative battery cable 7 HOW TO USE THIS BOOK REM...

Page 568: ...Exploded view of the 2 3L and 2 5L Crankshaft Position CKP sensor Click to enlarge HOW TO USE THIS BOOK 564 REMOVAL INSTALLATION ...

Page 569: ...aft Position CKP sensor 5 0L engine is similar Click to enlarge Exploded view of the 4 0L VIN X Crankshaft Position CKP sensor 4 0L SOHC VIN E engine is similar Vehicle Speed Sensor VSS HOW TO USE THIS BOOK Vehicle Speed Sensor VSS 565 ...

Page 570: ...e of the transmission assembly Apply parking brake block the rear wheels then raise and safely support the front of the vehicle on jackstands 1 From under the right hand side of the vehicle disengage the wiring harness connector from the VSS 2 Loosen the VSS hold down bolt then pull the VSS out of the transmission housing 3 To install If a new sensor is being installed transfer the driven gear ret...

Page 571: ...COMPONENT LOCATIONS 2 3L ENGINE 1 OF 3 Click to enlarge COMPONENT LOCATIONS 567 ...

Page 572: ...2 3 ENGINE 1 OF 3 Click to enlarge HOW TO USE THIS BOOK 568 COMPONENT LOCATIONS ...

Page 573: ...2 3 ENGINE 2 OF 3 Click to enlarge HOW TO USE THIS BOOK COMPONENT LOCATIONS 569 ...

Page 574: ...2 3 ENGINE 3 OF 3 Click to enlarge HOW TO USE THIS BOOK 570 COMPONENT LOCATIONS ...

Page 575: ...3 0L ENGINE 1 OF 2 Click to enlarge HOW TO USE THIS BOOK COMPONENT LOCATIONS 571 ...

Page 576: ...3 0L ENGINE 2 OF 2 Click to enlarge HOW TO USE THIS BOOK 572 COMPONENT LOCATIONS ...

Page 577: ...4 0L ENGINE 2 OF 2 Click to enlarge HOW TO USE THIS BOOK COMPONENT LOCATIONS 573 ...

Page 578: ...4 0L SOHC ENGINE 1 OF 3 Click to enlarge HOW TO USE THIS BOOK 574 COMPONENT LOCATIONS ...

Page 579: ...4 0L SOHC ENGINE 2 OF 3 Click to enlarge HOW TO USE THIS BOOK COMPONENT LOCATIONS 575 ...

Page 580: ...4 0L SOHC ENGINE 3 OF 3 Click to enlarge HOW TO USE THIS BOOK 576 COMPONENT LOCATIONS ...

Page 581: ...5 0L ENGINE 1 OF 3 Click to enlarge HOW TO USE THIS BOOK COMPONENT LOCATIONS 577 ...

Page 582: ...5 0L ENGINE 2 OF 3 Click to enlarge HOW TO USE THIS BOOK 578 COMPONENT LOCATIONS ...

Page 583: ...5 0L ENGINE 3 OF 3 Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK COMPONENT LOCATIONS 579 ...

Page 584: ... of recognizing many internal faults certain faults will not be recognized Because the computer system sees only electrical signals it cannot sense or react to mechanical or vacuum faults affecting engine operation Some of these faults may affect another component which will set a code For example the PCM monitors the output signal to the fuel injectors but cannot detect a partially clogged inject...

Page 585: ...VICE ENGINE SOON dashboard warning lamp is referred to as the Malfunction Indicator Lamp MIL The lamp is connected to the engine control assembly and will alert the driver to certain malfunctions within the EEC system When the lamp is lit the PCM has detected a fault and stored an identity code in memory The engine control system will usually enter either FMEM or HLOS mode and driveability will be...

Page 586: ...onnector unfasten it from its protective cover which is labeled EEC TEST Reading Codes Inexpensive scan tools such as this Auto Xray are available to interface with your Ford vehicle HOW TO USE THIS BOOK Diagnostic Connector 583 ...

Page 587: ... 5 Connect the scan tool to the Data Link Connector DLC 3 8L and 4 6L engines or the Assembly Line Diagnostic Link ALDL 5 0L engine Make certain the test button on the scan tool is unlatched or up 6 Turn the ignition switch to the ONposition without starting the engine KOEO 7 Using the scan tool retrieve and record any continuous memory DTC s 8 Turn the ignition switch to the OFFposition 9 Start t...

Page 588: ...cedure use a jumper wire to connect the signal return pin on the diagnostic connector to the self test input connector The self test input line is the separate wire and connector with or near the diagnostic connector The codes will be transmitted as groups of needle sweeps This method may be used to read either 2 or 3 digit codes The Continuous Memory codes are separated from the other codes by 6 ...

Page 589: ...ocessor to compensate for component tolerances and wear It should not be routinely cleared during diagnosis If an emissions related part is replaced during repair the KAM must be cleared Failure to clear the KAM may cause severe driveability problems since the correction factor for the old component will be applied to the new component To clear the Keep Alive Memory disconnect the negative battery...

Page 590: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK Diagnostic Trouble Code Charts 587 ...

Page 591: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK 588 Diagnostic Trouble Code Charts ...

Page 592: ...Click to enlarge HOW TO USE THIS BOOK Diagnostic Trouble Code Charts 589 ...

Page 593: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK 590 Diagnostic Trouble Code Charts ...

Page 594: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK Diagnostic Trouble Code Charts 591 ...

Page 595: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK 592 Diagnostic Trouble Code Charts ...

Page 596: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK Diagnostic Trouble Code Charts 593 ...

Page 597: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK 594 Diagnostic Trouble Code Charts ...

Page 598: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge HOW TO USE THIS BOOK Diagnostic Trouble Code Charts 595 ...

Page 599: ...OBD II DIAGNOSTIC TROUBLE CODE DTC APPLICATIONS Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 596 Diagnostic Trouble Code Charts ...

Page 600: ...ment emissions label most manufacturers make the labels available for purchase The labels can usually be ordered from a local dealer Vacuum hose routing for all 1991 93 models and 1994 Ranger models Vacuum hose routing for 1994 Explorer models Vacuum hose routing for 1995 99 Ranger models with the 2 3L and 2 5L engine Vacuum hose routing for 1995 99 Ranger models with the 3 0L engine Vacuum hose r...

Page 601: ...SPECIFICATION CHARTS IAT and ECT sensor specifications chart Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning SPECIFICATION CHARTS 599 ...

Page 602: ...e fuel will often lead to solving most basic problems For ignition system diagnosis and testing please refer to the information on engine electrical components and ignition systems found earlier in this manual If the ignition system checks out there is spark then you must determine if the fuel system is operating properly is there fuel Chilton Automotive Information Systems 2004 Thomson Delmar Lea...

Page 603: ...t and grease from the fitting Spread the two clip legs about 1 8 in 3mm each to disengage from the fitting and pull the clip outward from the fitting Use finger pressure only do not use any tools 1 Grasp the fitting and hose assembly and pull away from the steel line Twist the fitting and hose assembly slightly while pulling if the assembly sticks 2 Inspect the hairpin clip for damage replacing th...

Page 604: ...Hairpin clip fuel fitting installation Click to enlarge HOW TO USE THIS BOOK 604 REMOVAL INSTALLATION ...

Page 605: ...lable use a pair of narrow 6 inch slip jaw pliers with a jaw width of 0 2 in 3mm or less Align the jaws of the pliers with the openings of the fitting case and compress the part of the retaining clip that engages the case Compressing the retaining clip will release the fitting which may be pulled from the connector Both sides of the clip must be compressed at the same time to disengage 2 Inspect t...

Page 606: ...Duckbill clip fuel fitting installation Click to enlarge Spring Lock Coupling HOW TO USE THIS BOOK 606 REMOVAL INSTALLATION ...

Page 607: ...inside the cage of the male fitting The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage As an additional locking feature most vehicles have a horseshoe shaped retaining clip that improves the retaining reliability of the spring lock coupling Spring lock fitting removal and installation procedures Click to enlarge HOW TO USE THIS BOOK REMOVAL IN...

Page 608: ...Spring lock horseshoe shaped retaining clip installation Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 608 REMOVAL INSTALLATION ...

Page 609: ...nk mounted pumps can be either high or low pressure depending on the model The inertia switch opens the power circuit to the fuel pump in the event of a collision Once tripped the switch must be reset manually by pushing the reset button on the assembly Check that the inertia switch is reset before diagnosing power supply problems to the fuel pump The fuel injectors used with SFI system are electr...

Page 610: ...dry chemical Class B fire extinguisher near the work area Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame Always use a second wrench when loosening or tightening fuel line connections fittings This will prevent unnecessary stress and torsion to fuel piping Always follow the proper torque specifications Always replace worn fuel fitting O rings with new ones Do...

Page 611: ... of the transmission hump in the passenger side footwell RESETTING THE SWITCH Turn the ignition switch OFF 1 Ensure that there is no fuel leaking in the engine compartment along any of the lines or at the tank There should be no odor of fuel as well 2 If no leakage and or odor is apparent reset the switch by pushing the reset button on the top of the switch 3 You may need to pull the carpet down a...

Page 612: ...ation Click to enlarge The Inertia Fuel Shutoff IFS switch when an impact occurs the ball breaks loose from the magnet and strikes the target plate which opens the electrical contacts Click to enlarge HOW TO USE THIS BOOK 612 RESETTING THE SWITCH ...

Page 613: ...uel Pump REMOVAL INSTALLATION To gain access to the fuel pump it is necessary to remove the fuel tank Depressurize the fuel system and remove the fuel tank from the vehicle 1 Remove any dirt that has accumulated around the fuel pump attaching flange to prevent it from entering the tank during service 2 Turn the fuel pump locking ring counterclockwise using a locking ring removal tool and remove th...

Page 614: ...Fuel pump and sending unit used on the Regular Cab Ranger pick up Click to enlarge HOW TO USE THIS BOOK 614 REMOVAL INSTALLATION ...

Page 615: ...Fuel pump and sending unit used on the Super Cab Ranger pick up Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 615 ...

Page 616: ... the vehicle 2 Install a minimum of 10 gallons of fuel and check for leaks 3 Install a pressure gauge on the throttle body valve and turn the ignition ONfor 3 seconds Turn the key OFF then repeat the key cycle five to ten times until the pressure gauge shows at least 30 psi Reinspect for leaks at the fittings 4 Remove the pressure gauge Start the engine and check for fuel leaks 5 HOW TO USE THIS B...

Page 617: ...an be checked using an inexpensive pressure vacuum gauge If the pressure tap is not installed or an adapter is not available use a T fitting to install the pressure gauge between the fuel filter line and the throttle body fuel inlet or fuel rail To test the fuel pump follow the accompanying diagnostic charts Testing fuel pressure requires the use of a special pressure gauge Ford Tool T20L 3314 B R...

Page 618: ...Fuel pressure test chart part 1 Click to enlarge HOW TO USE THIS BOOK 618 TESTING ...

Page 619: ...Fuel pressure test chart part 2 Click to enlarge Fuel pressure test chart part 3 Click to enlarge HOW TO USE THIS BOOK TESTING 619 ...

Page 620: ...TALLATION Exploded view of the 2 3L and 2 5L engine throttle body assembly Click to enlarge Exploded view of the 2 9L engine throttle body assembly and related components Click to enlarge HOW TO USE THIS BOOK 620 Throttle Body Assembly ...

Page 621: ...Exploded view of the 3 0L engine throttle body upper intake manifold assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 621 ...

Page 622: ...s a 1 piece casting which includes the upper intake manifold In order to remove the throttle body the entire upper manifold must be removed Refer to Section 3 for the proper procedures Loosen the air inlet tube clamps then separate the tube from the throttle body and air cleaner housing Remove the tube from the vehicle 1 If equipped remove the throttle linkage shield 2 HOW TO USE THIS BOOK 622 REM...

Page 623: ...ottle body first remove the air intake hose then the linkage shield Next disconnect the throttle control cable s from the throttle body as well as any electrical connections HOW TO USE THIS BOOK REMOVAL INSTALLATION 623 ...

Page 624: ...l and disengage the engine wiring harness connectors from the Throttle Position TP sensor and the Idle Air Control IAC valve both are mounted on the throttle body 4 Remove the throttle body to upper intake attaching bolts Remove the four mounting nuts then carefully separate the throttle body from the upper intake manifold 5 HOW TO USE THIS BOOK 624 REMOVAL INSTALLATION ...

Page 625: ...al 7 Install the throttle body along with a new gasket onto the upper intake manifold Install and tighten the mounting nuts in a crisscross pattern to specifications 8 Engage the TP sensor and IAC valve wiring connectors and remove the temporary labels 9 Reattach the accelerator and speed control cables if applicable to the throttle body lever 10 If removed install the throttle linkage shield 11 I...

Page 626: ...onnect the fuel supply and return line retaining clips 2 Detach the vacuum line from the fuel pressure regulator 3 Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold 4 Exploded view of the 2 3L and 2 5L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK 626 REMOVAL INSTALLATION ...

Page 627: ...Exploded view of the 2 9L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 627 ...

Page 628: ...loded view of the 3 0L engine fuel supply rail and injectors Click to enlarge Exploded view of the 4 0L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK 628 REMOVAL INSTALLATION ...

Page 629: ...n disconnect the injector wire harness plugs Label and disconnect the fuel injector wire harness plugs 5 On the 2 3L and 2 5L engine remove the two fuel supply manifold retaining bolts 6 On the 4 0L VIN X engine remove the six upper intake manifold attaching studs 7 HOW TO USE THIS BOOK REMOVAL INSTALLATION 629 ...

Page 630: ...ing bolts 8 Carefully disengage the fuel rail assembly from the fuel injectors by lifting and gently rocking the rail 9 Some models use small retaining clips to secure the injectors in the supply manifold Click to enlarge Lift upwards with a rocking motion to disengage the injectors then remove the supply manifold HOW TO USE THIS BOOK 630 REMOVAL INSTALLATION ...

Page 631: ...ove the injectors from the engine by gently rocking it while pulling upwards Place all removed components on a clean surface to prevent contamination by dirt or grease 11 Never use silicone grease it will clog the injector All injectors and the fuel rail must be handled with extreme care to prevent damage to sealing areas and sensitive fuel metering orifices HOW TO USE THIS BOOK REMOVAL INSTALLATI...

Page 632: ...Carefully install the fuel rail assembly and injectors into the lower intake manifold Make certain to correctly position the insulators Push down on the fuel rail to make sure the O rings are seated 16 Hold the fuel rail assembly in place and install the retaining bolts finger tight Then tighten the bolts to specifications 17 Connect the fuel supply and return lines 18 Attach the vacuum hose to th...

Page 633: ... other engine components Once access to the injector is gained and the wiring is disconnected from it set the DVOM to measure resistance ohms Measure the resistance of the injector by probing one terminal with the positive DVOM lead and the other injector terminal with the negative lead The resistance measured should be between 11 4 ohms If the resistance is not within this range the fuel injector...

Page 634: ...N E Engine Depressurize the fuel system remove shielding as needed 1 Remove the vacuum line at the pressure regulator 2 Fuel pressure regulator on the 2 3L and 2 5L engine 3 0L and 5 0L engines are similar Click to enlarge HOW TO USE THIS BOOK 634 REMOVAL INSTALLATION ...

Page 635: ...Fuel pressure regulator on the 2 9L engine Click to enlarge Fuel pressure regulator on the 4 0L engine HOW TO USE THIS BOOK REMOVAL INSTALLATION 635 ...

Page 636: ...en loosen the fuel return line fitting and disconnect it from the regulator If necessary disconnect the fuel return line from the regulator 3 Some engines use two standard hex head bolts to retain the regulator instead of the Allen head screws HOW TO USE THIS BOOK 636 REMOVAL INSTALLATION ...

Page 637: ...ht rocking motion to unseat the O ring seal Remove the three Allen head retaining screws from the regulator housing 4 Remove the pressure regulator assembly gasket and O ring Discard the gasket and check the O ring for signs of cracks or deterioration 5 HOW TO USE THIS BOOK REMOVAL INSTALLATION 637 ...

Page 638: ...tened to 70 97 inch lbs 8 11 Nm 9 On the 2 3L and 2 5L engine install the fuel manifold shield and tighten the bolts to 15 3 ft lbs 1 30 Nm Install the vacuum line at the pressure regulator 10 If removed connect the fuel return line 11 Build fuel pressure in the system by turning the ignition ONand OFF without starting the engine at least five times Leave the ignition ONat least 5 seconds each tim...

Page 639: ...er 6 Remove the fuel supply and return line assembly from the vehicle with the regulator assembly attached 7 To install Clean the gasket mating surfaces If scraping is necessary be careful not to damage the fuel pressure regulator or supply line gasket mating surfaces 8 Lubricate the pressure regulator O ring with light engine oil Do not use silicone grease it will clog the injectors 9 HOW TO USE ...

Page 640: ...t least 5 seconds each time Check for fuel leaks 17 Pressure Relief Valve REMOVAL INSTALLATION The fuel pressure relief valve cap on the valve must be removed If the fuel supply manifold is installed on the engine remove the fuel tank filler cap and relieve fuel system pressure 1 Using a deep socket or an open end wrench remove the valve from the fuel supply manifold 2 To install Install and tight...

Page 641: ...plate is removed Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank 5 On vehicles equipped with a metal retainer fastening the filler pipe to the fuel tank remove the screw holding the retainer to the fuel tank flange 6 Disengage the fuel lines and the electrical connections to the fuel tank sending unit fuel pump assembly On some vehicles these are inaccessible on top ...

Page 642: ...Exploded view of the Explorer Mountaineer fuel filler assembly Click to enlarge HOW TO USE THIS BOOK 642 REMOVAL INSTALLATION ...

Page 643: ...Exploded view of the Explorer Mountaineer fuel tank assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 643 ...

Page 644: ...Exploded view of the Ranger fuel filler assembly and pump mounting Click to enlarge HOW TO USE THIS BOOK 644 REMOVAL INSTALLATION ...

Page 645: ...Exploded view of the Ranger Super Cab fuel tank assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 645 ...

Page 646: ... installed 4 11 Raise the fuel tank into position in the vehicle If necessary attach the fuel lines and sending unit electrical connector before the tank is in its final position 12 Lubricate the fuel filler pipe with a water based lubricant Install the tank onto the filler pipe then bring the tank into final position Be careful not to deform the tank 13 Position the tank straps around the tank an...

Page 647: ... already attached connect the sending unit 17 If removed install the fuel tank skid plate 18 Lower the vehicle 19 Fill the tank with fuel and check all connections for leaks 20 Sending Unit REMOVAL INSTALLATION Please refer to Fuel Pump Removal Installation Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK Sending Unit 647 ...

Page 648: ...from the positive battery terminal flows through the fuse and the switch and then to the light bulb The light illuminates and the circuit is completed through the ground wire back to the negative battery terminal In reality the two ground points shown in the illustration are attached to the metal frame of the vehicle which completes the circuit back to the battery The normal automotive circuit dif...

Page 649: ... electricity Very low resistance materials are said to be conductors Copper wire is among the best conductors Silver is actually a superior conductor to copper and is used in some relay contacts but its high cost prohibits its use as common wiring Most automotive wiring is made of copper Size the larger the wire size being used the less resistance the wire will have This is why components which us...

Page 650: ...ctrical load The power removed from the battery is replaced by the alternator restoring the battery to its original chemical state The Alternator On some vehicles there isn t an alternator but a generator The difference is that an alternator supplies alternating current which is then changed to direct current for use on the vehicle while a generator produces direct current Alternators tend to be m...

Page 651: ...Most vehicles use one or more fuse panels This one is located on the driver s side kick panel Circuit Breaker a circuit breaker is basically a self repairing fuse It will open the circuit in the same fashion as a fuse but when the surge subsides the circuit breaker can be reset and does not need replacement Fusible Link a fusible link fuse link or main link is a short length of special high temper...

Page 652: ...itch called a relay Since these circuits carry a large amount of current the thickness of the wire in the circuit is also greater If this large wire were connected from the load to the control switch the switch would have to carry the high amperage load and the fairing or dash would be twice as large to accommodate the increased size of the wiring harness To prevent these problems a relay is used ...

Page 653: ...RING HARNESSES The average vehicle contains meters and meters of wiring with hundreds of individual connections To protect the many wires from damage and to keep them from becoming a confusing tangle they are organized into bundles enclosed in plastic or taped together and called wiring harnesses Different harnesses serve different parts of the vehicle Individual wires are color coded to help trac...

Page 654: ...ber Gauge wire size refers to the size of the strands of the conductor not the size of the complete wire with insulator It is possible therefore to have two wires of the same gauge with different diameters because one may have thicker insulation than the other It is essential to understand how a circuit works before trying to figure out why it doesn t An electrical schematic shows the electrical c...

Page 655: ...erproof connectors are most commonly used in the engine compartment or where the connector is exposed to the elements Test Equipment Pinpointing the exact cause of trouble in an electrical circuit is most times accomplished by the use of special test equipment The following describes different types of commonly used test equipment and briefly explains how to use them in diagnosis In addition to th...

Page 656: ...e hot terminal of the component but first make sure the component uses 12 volts in operation Some electrical components such as fuel injectors or sensors are designed to operate on about 4 to 5 volts and running 12 volts directly to these components will cause damage TEST LIGHTS A 12 volt test light is used to detect the presence of voltage in a circuit The test light is used to check circuits and...

Page 657: ...llow the reading of different voltage ranges The voltmeter has a positive and a negative lead To avoid damage to the meter always connect the negative lead to the negative side of the circuit to ground or nearest the ground side of the circuit and connect the positive lead to the positive side of the circuit to the power source or the nearest power source Note that the negative voltmeter lead will...

Page 658: ...ting techniques however which are standard Establish when the problem occurs Does the problem appear only under certain conditions Were there any noises odors or other unusual symptoms Isolate the problem area To do this make some simple tests and observations then eliminate the systems that are working properly Check for obvious problems such as broken wires and loose or dirty connections Always ...

Page 659: ... ohmmeter ground clip to a good ground and probe any easy to reach point in the circuit 2 If the light comes on or there is continuity there is a short somewhere in the circuit 3 To isolate the short probe a test point at either end of the isolated circuit the light should be on or the meter should indicate continuity 4 Leave the test light probe engaged and sequentially open connectors or switche...

Page 660: ... under load is critical especially if there is more than one load in the circuit since all voltage drops are cumulative Set the voltmeter selector switch to the 20 volt position 1 Connect the multimeter negative lead to a good ground 2 Operate the circuit and check the voltage prior to the first component load 3 There should be little or no voltage drop in the circuit prior to the first component ...

Page 661: ...g the resistance of a coolant temperature sensor with an ohmmeter Reading is 1 04 kilohms Spark plug wires can be checked for excessive resistance using an ohmmeter WARNING HOW TO USE THIS BOOK 662 RESISTANCE ...

Page 662: ...isreading the ohmmeter test value 4 Wire and Connector Repair Almost anyone can replace damaged wires as long as the proper tools and parts are available Wire and terminals are available to fit almost any need Even the specialized weatherproof molded and hard shell connectors are now available from aftermarket suppliers Be sure the ends of all the wires are fitted with the proper terminal hardware...

Page 663: ...tself to the body of a vehicle just like a spark plug jumping the gap and of course damaging some components such as the alternator diodes When the battery cable s are reconnected negative cable last be sure to check that your lights windshield wipers and other electrically operated safety components are all working correctly If your vehicle contains an Electronically Tuned Radio ETR don t forget ...

Page 664: ...sors quickly inflate the two air bags to reduce injury by cushioning the driver and front passenger from striking the dashboard windshield steering wheel and any other hard surfaces The air bag inflates so quickly in a fraction of a second that in most cases it is fully inflated before you actually start to move during an automotive collision Since the SRS is a complicated and essentially importan...

Page 665: ...g sensors inspected by a qualified automotive technician to ensure that they were not damaged If at any time the air bag light indicates that the computer has noted a problem have your vehicle s SRS serviced immediately by a qualified automotive technician A faulty SRS can cause severe physical injury or death DISARMING THE SYSTEM Disconnect the negative battery cable from the battery 1 Disconnect...

Page 666: ...ew of the blower motor mounting Click to enlarge Exploded view of the blower motor and wheel fan assembly Click to enlarge Without Air Conditioning Disconnect the negative battery cable 1 Remove the air cleaner or air inlet duct as necessary 2 HEATING AND AIR CONDITIONING 669 ...

Page 667: ...rical wire harness plug then remove the blower motor cooling tube from the motor Disconnect the wire harness connector from the blower motor by pushing down on the connector tabs and pulling the connector off of the motor 4 Disconnect the blower motor cooling tube at the blower motor 5 HOW TO USE THIS BOOK 670 REMOVAL INSTALLATION ...

Page 668: ...hoses with the 1 screws 13 If removed install the speed control module and the washer fluid reservoir 14 Install the air cleaner or air inlet duct as necessary 15 Connect the negative battery cable and check the system for proper operation 16 With Air Conditioning Disconnect the negative battery cable 1 In the engine compartment disconnect the wire harness from the motor by pushing down on the tab...

Page 669: ...r or air inlet duct as necessary 14 Connect the negative battery cable and check the blower motor in all speeds for proper operation 15 Blower Motor Resistor REMOVAL INSTALLATION Disconnect the negative battery cable 1 Disconnect the wire connector from the resistor assembly 2 Remove the 2 screws attaching the resistor assembly to the blower or evaporator case and remove the resistor 3 Installatio...

Page 670: ...TION When draining the coolant keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years old HOW TO USE THIS BOOK...

Page 671: ...s from the heater core tubes and plug hoses 2 In the passenger compartment remove the four screws attaching the heater core access cover to the plenum assembly and remove the access cover 3 then in the passenger compartment remove the under dash cover retaining screws HOW TO USE THIS BOOK 674 REMOVAL INSTALLATION ...

Page 672: ...in your way Remove the heater core access panel attaching screws then remove the cover by pulling downward and straight back to disengage the drain tube arrow Pull the heater core rearward and down removing it from the plenum assembly 4 HOW TO USE THIS BOOK REMOVAL INSTALLATION 675 ...

Page 673: ...gine compartment Do not over tighten hose clamps 3 Check the coolant level and add coolant as required Connect the negative battery cable 4 Start the engine and check the system for coolant leaks 5 1991 99 Models Exploded view of the blower motor housing and the heater air plenum assemblies Click to enlarge Disconnect the negative battery cable Allow the engine to cool down Drain the cooling syste...

Page 674: ...ssenger compartment remove the instrument panel Refer to Section 10 6 Pull the heater air plenum rearward from the firewall and remove it from the vehicle 7 Remove the heater core from the heater air plenum 8 Inspect all air seals on the components and firewall and replace any that are damaged 9 To install Install the heater core into the air plenum chamber 10 Position the heater air plenum agains...

Page 675: ...Example of the control head and the air flow paths in the plenum assembly with A C Click to enlarge REMOVAL INSTALLATION HOW TO USE THIS BOOK 678 REMOVAL INSTALLATION ...

Page 676: ...Exploded view of a cable equipped control head Click to enlarge Front and rear view of a cableless control head Disconnect the negative battery cable 1 HOW TO USE THIS BOOK REMOVAL INSTALLATION 679 ...

Page 677: ...ol cables through the control assembly opening in the instrument panel for a distance of approximately 2 in 203mm 1 Hold the control assembly up to the instrument panel with its face directed toward the floor of the vehicle This will locate the face of the control in a position that is 30 degrees out of its installed position 2 Carefully bend and attach the function cable that has a white color co...

Page 678: ...partment opening remove the cable jacket from the metal attaching clip on the top of the plenum by depressing the clip tab and pulling the cable out of the clip 2 The adjustable end should remain attached to the door cams To adjust the temperature control cable set the temperature lever at COOL and hold With the cable end attached to the temperature door cam push gently on the cable jacket to seat...

Page 679: ...air plenum Click to enlarge Control cable routing diagram Click to enlarge Temperature and Function Cables Disconnect the negative battery cable 1 Remove the control assembly from the instrument panel 2 HOW TO USE THIS BOOK 682 REMOVAL INSTALLATION ...

Page 680: ...he control end of the cable through the instrument panel until the ends stick out of the control opening It is not necessary to insert the cable into any routing devices previously used The routing aids are only necessary when the entire instrument panel is removed and reinstalled 11 Attach the function and temperature cables to the control Install the control assembly in the instrument panel 12 A...

Page 681: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 684 REMOVAL INSTALLATION ...

Page 682: ...plifier regulates the throttle actuator to keep the requested speed When the brake pedal is depressed an electrical signal from the stoplamp switch returns the system to stand by mode The vacuum dump valve also mechanically releases the vacuum in the throttle actuator thus releasing the throttle independently of the amplifier control This feature is used as a safety backup Vacuum controlled cruise...

Page 683: ...requested speed When the brake pedal is depressed an electrical signal from the stoplamp and deactivator switches return the system to stand by mode This system operates independently of engine vacuum therefore no vacuum lines are required Electronic cruise control system components 2 3L Ranger shown others similar Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learnin...

Page 684: ...emoval tool Click to enlarge Exploded view of the radio mounting and wire connections Note the rear support and the bracket that it attaches to Click to enlarge Disconnect the negative battery cable 1 On 1991 92 models remove the finish panel from around the radio assembly 2 ENTERTAINMENT SYSTEMS 687 ...

Page 685: ...25 4mm to release the retainer clips then pull straight out to remove Insert the radio removal tool T87P 19061 A or equivalent into the radio face 3 Press in 1 inch 25 4mm to release the retaining clips then using the tool as handles pull the radio out of the instrument panel 4 HOW TO USE THIS BOOK 688 REMOVAL INSTALLATION ...

Page 686: ...de the radio into the instrument panel Ensure that the rear mounting bracket is engaged on the mounting track in the panel 6 If removed install the finish panel 7 Connect the battery cable 8 Check the operation of the radio 9 Speakers REMOVAL INSTALLATION WARNING Never operate the radio with one of the speakers disconnected Damage to the radio can occur HOW TO USE THIS BOOK Speakers 689 ...

Page 687: ...ng screws Pull out gently on the speaker and disconnect the wire harness plug from it Body Mounted Rear Speakers On Ranger models remove the four speaker grille attaching screws and remove the grille 1 On Explorer Mountaineer models gently pry the speaker grille from the trim panel 2 On SuperCab models Remove the four speaker mounting screws 3 Pull the speaker out from the trim panel and disconnec...

Page 688: ...To remove a body mounted speaker first remove the grille attaching screws then pull the grille from the trim panel Remove the four speaker mounting screws HOW TO USE THIS BOOK REMOVAL INSTALLATION 691 ...

Page 689: ... then pull the speaker out and disconnect the wire harness plug from the back Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 692 REMOVAL INSTALLATION ...

Page 690: ...he wiper arm off of the windshield slide the latch out and away from the pivot shaft then lift it straight up and off of the shaft to remove To install Be sure the wipers are in the parked position and the blade assembly is in its correct position 3 Push the main head over the pivot shaft 4 Hold the main arm head onto the pivot shaft while raising the blade end of the wiper arm and push the slide ...

Page 691: ...untaineer models Click to enlarge Rear Wiper WARNING Use a towel or similar device to protect the vehicle finish when performing this procedure Raise the windshield wiper blade arm off of the glass and place it into the service position 1 Using a small flat bladed prytool release the retaining clip at the base of the windshield wiper pivot 2 HOW TO USE THIS BOOK 694 REMOVAL INSTALLATION ...

Page 692: ...ower the wiper blade arm against the glass 6 The blade is properly positioned when it firmly contacts the windshield wiper arm stop If it does not remove the arm again and reposition it so that it does Rear windshield wiper arm positioning for the Explorer and Mountaineer models Click to enlarge Windshield Wiper Motor REMOVAL INSTALLATION Front Wiper Motor HOW TO USE THIS BOOK Windshield Wiper Mot...

Page 693: ...ge assemblies Click to enlarge Turn the wiper switch on Turn the ignition switch on until the blades are straight up and then turn ignition off to keep them there 1 Remove the right wiper arm and blade 2 HOW TO USE THIS BOOK 696 REMOVAL INSTALLATION ...

Page 694: ...w the linkage to drop into the cowl 4 Remove the linkage access cover located on the right side of the dash panel near the wiper motor 5 Reach into the access hole and disconnect the wiper motor linkage clip from the motor shaft Remove the clip Also remove the linkages from the wiper motor shaft HOW TO USE THIS BOOK REMOVAL INSTALLATION 697 ...

Page 695: ... clip away from the linkage until it clears the nib on the crank pin Then push the clip off the linkage 7 Disconnect the wiper motor s wiring harness plug and remove the harness from any holding clips Remove the ground wire retaining nut HOW TO USE THIS BOOK 698 REMOVAL INSTALLATION ...

Page 696: ... 8 Disconnect the wiper motor s wiring connector 9 remove the wiper motor s three attaching screws and remove the motor 10 Remove the three wiper motor to firewall attaching screws then withdraw the wiper motor and crank assembly from the firewall To install HOW TO USE THIS BOOK REMOVAL INSTALLATION 699 ...

Page 697: ... of the clip Reinstall the right wiper pivot shaft and nut 1 Reconnect the battery and turn the ignition ON Turn the wiper switch off so the wiper motor will park then turn the ignition OFF Replace the right linkage access cover 2 Install the right wiper blade and arm 3 Check the system for proper operation 4 Rear Window Wiper Motor Rear wiper motor assembly and related components Click to enlarge...

Page 698: ...ump without fluid in the reservoir Repeatedly running the reservoir dry will ruin the pump The front washer fluid reservoir is connected to the coolant overflow tank which will be removed as an assembly Disconnect the electrical plug and hose from the washer fluid reservoir Also if removing the front washer pump disconnect the coolant overflow hose from its reservoir 1 Remove the reservoir attachi...

Page 699: ...ring mounting Using a small prytool pry out the pump retaining ring 4 Use a pair of pliers and grasp the pump on one wall around the electrical terminals Pull out the motor and seal from the reservoir 5 HOW TO USE THIS BOOK 702 REMOVAL INSTALLATION ...

Page 700: ...motor with the notch on the reservoir 8 Install the motor so that the seal seats against the bottom of the chamber 9 Use a 1 inch 25 4mm socket preferable a 12 point socket hand press the retaining ring securely against the motor end plate 10 Install the reservoir assembly 11 Connect the hoses and electrical harness plug 12 Fill the reservoir and operate the washer system Check for leaks 13 Chilto...

Page 701: ...ry remove the left and right A C register vents from the dash 3 Exploded views of the 1991 94 instrument cluster and trim panel assemblies Click to enlarge Unsnap the instrument cluster trim panel by pulling rearwards around the edge of the panel Depress the hazard warning switch 4 way flashers and remove the trim panel 4 Remove the four screws securing the instrument cluster to the dash mounting ...

Page 702: ... and apply the parking brake then turn the ignition switch to unlock the steering wheel and pull the gear select lever into the Low L range 2 6 Pull the cluster assembly rearward to gain access to the speedometer cable 7 If there is insufficient slack in the cable for gaining access disconnect the cable from the transmission Once disconnected pull the cluster out gently until enough clearance is g...

Page 703: ...e instrument cluster near its opening and attach the electrical plugs to it 11 Connect the speedometer cable to the speedometer head If necessary reconnect the speedometer cable to the transmission 12 If removed install the two PRNDL indicator retaining screws 13 Insert the cluster into the dash and install the four attaching screws 14 Ensure that the hazard warning switch is depressed and install...

Page 704: ...trim and knee bolster attaching screws 3 Remove the lower trim and knee bolster 4 Remove the cluster finish panel and unplug the headlamp and dimmer switch harnesses from it 5 Exploded view of the instrument cluster mounting Click to enlarge Remove the four instrument cluster retaining screws 6 HOW TO USE THIS BOOK 708 REMOVAL INSTALLATION ...

Page 705: ... the four instrument cluster retaining screws 11 Connect the headlamp and dimmer switch harnesses to the cluster finish panel then install it 12 Install the lower trim and knee bolster panels and the attaching screws 13 Install the center finish panel 14 Install the radio 15 Connect the negative battery cable Start the vehicle and check all gauges lamps and signals for proper operation 16 Fuel Oil...

Page 706: ...large Remove the lens from the instrument cluster 3 Pull the gauge from the cluster 4 To install Install the gauge by pushing it firmly into position 5 Install the cluster lens and install the cluster into the instrument panel 6 HOW TO USE THIS BOOK 710 REMOVAL INSTALLATION ...

Page 707: ...Disconnect the electrical lead from the switch 4 Exploded view of the rear wiper rear defogger fog light and headlight switch assemblies Click to enlarge To install Connect the wiring and install the switch in the instrument panel 5 Install the cluster finish panel 6 Connect the negative battery cable Check the operation of the switch 7 Headlight Switch HOW TO USE THIS BOOK Rear Wiper Switch 711 ...

Page 708: ... storage bin snaps out 3 Pull the headlight switch knob to the headlight on position Depress the shaft release button and remove the knob and shaft assembly View of the 1991 94 model headlight switch control knob release button Click to enlarge 4 2 On 1995 99 models remove the instrument panel finish panel 3 Unscrew the mounting nut and remove the switch from the instrument panel then remove the w...

Page 709: ...e and check the operation of the headlight switch 8 Back up Light Switch The back up light switch used on the automatic transmissions is also the neutral safety switch Refer to Section 7 for the proper procedures Ford used two different manual transmissions the Mitsubishi and the Mazda made 5 speed OverDrive OD transmissions The back up light switch is located on the right side of the transmission...

Page 710: ...n is the reverse of the removal procedure If necessary or since your there check the transmission fluid level and top off as needed 5 Location of the back up light switch on the Mazda transmission Click to enlarge Location of the back up light switch on the Mitsubishi transmission Click to enlarge HOW TO USE THIS BOOK 714 Manual Transmissions ...

Page 711: ...LIGHTING Headlights REMOVAL INSTALLATION Examples of various types of automotive light bulbs LIGHTING 717 ...

Page 712: ...w of the front headlight assembly and related components Click to enlarge If equipped open the headlight access panel by sliding the latch and lifting the panel upwards HOW TO USE THIS BOOK 718 REMOVAL INSTALLATION ...

Page 713: ...enlarge Open the vehicle s hood and secure it in an upright position 1 If necessary open the bulb access panel by depressing the latch then lifting 2 To remove the bulb grasp the retainer and rotate it counterclockwise to unlock it HOW TO USE THIS BOOK REMOVAL INSTALLATION 719 ...

Page 714: ...h the harness plug Firmly push the bulb onto the plug until the spring clip latches over the bulb s projection 6 WARNING Do not touch the glass bulb with your fingers Oil from your fingers can severely shorten the life of the bulb If necessary wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation Position the headlight bulb and secure it with the locking ring 7...

Page 715: ...d by a repair shop which is equipped with headlight aiming tools Improper adjustments may be both dangerous and illegal For most of the vehicles covered by this manual horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring There is no adjustment for focus this is done during ...

Page 716: ...as much as possible by closing shades or hanging cloth over the windows 2 Turn the headlights ONand mark the wall at the center of each light s low beam then switch on the brights and mark the center of each light s high beam A short length of masking tape which is visible from the front of the vehicle may be used Although marking all four positions is advisable marking one position from each ligh...

Page 717: ...riginal spot It must be parked no closer to or farther away from the wall than the second vehicle 4 Perform any necessary repairs but make sure the vehicle is not moved or is returned to the exact spot from which the lights were marked Turn the headlights ONand adjust the beams to match the marks on the wall 5 Have the headlight adjustment checked as soon as possible by a reputable repair shop 6 S...

Page 718: ...move the side marker parking and turn signal bulbs and sockets from the headlamp and trim assembly They can be removed by turning them 3 If replacing a lens remove the retaining screws for the lens to be changed and remove it from the headlight door 4 To install If removed install the removed lens assembly 5 Install the bulbs and sockets 6 Install the headlight and trim assembly 7 Check the operat...

Page 719: ...r lens assembly Click to enlarge Remove the marker turn signal lens retaining screws or nut 1 To change a turn signal marker bulb first unfasten the lens from the body the reach behind the lens HOW TO USE THIS BOOK REMOVAL INSTALLATION 725 ...

Page 720: ...simply pull it straight out To install Install the bulb into the lamp socket 5 Install the lamp socket to the lens and twist it to lock it in position 6 Position the lens assembly ensure that the barbed retainers are aligned with their mounting clips and press the assembly until fully seated 7 Install the marker turn signal lens retaining screws or nut 8 Check the operation of the lights 9 Rear ma...

Page 721: ...Exploded view of the rear light assembly used on the Ranger model Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 727 ...

Page 722: ...he rear light assembly used on the Explorer Mountaineer models Click to enlarge To change a rear brake signal or back up bulb on the Ranger first remove the two outer screws HOW TO USE THIS BOOK 728 REMOVAL INSTALLATION ...

Page 723: ...m use barbed push pins Remove the 2 Explorer Mountaineer models or 4 Ranger models screws retaining the lamp assembly to the vehicle 1 Remove the lamp assembly from the vehicle by pulling it outward On the Explorer Mountaineer models make sure the 2 barbed retainers at the bottom of the assembly release 2 HOW TO USE THIS BOOK REMOVAL INSTALLATION 729 ...

Page 724: ...aight outward 4 To install Install the bulb into the lamp socket 5 Install the lamp socket to the lens and twist it to lock it in position 6 Position the lens assembly to the body On Explorer Mountaineer models ensure that the barbed retainers are aligned with their mounting clips and press the assembly until fully seated 7 Install the lens assembly retaining screws four screws used on the Ranger ...

Page 725: ...Exploded view of the Ranger high mount brake and cargo light assembly Explorer Mountaineer models are similar but without cargo light Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 731 ...

Page 726: ... Pull the bulb straight out from the lamp socket to remove it 4 To install Install the bulb into the lamp socket 5 Install the lamp socket to the lens and either twist it to lock it in position or install its retaining screw 6 Position the lens assembly to the body 7 Install the lens assembly retaining screws 8 Check the operation of the lights 9 License Plate Light Exploded view of the rear licen...

Page 727: ...ing then pulling Next remove the bulb from the socket by pulling it straight out Dome and Map Lights Remove the plastic cover 1 Pull the map and or area bulb from the dome light assembly 2 Installation is the reverse of the removal procedure 3 HOW TO USE THIS BOOK REMOVAL INSTALLATION 733 ...

Page 728: ...contacts Cargo Light The Ranger has a rear cargo light which illuminates the pick up bed It is incorporated with the high mount brake light For removal installation procedures refer to the high mount brake light procedures earlier in this Section and remove the cargo lamp socket and bulb instead of the brake lamp components Fog Driving Lights REMOVAL INSTALLATION HOW TO USE THIS BOOK 734 REMOVAL I...

Page 729: ...ded view of the fog lamps and related components Ranger shown Explorer similar Click to enlarge Use a small prytool to lift the locking tab and release the lens HOW TO USE THIS BOOK REMOVAL INSTALLATION 735 ...

Page 730: ... the lens 2 Disconnect the electrical harness plug from the pigtail connector 3 Remove the rubber boot from the back of the lens assembly 4 Release the bulb socket retainer from its locking tab 5 Remove the bulb and socket from the lens and pull the bulb from the socket 6 WARNING Never touch the bulb with your bare hands The naturals oils from your skin will remain on the bulb causing a localized ...

Page 731: ...e rubber boot 9 Connect the electrical harness plug and position the lens assembly into the lamp housing 10 Engage the lens retaining tab Ensure that the lens is securely held in the lamp housing 11 Check the light for proper operation 12 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK REMOVAL INSTALLATION 737 ...

Page 732: ...talling the kit follow the manufacturer s instructions The color coding of the wires is usually standard throughout the industry One point to note some domestic vehicles and most imported vehicles have separate turn signals On most domestic vehicles the brake lights and rear turn signals operate with the same bulb For those vehicles with separate turn signals you can purchase an isolation unit so ...

Page 733: ...CIRCUIT PROTECTION Fuses Fuse panel and identification for 1991 94 Ranger models Click to enlarge CIRCUIT PROTECTION 741 ...

Page 734: ...Fuse panel and identification for 1991 94 Explorer models Click to enlarge HOW TO USE THIS BOOK 742 Fuses ...

Page 735: ...Fuse panel and power distribution box identification for 1995 99 Ranger models Part 1 Click to enlarge HOW TO USE THIS BOOK Fuses 743 ...

Page 736: ...Fuse panel and power distribution box identification for 1995 99 Ranger models Part 2 Click to enlarge HOW TO USE THIS BOOK 744 Fuses ...

Page 737: ...Fuse panel and power distribution box identification for 1995 99 Ranger models Part 3 Click to enlarge HOW TO USE THIS BOOK Fuses 745 ...

Page 738: ...Fuse panel and power distribution box identification for 1995 99 Explorer Mountaineer models Part 1 Click to enlarge HOW TO USE THIS BOOK 746 Fuses ...

Page 739: ...Fuse panel and power distribution box identification for 1995 99 Explorer Mountaineer models Part 2 Click to enlarge HOW TO USE THIS BOOK Fuses 747 ...

Page 740: ...ation for 1995 99 Explorer Mountaineer models Part 3 Click to enlarge REPLACEMENT Fuse Panel Located inside the passenger compartment under the drivers side of the instrument panel Turn the ignition switch OFF 1 HOW TO USE THIS BOOK 748 REPLACEMENT ...

Page 741: ...s 4 Look through the side of the fuse body to determine if the fuse element is blown 5 To install Check the amperage rating of the fuse which was removed and obtain a new fuse of the same rating 6 WARNING Never replace a blown fuse with a new fuse of a higher rating Severe electrical damage as well as possible electrical fire could result Align the fuse with its mounting position and push it into ...

Page 742: ...ss and should not be confused with standard wire It is several wire gauges smaller than the circuit which it protects Under no circumstances should a fuse link replacement repair be made using a length of standard wire cut from bulk stock or from another wiring harness The fusible links are located near the starter solenoid and shares the terminal with the battery to starter solenoid cable Circuit...

Page 743: ...he steering column First remove the two fasteners from the lower edge of the cover Then pull the cover downward until the spring clips disengage from the instrument panel The turn signal flasher unit is mounted on the front of the fuse panel and the hazard warning flasher is mounted on the rear of the fuse panel Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BO...

Page 744: ...nia 1993 Explorer body wiring except California 1993 Explorer 4 0L engine wiring California 1993 Explorer body wiring California 1994 Ranger 2 3L engine wiring except California 1994 Ranger 2 3L engine wiring California 1994 Ranger 3 0L engine wiring 1994 Ranger 4 0L engine wiring except California 1994 Ranger 4 0L California engine wiring 1994 Ranger body wiring 1994 Explorer 4 0L engine wiring 1...

Page 745: ...lywheel and incorporates a diaphragm spring which provides the pressure to engage the clutch The cover also houses the pressure plate When the clutch pedal is released the driven disc is sandwiched between the pressure plate and the smooth surface of the flywheel thus forcing the disc to turn at the same speed as the engine crankshaft The transmission contains a mainshaft which passes all the way ...

Page 746: ...on the Mitsubishi 5 speed transmission as follows Remove the plastic shift pattern insert from the shift knob 1 Heat the shift lever knob to 140 180 F 60 82 C using a heat gun 2 Position a block of wood beneath the shift lever knob and carefully hammer the knob from the lever Be careful not to damage the finish on the shift lever 3 2 Place the gearshift lever in Nposition 3 Remove the shifter boot...

Page 747: ...ver knob was removed heat it to 140 180 F 60 82 C using a heat gun Tap the knob onto the shift lever using a 7 16 in 11mm will work socket and mallet 9 Place the shift lever in Nposition Then align the shift pattern plastic insert with the vehicle centerline and install it to the shift lever knob 10 Neutral Sensing Switch All manual transmission vehicles are equipped with a neutral sensing switch ...

Page 748: ...ed Click to enlarge Location of the transmission switches Mitsubishi 5 speed Click to enlarge Disconnect the negative battery cable 1 Raise and support the vehicle safely 2 Place the transmission in any position other than N 3 HOW TO USE THIS BOOK 758 REMOVAL INSTALLATION ...

Page 749: ...the extension housing seal 3 Matchmark the driveshaft to the rear axle flange Disconnect the driveshaft and pull it rearward from the unit 4 Remove the extension housing seal using tool T71P 77218 A or equivalent remove the extension housing seal 5 To install Lubricate the inside diameter of the oil seal and install the seal into the extension housing using tool T71P 77022 A Check to ensure that t...

Page 750: ...equivalent 8 Lower the vehicle 9 Reconnect the negative battery cable 10 Extension housing seal installation Click to enlarge Four Wheel Drive Models Refer to the transfer case procedures for the front and or rear output shaft seals Transmission REMOVAL INSTALLATION HOW TO USE THIS BOOK 760 REMOVAL INSTALLATION ...

Page 751: ...er assembly other models are similar Click to enlarge Disconnect the negative battery cable 1 Remove the gearshift lever assembly from the control housing 2 Cover the opening in the control housing with a cloth to prevent dirt from falling into the unit 3 Raise the vehicle and support it safely 4 HOW TO USE THIS BOOK REMOVAL INSTALLATION 761 ...

Page 752: ...install Check that the mating surfaces of the clutch housing engine rear and dowel holes are free of burrs dirt and paint 18 Place the transmission on the transmission jack Position the transmission under the vehicle then raise it into position Align the input shaft splines with the clutch disc splines and work the transmission forward into the locating dowels 19 Install the transmission to engine...

Page 753: ...ing within the pressure plate cover transmission side In a relaxed state when the clutch pedal is fully released this spring is convex that is it is dished outward toward the transmission Pushing in the clutch pedal actuates the attached linkage Connected to the other end of this is the throw out fork which hold the throw out bearing When the clutch pedal is depressed the clutch linkage pushes the...

Page 754: ... and separate from the switch 4 Remove the switch from the pushrod 5 View of the 3 function clutch interlock or CPP switch To install Fit the switch to the master cylinder pushrod 6 Install the plastic retainer 7 Rotate the switch into the position to attach the clip Reconnect the switch connector 8 Reconnect the negative battery cable 9 Master Cylinder and Reservoir The hydraulic clutch system op...

Page 755: ...h openings 5 Remove the bolts retaining the clutch master cylinder to the dash panel and remove the clutch master cylinder assembly 6 To install Install the pushrod through the hole in the engine compartment Make certain it is located on the correct side of the clutch pedal Place the master cylinder assembly in position and install the retaining bolts Tighten to 1 12 ft lbs 11 16Nm 7 Insert the co...

Page 756: ...ylinder Click to enlarge Before performing any service that requires removal of the slave cylinder the master cylinder and pushrod must be disconnected from the clutch pedal If not disconnected permanent damage to the master cylinder assembly will occur if the clutch pedal is depressed while the slave cylinder is disconnected HOW TO USE THIS BOOK 766 REMOVAL INSTALLATION ...

Page 757: ...nsmission assembly 3 On the 2 9L 4WD vehicles the clutch housing must be removed with the transmission assembly Remove the slave cylinder to transmission retaining bolts 4 Remove the slave cylinder from the transmission input shaft 5 To install Fit the slave cylinder over the transmission input shaft with the bleed screws and coupling facing the left side of the transmission 6 Install the slave cy...

Page 758: ...e system Notice the bleed screw outlet When the slave is full a steady stream of fluid comes from the slave outlet Tighten the bleed screw 4 Depress the clutch pedal to the floor and hold for 1 2 seconds Release the pedal as rapidly as possible The pedal must be released completely Pause for 1 2 seconds Repeat 10 times 5 Check the fluid level in the reservoir The fluid should be level with the ste...

Page 759: ...the clutch components for 2 3L 2 5L 3 0L 4 0L engines other engines are similar Click to enlarge Pressure plate bolt torque sequence Disconnect the negative battery cable 1 HOW TO USE THIS BOOK REMOVAL INSTALLATION 769 ...

Page 760: ...led position of the pressure plate and cover the flywheel to aid during re assembly 7 Loosen and remove the clutch and pressure plate bolts evenly a little at a time then carefully remove the pressure plate and clutch assembly from the flywheel Loosen the pressure plate and cover attaching bolts evenly until the pressure plate springs are expanded and remove the bolts 8 Remove the pressure plate a...

Page 761: ...g To install Position the clutch disc on the flywheel so that the Clutch Alignment Shaft Tool T74P 727 K or equivalent can enter the clutch pilot bearing and align the disc 10 Be sure that the flywheel surface is clean before installing the clutch HOW TO USE THIS BOOK REMOVAL INSTALLATION 771 ...

Page 762: ...assembly align the assembly and flywheel according to the marks made during the removal operations Position the pressure plate and cover assembly on the flywheel align the pressure plate and disc and install the retaining bolts that fasten the assembly to the flywheel Tighten the bolts to 15 25 ft lbs 21 35 Nm in the proper sequence Remove the clutch disc pilot tool 11 HOW TO USE THIS BOOK 772 REM...

Page 763: ... into the vehicle 1 Connect the coupling by pushing the male coupling into the slave cylinder 2 Connect the hydraulic clutch master cylinder pushrod to the clutch pedal 3 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK REMOVAL INSTALLATION 773 ...

Page 764: ...and Mountaineer They may be identified by checking the transmission code on the Safety Standard Certification Label attached to the driver s side door post in the space marked Trans The transmissions can also be identified by a tag attached to the lower left hand extension attaching bolt The transmission codes are as follows 1991 94 code T is for the A4LD transmission 1995 99 code T is for the 4R4...

Page 765: ...ransmissions Starting in 1995 the switch was used not only for neutral start sensing and back up light activation but also as a gear position range sensor The Powertrain Control Module reads the sensor to determine which gear position the transmission is in and adjusts fuel and spark timing accordingly The new switch is called the Transmission Range TR sensor To install the Transmission Range TR s...

Page 766: ...al control lever retaining nut as well as the lever 6 Remove the two retaining bolts and the sensor 7 To install Ensure that the transmission shift lever is in the Neutral N position 8 Install the TR sensor and loosely install the retaining bolts 9 HOW TO USE THIS BOOK REMOVAL INSTALLATION 777 ...

Page 767: ... Align TR sensor slots using the Transmission Range Sensor Alignment Tool T97L 70010 AH or equivalent 10 Tighten the retaining bolts to 7 9 ft lbs 9 12 Nm 11 Install the manual control lever to the sensor and tighten the retaining bolt HOW TO USE THIS BOOK 778 REMOVAL INSTALLATION ...

Page 768: ...nt Raise and safely support the vehicle 1 Block the rear wheels and apply the parking brake 2 Place the transmission shift control lever in the Neutral N position 3 Remove the nut securing the transmission control manual lever to the TR sensor 4 Loosen the two TR sensor retaining bolts 5 Align the TR sensor slots using the Transmission Range Sensor Alignment Tool T97L 70010 AH or equivalent 6 Tigh...

Page 769: ...he clamp 4 Pull the vacuum diaphragm from the transmission case and remove the vacuum diaphragm control rod from the transmission case 5 To install Install the vacuum diaphragm control rod from the transmission case 6 Push the vacuum diaphragm into the case and secure it with the clamp and bolt Tighten to 80 106 inch lbs 9 12Nm 7 Fit the vacuum hose to the diaphragm 8 Lower the vehicle 9 Reconnect...

Page 770: ...A or equivalent 4 To install Before install the replacement seal inspect the sealing surface of the universal joint yoke for scores If scoring is found replace the yoke Install the new seal using seal installer T74P 77052 A or equivalent Coat the inside diameter at the end of the rubber boot portion of the seal with long life lubricant C1AZ 1590 BA or equivalent 5 Align the matchmarks and install ...

Page 771: ...sion fluid 3 Remove the converter access cover from the lower right side of the converter housing on the 3 0L engine Remove the cover from the bottom of the engine oil pan on the 2 3L and 2 5L engine Remove a bolt on the access cover of the 2 9L engine and swing the cover open Remove the access cover and adapter plate bolts from the lower left side of the converter housing on all other application...

Page 772: ...t and breaker bar on the crankshaft pulley attaching bolt Rotate the pulley clockwise as viewed from the front to gain access to each of the nuts 5 On belt driven overhead cam engines never rotate the pulley in a counterclockwise direction as viewed from the front HOW TO USE THIS BOOK REMOVAL INSTALLATION 783 ...

Page 773: ...sfer case 4WD or extension housing 2WD Remove the speedometer cable and or vehicle speed sensor from the transfer case 4WD or extension housing 2WD 6 On 2WD vehicles scribe a mark indexing the driveshaft to the rear axle flange Remove the driveshaft 7 HOW TO USE THIS BOOK 784 REMOVAL INSTALLATION ...

Page 774: ...using to engine bolts 18 Slightly lower the jack to gain access to the oil cooler lines Disconnect the oil cooler lines at the transmission Plug all openings to keep dirt and contamination out 19 Move the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flywheel Lower the transmission from the vehicle 20 If necessary remove the torque converter...

Page 775: ...rter must be pushed and at the same time rotated through what feels like 2 notches or bumps When fully installed rotation of the converter will usually result in a clicking noise heard caused by the converter surface touching the housing to case bolts Lightly lubricate the converter hub with transmission fluid Note the machined fluid pump drive flat on the very edge of the hub arrow HOW TO USE THI...

Page 776: ...e transmission on the jack 2 Rotate the converter so that the drive studs are in alignment with the holes in the flywheel 3 Move the converter and transmission assembly forward into position being careful not to damage the flywheel and converter pilot The converter housing is piloted into position by the dowels in the rear of the engine block 4 During this move to avoid damage do not allow the tra...

Page 777: ...ls and engage the parking brake 1 From inside the vehicle place the gear shift lever in the overdrive position shown as a circle with the letter D in the middle On 1991 vehicles hang an 8 lb 3 6Kg weight on the lever On 1992 99 vehicles use a 3 lb 1 4Kg weight 2 Raise and safely support the vehicle 3 From underneath use a prytool to remove the shift control cable end from the transmission manual c...

Page 778: ... adjustment check for Park P engagement Start the engine and check all the lever positions for proper operation 13 SHIFT SELECT INDICATOR To test the shift select indicator Turn the engine OFF apply the parking brake and place the transmission select lever in the OD overdrive position 1 Hang a 3 lb 1 4Kg weight on the select lever 2 Look at the selector indicator on the instrument panel The pointe...

Page 779: ...tor cable end screw then move the cable end to properly position the pointer until it is centered on the overdrive graphic Tighten the cable end screw 10 On 1992 and later vehicles there are two styles of thumb wheel adjusters One style is mounted to the indicator assembly Click to enlarge HOW TO USE THIS BOOK 790 ADJUSTMENTS ...

Page 780: ...rom the lever 14 Operate the shift select lever in all positions and ensure that the indicator pointer aligns with all of the position graphics 15 KICKDOWN CABLE The kickdown cable is self adjusting over a tolerance range of 1 in 4mm If the cable requires readjustment reset the by depressing the semi circular metal tab on the self adjuster mechanism and pulling the cable forward toward the front o...

Page 781: ...View of the transmission kickdown cable assemble and its adjusting points Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 792 KICKDOWN CABLE ...

Page 782: ...e rear axle and also the front drive axle when electronically actuated This system consists of a pushbutton control an electronic control module an electric shift motor with an integral shift position sensor and a speed sensor The electric shift motor mounted externally at the rear of the transfer case drives a rotary helical cam The cam moves the 2WD 4WD shift fork and 4H 4L reduction shift fork ...

Page 783: ... REMOVAL INSTALLATION Remove the rear output shaft seal slide hammer and seal removal tool shown Click to enlarge Raise and safely support the vehicle 1 Matchmark the rear driveshaft to the transfer case yoke then disconnect the shaft from the yoke Wire the driveshaft up and out of the way 2 Using a 30mm 1 18 in thin wall socket remove the rear output shaft yoke retaining nut 3 Some fluid may drib...

Page 784: ...um long life grease to the seal lip 6 Position the new seal to the output housing and using an appropriate driver such as the Output Shaft Seal Replacer T83T 7065 B and Driver Handle T80T 4000 W press the seal into the housing until fully seated 7 Install the rear out put shaft yoke rubber seal and washer 8 Install the output shaft yoke retaining nut and tighten to 250 280 ft lbs 339 381 Nm 9 Conn...

Page 785: ...eal using Impact Slide Hammer Tool T50T 100 A or equivalent 8 To install Ensure that the output housing bore is free of any dirt burrs or nicks Apply premium long life grease to the seal lip 9 Position the new seal to the output housing and using an appropriate driver such as the Output Shaft Seal Replacer T83T 7065 B and Driver Handle T80T 4000 W press the seal into the housing until fully seated...

Page 786: ...moved from the vehicle and their cases must be split The output shaft is retained internally by a snapring Consult a professional repair shop as specialized knowledge of transfer cases is required Transfer Case Assembly REMOVAL INSTALLATION Exploded view of the 13 54 mechanical shift transfer case Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 797 ...

Page 787: ...utput shaft 7 Disconnect the rear driveshaft from the transfer case output shaft yoke 8 If equipped disconnect the speedometer driven gear from the transfer case rear cover 9 If equipped disconnect the electrical wire harness plug from the Vehicle Speed Sensor VSS 10 Disconnect the vent hose from the mounting bracket 11 On manual shift models perform the following Remove the shift lever retaining ...

Page 788: ...e transmission output shaft aligns with the splined transfer case input shaft 18 Slide the transfer case forward on to the transmission output shaft and onto the dowel pin Install transfer case retaining bolts and torque them to specification 19 The remainder of the installation procedure is the reverse of removal Check the fluid level and if necessary top off with Dexron Mercon automatic transmis...

Page 789: ...cts the forward right edge of the shift lever 4 Hold the cam plate in this position and torque the larger bolt first to 70 90 ft lbs 95 122 Nm and torque the smaller bolt to 31 42 ft lbs 42 57 Nm 5 Move the transfer case in cab shift lever to all shift positions to check for positive engagement There should be a clearance between the shift lever and the cam plate in the 2Hfront and 4Hrear clearanc...

Page 790: ...s a centering socket yoke and a center slip at the transfer case end of each shaft A single U joint is used at the axle end of the shaft The Constant Velocity CV type U joint allows the driveline angel to be adjusted according to the up and down movement of the vehicle without disturbing the power flow The CV U joint is composed of an outer bearing retainer and flange spring cap circlip inner bear...

Page 791: ...or tears Inspect the stud yoke splines for wear or damage Replace any damage parts 6 To install Apply a light coating of Multi purpose Long Life lubricant C1AZ 19490 B or equivalent to the yoke splines and the edge of the inner diameter of the rubber boot 7 Slide the driveshaft into the transfer case front output yoke assembly Make certain the wide tooth splines on the slip yoke are indexed to the...

Page 792: ...ew clamp on the boot Position the clamp tabs in the slots so each tab fits into a slot Then crimp the clamp securely using a pair of clamp pliers T63P 9171 A or equivalent Do not crimp to the point where the clamp damage the boot 3 Double Cardan Type Front and Rear Driveshaft REMOVAL INSTALLATION Rear driveshaft single double cardan type Click to enlarge Disconnect the negative battery cable 1 Rai...

Page 793: ...e Disconnect the U joint from the flange at the rear axle 4 Remove the driveshaft 5 To install Position the single U joint end of the driveshaft to the rear axle and install the retaining bolts Tighten the bolts to 61 87 ft lbs 83 118Nm 6 Position the double Cardan U joint to the transfer case and install the retaining bolts Tighten the bolts to 12 16 ft lbs 17 22Nm 7 Lower the vehicle 8 Re connec...

Page 794: ...earing in a vice and tap on the center yoke to free it from the bearing Lift the 2 bearing cups from the spider 5 Re position the tool on the yoke and move the remaining bearing in the opposite direction so that it protrudes approximately 3 8 in 10mm out of the yoke 6 Position the bearing in a vice Tap on the center yoke to free it from the bearing Remove the spider from the center yoke 7 Pull the...

Page 795: ... driveshaft boot in its original position 21 To assemble the double Cardan joint position the spider in the driveshaft yoke Make certain the spider bosses or lubrication plugs on kits will be in the same position as originally installed Press in the bearing using the U joint tool Then install the snaprings 22 Pack the socket relief and the ball with Multi purpose Long Life lubricant C1AZ 1920 B or...

Page 796: ...lug the extension housing to prevent lubricant leakage 4 To install Lubricate the slip yoke splines with Multi purpose Long Life lubricant C1AZ 19490 B or equivalent Remove the plug from the extension housing 5 Inspect the extension housing seal Replace if necessary 6 Install the driveshaft assembly Do not allow the slip yoke assembly to bottom on the output shaft with excessive force 7 Install th...

Page 797: ... to frame retaining bolts Remove the spacers under the center bearing bracket if installed 3 Remove the retaining bolts and disconnect the driveshaft from the axle companion flange 4 Remove the retaining bolts that retains the driveshaft to the rear of the transfer case 5 Remove the driveshaft 6 To install Install the driveshaft into the rear of the transfer case Make certain that the driveshaft i...

Page 798: ...certain the center bearing bracket assembly is reinstalled square to the vehicle If the spacers were installed under the center bearing be sure to reinstall them DISASSEMBLY ASSEMBLY U joint bearing removal Click to enlarge U joint bearing installation HOW TO USE THIS BOOK DISASSEMBLY ASSEMBLY 809 ...

Page 799: ... the driveshaft slip splines with Multi purpose Long Life lubricant C1AZ 19490 B or equivalent 1 With the boot loosely installed on the driveshaft tube install the slip yoke into the driveshaft splines in their original orientation 2 Using new clamps install the driveshaft boot in its original position 3 10 Start a new bearing cup into the yoke at the rear of the driveshaft 11 Position the new spi...

Page 800: ...g the driveshaft to the transfer case 3 Remove the bolts retaining the driveshaft to the rear axle flange 4 Remove the driveshaft 5 To install Position the driveshaft to the rear axle flange so that the marks made previously are line up Install and tighten the retaining bolts to 61 87 ft lbs 83 118Nm 6 Position the driveshaft to the transfer case flange so that the marks made previously are line u...

Page 801: ...CV joint exploded view Click to enlarge Removing the shroud from the outer bearing race and flange Click to enlarge HOW TO USE THIS BOOK 812 DISASSEMBLY ASSEMBLY ...

Page 802: ...nd flange assembly 2 Carefully tap the shroud lightly with a blunt tool and remove the shroud Be careful not to damage the shroud dust boot or outer bearing race and flange assembly 3 Peel the boot upward and away from the outer bearing race and flange assembly 4 Remove the wire ring that retains the inner race to the outer race 5 Remove the inner race and shaft assembly from the outer race and fl...

Page 803: ...shaft using a new clamp Make certain the boot is seated in its groove 14 The clamp is a fixed diameter push on metal ring Install the inner bearing assembly on the shaft Make certain the circlip is exposed 15 Install a new circlip on the shaft Do not over expand or twist the circlip during installation 16 Install the spring and cap in the outer bearing retainer and flange 17 Fill the outer bearing...

Page 804: ...t replace the bearing 4 Inspect the rubber insulator for evidence of hardness cracking or deterioration Replace if damaged in any way 5 Re install the coupling shaft yoke 6 Be sure the yoke is re installed on the coupling shaft in the same orientation as it was originally installed The orientation is critical so that proper driveshaft balance and U joint phasing is maintained Tighten the retaining...

Page 805: ...cuum operated disconnect system mounted to the axle housing which locks and unlocks the axles See Vacuum Disconnect Axle Lock later in this section for service procedures All other models use the twin I beam style front axle assembly with either manual or automatic locking hubs at the wheel ends Manual Locking Hubs REMOVAL INSTALLATION Exploded view of the manual locking hub assembly and related c...

Page 806: ...ling straight outward 5 Inspect the O ring seal on the back side of the hub assembly and if damaged replace it 6 Installation is the reverse of the removal procedure Ensure that the rotor mounting face is flat and free of burrs dirt or grease especially where the O ring seal makes contact 7 Turn the hub assembly over HOW TO USE THIS BOOK 818 REMOVAL INSTALLATION ...

Page 807: ...equipped remove the lug nut retainer washers from the wheel studs 4 Some gentle tapping with a soft faced hammer may help to loosen the locking hub cover if it seems stuck Remove the automatic locking hub cover assembly from the rotor by pulling straight outward 5 Inspect the O ring seal on the back side of the hub assembly and if damaged replace it 6 Installation is the reverse of the removal pro...

Page 808: ...nd the two thrust spacers behind cam assembly from the wheel bearing adjusting nut 4 Installation is the reverse of the removal procedure Make sure to install the two thrust spacers first Also when pushing or pressing the locking cam into position ensure that the key in the cam assembly is aligned with the keyway of the front spindle 5 WARNING Extreme care must be taken when aligning the locking c...

Page 809: ...the system is mounted to the axle housing itself and is called a vacuum disconnect axle lock Refer to the procedures in this section Vacuum Disconnect Axle Lock The vacuum disconnect axle locking system was used on the Mountaineer 1995 99 Explorer and 1998 99 Ranger models only The axle locking controls are mounted to the axle housing All other models use manual or automatic locking hubs at the wh...

Page 810: ...e shift motor 4 Remove the four shift motor cover to axle housing retaining bolts 5 Pull the cover and shift motor assembly straight out from the axle housing 6 To disassemble the shift fork and shift motor from the cover proceed as follows Note the position of the shift fork to assure proper assembly 1 Remove the outboard snapring that retains the shift fork to the motor shaft and slide the fork ...

Page 811: ... hub locks and lock nuts 4 Remove the hub and rotor 5 Remove the nuts retaining the spindle to the steering knuckle Tap the spindle with a plastic or rawhide hammer to jar the spindle from the knuckle 6 Inspect the needle bearings inside the spindle bore If worn or damaged replace as follows Place the spindle in a vise on the second step of the spindle Wrap a shop towel around the spindle or use a...

Page 812: ...ion 13 Mountaineer 1995 99 Explorer and 1998 99 Ranger The Mountaineer 1995 99 Explorer and 1998 99 Ranger models do not use spindles Instead they use an internally splined wheel hub which is pressed into a sealed bearing If the assembly goes bad it must be replaced as an entire unit For removal installation procedures refer to Section 8 Axle Shafts and Seals REMOVAL INSTALLATION Except Mountainee...

Page 813: ...and rotor 5 Remove the nuts retaining the spindle to the steering knuckle Tap the spindle with a plastic or rawhide hammer to jar the spindle from the knuckle 6 Remove the front disc brake rotor shield 7 The left hand axle shaft is engaged inside of the front carrier assembly Depending on how the truck is sitting especially if it is not level some fluid may leak out of the front carrier assembly A...

Page 814: ...l from the axle shaft by driving them off with a hammer 1 Thoroughly clean the axle seal area of the shaft 2 Place the shaft in a press and install the new seal using the Spindle Axle Seal Installer Tool T83T 3132 A or equivalent 3 10 To install Install the right hand axle shaft as follows Ensure that the rubber boot is properly installed on the carrier stub shaft Slide a new outer axle shaft boot...

Page 815: ...ce removed these parts must never be reused during assembly Loosen the front wheel lug nuts 1 Raise and safely support the vehicle 2 Remove the wheels 3 Remove and discard the center wheel hub nut and washer 4 WARNING Never reuse the wheel hub nut and washer This nut is a torque prevailing design and cannot be reused Remove the disc brake caliper and position it aside 5 The hub shaft is a slip fit...

Page 816: ...VER reuse the wheel hub nut Remove the upper ball joint to steering knuckle retaining bolt Rotate the knuckle 1 downward and pull the CV joint 2 out of the wheel hub by compressing the axle shaft 3 inward HOW TO USE THIS BOOK 828 REMOVAL INSTALLATION ...

Page 817: ...shaft from the vehicle Remove the circlip from the inboard CV joint end and discard it 11 To install Install a new circlip to the inboard CV joint end 12 Position the halfshaft into the vehicle Slide the inboard CV joint end into the axle housing until it is fully seated Ensure that the circlip is engaged in the housing by attempting to pull the joint outwards 13 Install the outboard CV joint end ...

Page 818: ...ed view of the Dana 28 front drive axle found on Rangers other models are similar Click to enlarge Disconnect the negative battery cable 1 Raise and support the vehicle safely Remove the wheel and tire assembly 2 HOW TO USE THIS BOOK 830 Axle Housing ...

Page 819: ...on the under the left axle arm assembly Raise the axle arm until the arm is in position in the left pivot bracket Install the nut and bolt and tighten to 120 150 ft lbs 163 203Nm 10 Do not remove the jack from under the differential housing at this time Place new keystone clamps for the axle shaft boot on the axle shaft assembly Position the right axle arm on a jack and raise the right axle arm so...

Page 820: ...iminating driveshaft imbalance Disconnect the driveshaft from the front axle yoke 4 Remove the cotter pin and nut retaining the steering linkage to the spindle Disconnect the linkage from the spindle 5 Remove the left stabilizer bar link lower bolt Remove the link from the radius arm bracket 6 Position a jack under the left axle arm assembly ad slightly compress the coil spring 7 Remove the shock ...

Page 821: ...e arms Install a new stud and nut on the top of the axle and radius arm assembly and tighten to 190 230 ft lbs 258 311Nm Install the bolts in the front of the bracket and tighten to 27 37 ft lbs 37 50Nm 13 Install the seat spacer retainer and coil spring on the stud and nut Raise the jack to compress the coil spring Install the nut and tighten to 1 100 ft lbs 95 135Nm 14 Connect the shock absorber...

Page 822: ... not allow the driveshaft to hang unsupported damage to the shaft and or U joint can occur Disconnect the axle vent tube 4 Place a jack under the front axle to support it 5 Remove the left front axle to frame attaching bolt 6 Remove the remaining two axle to frame bolts 7 Lower the axle assembly and remove it from under the vehicle 8 To install Place the axle assembly on a jack and position it und...

Page 823: ...Install the axle halfshafts 14 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK REMOVAL INSTALLATION 835 ...

Page 824: ...r By dividing the number of teeth on the pinion gear into the number of teeth on the ring gear the numerical axle ratio 4 11 is obtained This also provides a good method of ascertaining exactly what axle ratio one is dealing with Another method of determining gear ratio is to jack up and support the truck so that both rear wheels are off the ground Make a chalk mark on the rear wheel and the drive...

Page 825: ...Integral axle carrier exploded view Click to enlarge Disconnect the negative battery cable 1 Raise and support the vehicle safely 2 HOW TO USE THIS BOOK 838 REMOVAL INSTALLATION ...

Page 826: ...To remove the axle first remove the rear axle cover and drain the fluid Next loosen the pinion shaft lock bolt HOW TO USE THIS BOOK REMOVAL INSTALLATION 839 ...

Page 827: ...er from the end of the axle shaft 2 Remove the axle shafts from the housing If the seals and or bearing are not being replaced be careful not to damage the seals with the axle shaft splines upon removal 3 For 3 73 1 and 4 10 1 ratio axles 6 Remove the pinion shaft lock bolt Place a hand behind the differential case and push out the pinion shaft until the step contacts the ring gear 1 Remove the C ...

Page 828: ...aft out of the axle carrier DO NOT rotate the axle with the pinion shaft removed Push in on the axle flange wheel side and remove the axle C lock A from the end of the axle B HOW TO USE THIS BOOK REMOVAL INSTALLATION 841 ...

Page 829: ...ge the bearing outer race Remove the bearing and seal as a unit 7 Axle shaft seal and bearing removal Click to enlarge To install If removed lubricate the new bearing with rear axle lubricant and install the bearing into the housing bore Use axle tube bearing replacer T78P 1225 A or equivalent 8 Apply Multi Purpose Long Life Lubricant C1AZ 19590 B or equivalent between the lips of the axle shaft s...

Page 830: ...12 Position the differential pinion shaft through the case and pinion gears aligning the hole in the shaft with the lock screw hole Install the lock bolt and tighten to 15 22 ft lbs 21 29Nm 13 Clean the gasket mounting surface on the rear axle housing and cover Apply a continuous bead of Silicone Rubber Sealant ESE M4G195 A or equivalent to the carrier casting face 14 Install the cover and tighten...

Page 831: ... be present on the axle 3 Mark the companion flanges and U joints for correct reinstallation position 4 Remove the driveshaft 5 Use a 2 jawed puller to remove the driveshaft companion flange Click to enlarge HOW TO USE THIS BOOK 844 REMOVAL INSTALLATION ...

Page 832: ...tion 8 Use a 2 jawed puller to remove the companion flange 9 Remove the seal with a small prybar and or locking pliers and hammer 10 To install Thoroughly clean the oil seal bore 11 If you are not absolutely certain of the proper seal installation depth the proper seal driver must be used If the seal is misaligned or damaged during installation it must be removed and a new seal installed Drive the...

Page 833: ...oad reading is higher than the specified values torque the nut just until the original reading is reached 15 WARNING Under no circumstances should the nut be backed off to reduce the preload reading If the preload is exceeded the yoke and bearing must be removed and a new collapsible spacer must be installed The entire process of preload adjustment must be repeated Install the driveshaft using the...

Page 834: ...lip U bolt nuts spring clips and spring seat caps 10 If the axle housing is mounted on top of the springs proceed as follows Slide the axle housing to the right side and lower the left side axle tube end until it clears the leaf spring 1 Slide the axle housing to the left side until the right side axle tube end will clear the leaf spring 2 11 Lower the axle housing and remove it from under the veh...

Page 835: ... the rear shock absorbers to the mounting bracket studs on the housing Torque the nuts to 60 ft lbs 18 Connect the driveshaft to the axle Torque the nuts to 8 15 ft lbs 19 Install the brake drums and wheels 20 Lower the vehicle 21 Reconnect the negative battery cable 22 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 848 REMOVAL INSTALLATION ...

Page 836: ...ial that may be present on the mounting surfaces of the hub drum or rotor that contacts the wheel Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the wheel lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion Install the lug nuts Be sure that the cone end of the lug nut faces inward 8 With the lug nuts loosely inst...

Page 837: ...er tubes in leaking wheels Do not replace wheels with used wheels Wheels that have been straightened or are leaking air or are used may have structural damage and could fail without warning Front Wheel Lug Studs REMOVAL INSTALLATION Except Mountaineer 1995 99 Explorer and 1998 99 Ranger Front wheel stud Click to enlarge Pressing the stud from the hub HOW TO USE THIS BOOK 850 INSPECTION ...

Page 838: ...ke rotor in the press so that the rotor is supported on the wheel mounting flange Be sure to allow enough clearance for the stud to pass through the hole 8 Do not apply ram pressure directly to the rotor surface Using the proper press stock press the lug stud in position until the stud is flush against the inner surface of the disc brake rotor hub 9 Install the disc brake rotor Reposition the brak...

Page 839: ...lange 8 Remove the lug nut and washers 9 Install the brake rotor bracket and caliper 10 Install the wheel and snug all of the lug nuts 11 Lower the vehicle then tighten the wheel lug nuts to specification 12 INSPECTION Replace wheels if they are bent cracked leaking air or heavily rusted or if the lug nuts often become loose Do not use bent wheels that have been straightened or do not use inner tu...

Page 840: ...ead the wheel lug nut with the flat washer side against the washers 3 Tighten the wheel nut until the stud head seats against the back side of the hub Do not use air tools as the serrations may be stripped from the stud 4 Remove the wheel lug nut and washers 5 Except on Mountaineer and 1991 99 Explorer install the brake drum 6 On Mountaineer and 1991 99 Explorer install the rear disc brake rotor b...

Page 841: ...2 WHEEL DRIVE FRONT SUSPENSION Introduction View of the 2WD front suspension except Mountaineer 1995 99 Explorer and 1992 99 Ranger Click to enlarge 2 WHEEL DRIVE FRONT SUSPENSION 855 ...

Page 842: ...n which utilizes coil springs to support the vehicle and radius rods to locate the I beam Mountaineer 1995 99 Explorer and 1992 99 Ranger models use unequal length control arms Short Long Arm SLA which utilize torsion bars to support the vehicle Coil Springs All models except the Mountaineer 1115 11 Explorer and 1118 11 Ranger use coil springs REMOVAL INSTALLATION HOW TO USE THIS BOOK 856 Introduc...

Page 843: ...for removal and installation of the spring the disc brake caliper must be removed from the spindle A Strut Spring Compressor T81P 5310 A or equivalent may be used to compress the spring sufficiently so that the caliper does not have to be removed After removal the caliper must be placed on the frame or otherwise supported to prevent suspending the caliper from the caliper hose These precautions ar...

Page 844: ...seat is cleared 5 Remove the spring from the vehicle 6 To install If removed install the bolt in the axle arm and install the nut all the way down Install the spring lower seat and lower insulator On the 1111 14 Explorer also install the stabilizer bar mounting bracket and spring spacer 7 With the axle in the lowest position install the top of the spring in the upper seat Rotate the spring into po...

Page 845: ...kstands so as to support the frame of the vehicle Do not position the jackstands under the lower control arms and do not use car ramps The lower control arms must be free to hang unhindered 1 Remove the torsion bar protector skid plate from the frame 2 Remove the torsion bar adjuster bolt from the support nut Count the number of turns required to remove the bolt and record it for installation 3 Us...

Page 846: ...pport nut and remove the tool 11 Lubricate the tip of the adjuster bolt and start it into the support nut 12 Tighten the adjuster the same number of turns you recorded earlier then rotate two additional turns 13 Install the torsion bar protector skid plate Tighten the bolts securely 14 Lower the vehicle and check the ride height adjustment 15 RIDE HEIGHT ADJUSTMENT To perform the ride height check...

Page 847: ...r bolt Recheck the ride height 9 To decrease the ride height raise the vehicle and loosen the torsion bar adjuster bolt Recheck the ride height 10 Once proper ride height is established raise and support the vehicle 11 If equipped with ARC suspension connect the front and rear air lines at the shocks 12 Remove the slip plates from under the wheels 13 Lower the vehicle 14 Shock Absorbers REMOVAL IN...

Page 848: ...ng the shock absorber to the lower mounting stud on the radius arm 1 Slide the lower shock absorber end off of the stud 2 Remove the nut washer and insulator from the upper shock absorber mount at the frame bracket and remove the shock absorber 3 A second wrench may be needed to hold the shock absorber from turning while removing the upper attaching nut HOW TO USE THIS BOOK 862 REMOVAL INSTALLATIO...

Page 849: ...osely 5 Position the shock absorber to the lower mounting stud and install the attaching nut loosely 6 Tighten the lower shock attaching bolts to 39 53 ft lbs 53 72 Nm and the upper shock attaching bolts to 25 34 ft lbs 34 46 Nm 7 Mountaineer 1995 99 Explorer and 1998 99 Ranger Exploded view of the Mountaineer 1995 99 Explorer and 1998 99 Ranger front shock absorber Click to enlarge HOW TO USE THI...

Page 850: ...he vehicle was alternately trying to leap off the ground and to pound itself into the pavement Countrary to popular rumor the shocks do not affect the ride height of the vehicle This is controlled by other suspension components such as springs and tires Worn shock absorbers can affect handling if the front of the vehicle is rising or falling excessively the footprint of the tires changes on the pa...

Page 851: ...e the lower spindle arm and the lower part of the axle jaw 3 A 1 32 in 0 8mm or greater movement between the lower part of the axle jaw and the lower spindle arm indicates that the lower ball joint must be replaced 4 To check the upper ball joints while the wheel is being moved observe the upper spindle arm and the upper part of the axle jaw 5 A 1 32 in 0 8mm or greater movement between the upper ...

Page 852: ... INSTALLATION Except Mountaineer 1995 99 Explorer and 1998 99 Ranger 2WD ball joint removal except Mountaineer 1995 99 Explorer and 1998 99 Ranger Click to enlarge HOW TO USE THIS BOOK 866 REMOVAL INSTALLATION ...

Page 853: ...4635 C forcing screw D79T 3010 AE and ball joint remover T83T 3050 A or equivalent on the lower ball joint 3 Turn forcing screw clockwise until the lower ball joint is removed from the steering knuckle 4 Repeat the previous steps for the upper ball joint 5 Always remove the lower ball joint first To install Clean the steering knuckle bore and insert lower ball joint in knuckle as straight as possi...

Page 854: ...untaineer 295 99 Explorer and 298 99 Ranger 291 94 Explorer spindle removal Ranger similar Click to enlarge Raise the front of the vehicle and install jackstands 1 Remove the wheel and tire assembly 2 Remove the caliper assembly from the rotor and hold it out of the way with wire 3 Remove the dust cap cotter pin nut nut retainer washer and outer bearing and remove the rotor from the spindle 4 Remo...

Page 855: ...ll joint If camber adjustment is necessary special adapters must be installed 15 Tighten the lower ball joint stud to 104 146 ft lbs 141 28 Nm for 291 94 models and 89 133 ft lbs 120 10 Nm for 295 99 models Continue tightening the castellated nut until it lines up with the hole in the ball joint stud Install the cotter pin Install the dust shield 16 If removed install the front wheel ABS sensor an...

Page 856: ...ining the tie rod end to the steering knuckle 5 Disconnect the tie rod end from the steering knuckle using a jawed puller such as Pitman Arm Puller T64P 3590 F or equivalent 6 If equipped unbolt the front wheel ABS sensor and wire harness from the steering knuckle 7 Unload the torsion bar Follow the torsion bar removal procedures but do not remove the bar 8 Support the lower control arm with a jac...

Page 857: ...ng nut to the lower ball joint stud and tighten to 84 113 ft lbs 113 153 Nm Install the cotter pin advancing tightening the nut as needed Never loosen the ball joint nut in order to install the cotter pin 17 Connect the tie rod end to the steering knuckle and install the retaining nut Tighten to 57 77 ft lbs 77 104 Nm and install the cotter pin advancing tightening the nut as needed Never loosen t...

Page 858: ...herwise supported to prevent suspending the caliper from the caliper hose These precautions are absolutely necessary to prevent serious damage to the tube portion of the caliper hose assembly Disconnect the lower end of the shock absorber from the shock lower bracket bolt and nut 2 Remove the front spring Loosen the axle pivot bolt 3 Remove the spring lower seat from the radius arm and then remove...

Page 859: ...the seat goes over the arm to axle bolt 11 Install the front spring 12 Connect the lower end of the shock absorber to the stud on the radius arm with the retaining nut and tighten to specifications 13 Stabilizer Bar REMOVAL INSTALLATION Ranger As required raise and support the vehicle safely 1 Remove the nuts and bolts retaining the stabilizer bar to the end links 2 Remove the retainers and the st...

Page 860: ...bly 3 Remove the stabilizer bar from the vehicle 4 To install Place stabilizer bar in position on the frame mounting brackets 5 Install retainers and tighten retainer bolt to 35 50 ft lbs 47 67 Nm If removed install the stabilizer bar link assembly to the stabilizer bar Install the nut and washer and tighten to 30 41 ft lbs 40 55 Nm 6 Position the stabilizer bar link in the I beam mounting bracket...

Page 861: ...le If necessary remove the mounting brackets and insulators from the bar 5 To install Inspect all of the stabilizer bar mounting and end link bushings Replace any that are cracked squashed swollen or damaged 6 Position the stabilizer bar mounting brackets to the frame and install the retaining bolts loosely 7 Install the end link assembly to the bar end and the lower control arm Install the end li...

Page 862: ...he radius arm to the I Beam front axle 2 Remove the axle to frame pivot bracket bolt and nut 3 To install Position the axle to the frame pivot bracket and install the bolt and nut finger tight 4 Position the opposite end of the axle to the radius arm install the attaching bolt from underneath through the bracket the radius arm and the axle Install the nut and tighten to 188 254 ft lbs 255 345 Nm 5...

Page 863: ...the axle pivot bolt and nut Tighten the axle to frame pivot bracket bolt to 111 148 ft lbs 150 200 Nm 8 Install the front wheel spindle 9 Upper Control Arm Only the Mountaineer 1995 99 Explorer and 1998 99 Ranger models have control arms REMOVAL INSTALLATION HOW TO USE THIS BOOK REMOVAL INSTALLATION 877 ...

Page 864: ...ional shop Position the steering wheel to the on center position Loosen the wheel lug nuts 1 Raise and safely support the vehicle Position the jack stands under the lower control arms 2 Remove the wheel lug nuts and wheel 3 Before removing the steering knuckle to upper ball joint retaining pinch bolt secure the steering knuckle from tilting HOW TO USE THIS BOOK 878 REMOVAL INSTALLATION ...

Page 865: ...ts 2 Pull the control arm from the vehicle frame 3 7 To install For right side control arm if removed install the ball joint assembly and retaining nuts to the control arm and tighten the nuts to 95 128 ft lbs 128 173 Nm 8 Install the control arm pivot points into the frame pockets 9 Install the cam bolts and nuts align the matchmarks and tighten the nuts to 84 113 ft lbs 113 153 Nm 10 Connect the...

Page 866: ...Arm Puller T64P 3590 F or equivalent 8 WARNING Fasten a support either out of a block of wood or wire wrapped around the frame and support the weight of the steering knuckle brake assembly Do not allow the steering knuckle brake assembly to hang from the upper ball joint as this may damage the joint Position a jack under the lower control arm then remove the lower ball joint retaining nut 9 Raise ...

Page 867: ...ower control arm to frame bolts must be tightened with the weight of the vehicle resting on the wheels If clearance permits allow the vehicle to sit on the ground while tightening the bolts If necessary raise the vehicle again and position either car ramps under the wheels or jackstands on the lower control arms as close to the wheels as possible 23 Tighten the control arm to frame bolts to 111 14...

Page 868: ...Remove the nut and washer from the spindle then remove the outer bearing HOW TO USE THIS BOOK 882 REMOVAL INSTALLATION ...

Page 869: ...he grease seal Remove the inner bearing cone and roller assembly from the hub 5 Clean the inner and outer bearing assemblies in solvent Inspect the bearings and the cones for wear and damage Replace defective parts as required 6 Use a small prytool to remove the old seal HOW TO USE THIS BOOK REMOVAL INSTALLATION 883 ...

Page 870: ...or equivalent and replace the cups Be sure to seat the cups properly in the hub 9 Use a bearing packer tool and properly repack the wheel bearings with the proper grade and type grease If a bearing packer is not available work as much of the grease as possible between the rollers and cages Also grease the cone surfaces 10 Thoroughly pack the bearing with fresh high temperature wheel bearing grease...

Page 871: ...ler assembly and flatwasher on the spindle Install the adjusting nut Adjust the wheel bearings 14 Install the retainer a new cotter pin and the grease cap Install the caliper 15 Lower the vehicle and tighten the lug nuts to 100 ft lbs Before driving the vehicle pump the brake pedal several times to restore normal brake pedal travel 16 CAUTION Retighten the wheel lug nuts to specification after abo...

Page 872: ...oe linings by rocking the entire wheel assembly in and out several times in order to push the caliper and brake pads away from the rotor An alternate method to obtain proper running clearance is to tap lightly on the caliper housing Be sure not to tap on any other area that may damage the disc brake rotor or the brake lining surfaces Do not pry on the phenolic caliper piston The running clearance ...

Page 873: ...or steering components accident damage or even unmatched tires If any worn or damaged components are found they must be replaced before the wheels can be properly aligned Wheel alignment requires very expensive equipment and involves minute adjustments which must be accurate it should only be performed by a trained technician Take your vehicle to a properly equipped shop Following is a description...

Page 874: ...r compromises straight line stability increases bump steer and torque steer Camber influences tire contact with the road Click to enlarge TOE Looking down at the wheels from above the vehicle toe angle is the distance between the front of the wheels relative to the distance between the back of the wheels If the wheels are closer at the front they are said to be toed in or to have negative toe A sm...

Page 875: ...With toe in the distance between the wheels is closer at the front than at the rear Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK TOE 889 ...

Page 876: ...4 WHEEL DRIVE FRONT SUSPENSION Introduction Front Suspension Component Locations Click to enlarge 4 WHEEL DRIVE FRONT SUSPENSION 891 ...

Page 877: ... suspension except Mountaineer 1995 99 Explorer and 1998 99 Ranger Click to enlarge Exploded view of the 4WD Mountaineer 1995 99 Explorer and 1998 99 Ranger front suspension HOW TO USE THIS BOOK 892 Introduction ...

Page 878: ...enlarge Raise the vehicle and install jackstands under the frame Position a jack beneath the spring under the axle Raise the jack and compress the spring 1 Remove the nut retaining the shock absorber to the radius arm Slide the shock out from the stud 2 Remove the nut that retains the spring to the axle and radius arm Remove the retainer 3 HOW TO USE THIS BOOK Coil Springs 893 ...

Page 879: ... the caliper from the brake line hose These precautions are absolutely necessary to prevent serious damage to the tube portion of the caliper hose assembly If required remove the stud from the axle assembly 6 To install If removed install the stud on the axle and torque to 190 230 ft lbs Install the lower seat and spacer over the stud 7 Place the spring in position and slowly raise the front axle ...

Page 880: ...time the torsion bar or its adjuster is removed the vehicle ride height must be checked Raise and safely support the front of the vehicle Place the jackstands so as to support the frame of the vehicle Do not position the jackstands under the lower control arms and do not use car ramps The lower control arms must be free to hang unhindered 1 Remove the torsion bar protector skid plate from the fram...

Page 881: ...Use Torsion Bar Tool T95T 520 A or equivalent to raise the adjuster lever 10 Install the support nut and remove the tool 11 Lubricate the tip of the adjuster bolt and start it into the support nut 12 Tighten the adjuster the same number of turns you recorded earlier then rotate two additional turns 13 Install the torsion bar protector skid plate Tighten the bolts securely 14 Lower the vehicle and ...

Page 882: ...uld be 4 33 4 56 in 110 116mm 7 For vehicles with ARC suspension ride height should be 3 26 3 50 in 83 89mm 8 To increase the ride height raise the vehicle and tighten the torsion bar adjuster bolt Recheck the ride height 9 To decrease the ride height raise the vehicle and loosen the torsion bar adjuster bolt Recheck the ride height 10 Once proper ride height is established raise and support the v...

Page 883: ...er mounting stud on the radius arm 1 Slide the lower shock absorber end off of the stud 2 Remove the nut washer and insulator from the upper shock absorber mount at the frame bracket and remove the shock absorber 3 A second wrench may be needed to hold the shock absorber from turning while removing the upper attaching nut HOW TO USE THIS BOOK 898 REMOVAL INSTALLATION ...

Page 884: ...emove the lower radius arm shock retaining nut then pull the lower shock mount from the stud Next unbolt the upper shock mount using a second wrench on the mount stud to keep it from spinning HOW TO USE THIS BOOK REMOVAL INSTALLATION 899 ...

Page 885: ... washer on the shock absorber rod and install the attaching nut loosely 5 Position the shock absorber to the lower mounting stud and install the attaching nut loosely 6 Tighten the lower shock attaching bolts to 39 53 ft lbs 53 72 Nm and the upper shock attaching bolts to 25 3 ft lbs 3 46 Nm 7 Mountaineer 1995 99 Explorer and 1998 99 Ranger WITHOUT AUTOMATIC RIDE CONTROL ARC HOW TO USE THIS BOOK 9...

Page 886: ...pper shock to frame attaching nut washer and insulator assembly 2 Remove the two lower shock to control arm attaching nuts 3 Slightly compress the shock absorber by hand and remove it from the vehicle 4 To install Position the lower washer and insulator on the shock absorber rod and position the shock absorber to the upper frame bracket mount 5 Position the upper insulator and washer on the shock ...

Page 887: ... 30 40 ft lbs 40 55 Nm 8 WITH AUTOMATIC RIDE CONTROL ARC Exploded view of the ARC suspension shock absorber Click to enlarge WARNING Always turn off the Automatic Ride Control ARC service switch before lifting the vehicle off of the ground Failure to do so could damage the ARC system components Refer to Section 1 for jacking procedures Place the vehicle in two wheel drive 1 HOW TO USE THIS BOOK 90...

Page 888: ...k absorber rod and position the shock absorber to the upper frame bracket mount 9 Position the upper insulator and washer on the shock absorber rod and install the attaching nut loosely 10 Position the lower shock absorber mounting studs into the control arm and install the attaching nuts loosely 11 Tighten the lower shock attaching nuts to 15 21 ft lbs 21 29 Nm and the upper shock attaching bolts...

Page 889: ...stalling the upper ball joint the lower ball joint must be installed first Failure to install the lower ball joint before the upper will result in a lack of clearance for the installation tool Remove the steering knuckle 1 Place knuckle in vise and remove snapring from bottom ball joint socket if so equipped 2 Assemble the C frame T74P 461 C forcing screw D79T 3010 AE and ball joint remover T83T 3...

Page 890: ... the tie rod nut and then remove the nut Tap on the tie rod stud to free it from the steering arm 8 Remove the upper ball joint cotter pin and nut Loosen the lower ball joint nut to the end of the stud 9 Strike the inside of the spindle near the upper and lower ball joints to break the spindle loose from the ball joint studs 10 Remove the camber adjuster sleeve If required use pitman arm puller T6...

Page 891: ... 6 WARNING Never reuse the wheel hub nut and washer This nut is a torque prevailing design and cannot be reused Remove the cotter pin and nut retaining the tie rod end to the steering knuckle 7 Disconnect the tie rod end from the steering knuckle using a jawed puller such as Pitman Arm Puller T64P 3590 F or equivalent 8 Unload the torsion bar Follow the torsion bar removal procedures but do not re...

Page 892: ...he ball joint nut in order to install the cotter pin 20 If removed install the ABS sensor to the wheel hub 21 Install the hub washer and nut then tighten to 157 213 ft lbs 212 288 Nm 22 Install the front disc brake splash shield rotor bracket and caliper 23 Install the wheel and snug all of the lug nuts 24 Reload the torsion bar pressure Refer to the torsion bar installation procedures Check and i...

Page 893: ... finger tight 6 Install the retainer and inner insulator on the radius arm stud and insert the stud through the radius arm rear bracket 7 Install the rear washer insulator and nut on the arm stud at the rear side of the arm rear bracket Tighten the nut to 80 120 ft lbs 8 Tighten the stud to 190 230 ft lbs Tighten the front bracket to axle bolts to 37 50 ft lbs and the lower bolt and washer to 190 ...

Page 894: ...e the end link to radius arm mounting bolts to remove the end links 1991 94 Explorer As required raise and support the vehicle safely 1 Remove the nuts and washer and disconnect the stabilizer link assembly from the front I beam axle 2 Remove the mounting bolts and remove the stabilizer bar retainers from the stabilizer bar assembly 3 HOW TO USE THIS BOOK REMOVAL INSTALLATION 909 ...

Page 895: ...to frame bolts 4 Remove the stabilizer bar from the vehicle If necessary remove the mounting brackets and insulators from the bar 5 To install Inspect all of the stabilizer bar mounting and end link bushings Replace any that are cracked squashed swollen or damaged 6 Position the stabilizer bar mounting brackets to the frame and install the retaining bolts loosely 7 Install the end link assembly to...

Page 896: ...ional shop Position the steering wheel to the on center position Loosen the wheel lug nuts 1 Raise and safely support the vehicle Position the jack stands under the lower control arms 2 Remove the wheel lug nuts and wheel 3 Before removing the steering knuckle to upper ball joint retaining pinch bolt secure the steering knuckle from tilting HOW TO USE THIS BOOK REMOVAL INSTALLATION 911 ...

Page 897: ...ts 2 Pull the control arm from the vehicle frame 3 7 To install For right side control arm if removed install the ball joint assembly and retaining nuts to the control arm and tighten the nuts to 95 128 ft lbs 128 173 Nm 8 Install the control arm pivot points into the frame pockets 9 Install the cam bolts and nuts align the matchmarks and tighten the nuts to 84 113 ft lbs 113 153 Nm 10 Connect the...

Page 898: ...Puller T64P 3590 F or equivalent 8 WARNING Fasten a support either out of a block of wood or wire wrapped around the frame and support the weight of the steering knuckle brake assembly Do not allow the steering knuckle brake assembly to hang from the upper ball joint as this may damage the joint Position a jack under the lower control arm then remove the lower ball joint retaining nut 9 Raise the ...

Page 899: ...he retaining nut in order to install the cotter pin 19 Install the shock absorber 20 Install the wheel and snug the lug nuts 21 Lower the vehicle and tighten the lug nuts to 100 ft lbs 135 Nm 22 The lower control arm to frame bolts must be tightened with the weight of the vehicle resting on the wheels If clearance permits allow the vehicle to sit on the ground while tightening the bolts If necessa...

Page 900: ...e using 4 prong spindle nut spanner wrench T86T 1197 A or equivalent Make sure the tabs on the tool engage the slots in the locknut 7 Remove the outer bearing cone and roller assembly from the hub Remove the hub and rotor from the spindle 8 Using seal removal tool 1175 AC or equivalent remove and discard the grease seal Remove the inner bearing cone and roller assembly from the hub 9 Clean the inn...

Page 901: ...ing removal and after the outer hub is removed wipe off any excess grease After the grease is wiped off remove the axle shaft snapring then pull the splined spacer from the axle shaft end HOW TO USE THIS BOOK 916 REMOVAL INSTALLATION ...

Page 902: ...Use a 4 pronged socket to loosen the outer wheel bearing locknut then remove the outer locknut Remove the lockwasher from behind the outer locknut HOW TO USE THIS BOOK REMOVAL INSTALLATION 917 ...

Page 903: ...washer engagement pin arrow While pushing inwards on the rotor hub assembly remove the outer wheel bearing then pull the rotor hub assembly from the spindle taking care not to scratch the bearing cups in the hub HOW TO USE THIS BOOK 918 REMOVAL INSTALLATION ...

Page 904: ...n the inner bearing cone and roller assembly in the inner cup A light film of grease should be included between the lips of the new grease seal 15 Install the grease seal by driving in place with hub seal replacer tool T83T 1175 B and Driver Handle T80T 900 W 16 Install the hub and rotor assembly onto the spindle Keep the hub centered on the spindle to prevent damage to the spindle and the retaine...

Page 905: ...e rotor hub assembly then using the correct seal installer drive the seal into the rotor hub until it is fully seated Ensure that the pin on the inner locknut engages one of the holes of the lock washer Click to enlarge HOW TO USE THIS BOOK 920 REMOVAL INSTALLATION ...

Page 906: ...acer then the snapring Click to enlarge WITH AUTOMATIC LOCKING HUBS Raise the vehicle and install jackstands 1 Remove the wheel and tire assembly 2 Remove the retainer washers from the lug nut studs and remove the automatic locking hub assembly from the spindle 3 HOW TO USE THIS BOOK REMOVAL INSTALLATION 921 ...

Page 907: ...sting nut 5 Use a magnet and remove the locking key from under the adjusting nut If required rotate the adjusting nut slightly to relieve pressure against the locking key 6 WARNING To prevent damage to the adjusting nut and spindle threads on vehicles equipped with automatic hubs look into the spindle keyway under the adjusting nut and remove the separate locking key before removing the adjusting ...

Page 908: ...perly in the hub 13 Use a bearing packer tool and properly repack the wheel bearings with the proper grade and type grease If a bearing packer is not available work as much of the grease as possible between the rollers and cages Also grease the cone surfaces 14 Position the inner bearing cone and roller assembly in the inner cup A light film of grease should be included between the lips of the new...

Page 909: ...When installing the outer hub cover align the cam pockets with the legs on the cover Click to enlarge Mountaineer 1995 99 Explorer and 1998 99 Ranger HOW TO USE THIS BOOK 924 REMOVAL INSTALLATION ...

Page 910: ... fit into the wheel hub and bearing a press is not normally required Ensure that the wheel hub shaft can be pushed inwards If not assemble a press to the front wheel studs and press the wheel hub shaft inwards slightly to break it loose 6 Remove the three wheel hub bearing to steering knuckle retaining bolts Remove the hub and bearing assembly 7 To install Install the ABS sensor to the wheel hub t...

Page 911: ...ole in the lockwasher 9 Install the outer wheel bearing locknut using 4 prong spindle nut spanner wrench tool T86T 1197 A or equivalent Tighten locknut to 150 ft lbs 10 Install the axle shaft spacer 11 Clip the snapring onto the end of the spindle 12 Install the manual hub assembly over the spindle Install the retainer washers 13 Install the wheel and tire assembly Install and torque lug nuts to s...

Page 912: ...key is damaged Install the two plastic thrust spacers and push or press the cam assembly onto the adjusting nut by lining up the keyway in the cam assembly with the separate locking key 12 WARNING Do not damage the locking key when installing the cam assembly Install the axle shaft spacer 13 Clip the snapring onto the end of the spindle 14 Install the manual hub assembly over the spindle Install t...

Page 913: ...REAR SUSPENSION Introduction Click to enlarge REAR SUSPENSION 929 ...

Page 914: ...Rear suspension Ranger top Explorer Mountaineer bottom Click to enlarge Leaf Springs REMOVAL INSTALLATION HOW TO USE THIS BOOK 930 Introduction ...

Page 915: ...iew of the Ranger U bolt and spring plate assembly Explorer Mountaineer similar Click to enlarge Exploded view of the spring to rear shackle assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 931 ...

Page 916: ... spring 3 Remove the shackle upper and lower nuts and bolts at the rear of the spring 4 Remove the spring and shackle assembly from the rear shackle bracket 5 To install Position the spring in the shackle Install the upper shackle spring bolt and nut with the bolt head facing outward 6 Position the front end of the spring in the bracket and install the bolt and nut 7 Position the shackle in the re...

Page 917: ...Without Automatic Ride Control ARC Rear shock absorber and related parts Ranger Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 933 ...

Page 918: ... bracket on the axle housing 2 Remove the retaining nut s from the upper shock absorber mounting 3 Remove the shock absorber from the vehicle 4 Installation is the reverse of the removal procedure Torque the lower shock absorber retaining bolt to 39 53 ft lbs 5 On the Ranger torque the upper shock absorber mounting nut to 39 53 ft lbs On the Explorer Mountaineer torque the upper shock absorber ret...

Page 919: ... the lower shock mounting from the drive axle then pull the lower shock mount from its bracket Finally unbolt the upper shock mount and remove the shock from the vehicle With Automatic Ride Control ARC HOW TO USE THIS BOOK REMOVAL INSTALLATION 935 ...

Page 920: ...bsorber mounting nut and bolt assembly and swing the shock out of the bracket 6 Remove the two upper shock attaching nuts from the top of the crossmember then remove the shock 7 Installation is the reverse of the removal procedure Tighten the upper attaching nuts to 15 21 ft lbs 21 29 Nm and the lower attaching bolt to 39 53 ft lbs 53 72 Nm 8 TESTING Visually check the shock absorbers for the pres...

Page 921: ...o enlarge WARNING If equipped always turn off the Automatic Ride Control ARC service switch before lifting the vehicle off of the ground Failure to do so could damage the ARC system components Refer to Section 1 for jacking procedures As required raise and support the vehicle 1 HOW TO USE THIS BOOK Stabilizer Bar 937 ...

Page 922: ... the axle with the brackets having the UPmarking in the proper position 4 Install the stabilizer bar and retainers on the mounting brackets with the retainers having the UPmarking in the proper position 5 Connect the stabilizer bar to the rear links Install the nuts bolts and washers and tighten 6 Tighten the mounting bracket U bolt nuts to 30 42 ft lbs 7 Chilton Automotive Information Systems 200...

Page 923: ...onnectors 4 Remove the steering wheel pad Loosen the bolt 2 or 3 turns from the steering shaft 5 CAUTION Tilt columns have a compression spring under the steering wheel that can unexpectantly pop up the steering wheel if the bolt is removed completely Using the proper steering wheel removal tool loosen the steering wheel on the steering column 6 WARNING Do not hammer on the steering wheel or the s...

Page 924: ...Next lift up and turn over the horn pad then disconnect the horn pad electrical plug from the column HOW TO USE THIS BOOK 940 REMOVAL INSTALLATION ...

Page 925: ...e steering wheel to shaft retaining bolt a couple of turns then assemble a puller to the wheel and loosen the wheel from the shaft Finally remove the retaining bolt HOW TO USE THIS BOOK REMOVAL INSTALLATION 941 ...

Page 926: ...nstalling the lock bolt Torque the steering wheel lock bolt to 23 33 ft lbs 31 45 Nm 8 1995 99 Models CAUTION Whenever working on a vehicle equipped with an air bag always refer to Section 6 for disarming procedures Follow the procedures outlined or severe injury or even death may occur The manufacturer recommends installing the steering wheel using a new wheel to shaft retaining bolt Before begin...

Page 927: ...the drivers side air bag module screws on the sides of the steering wheel 2 Remove the two air bag module retaining screws and carefully lift the module away from the steering wheel 3 Disconnect the air bag electrical harness plug at the sliding contact Also unplug the horn and if equipped cruise control wire harness connectors 4 HOW TO USE THIS BOOK REMOVAL INSTALLATION 943 ...

Page 928: ...an unexpectantly pop up the steering wheel if the bolt is removed completely Loosen but do not remove the steering wheel retaining bolt approximately 2 to 3 turns 6 Using the proper steering wheel removal tool loosen the steering wheel on the steering column 7 WARNING Do not hammer on the steering wheel or the steering shaft or use a knock off type steering wheel puller as damage to the steering c...

Page 929: ...r bag module and connect all of the wire harness plugs to it 14 Carefully install the module to the wheel and loosely install the side retaining bolts 15 Hold the module in position while tightening the retaining bolts to 67 92 inch lbs 7 6 10 4 Nm 16 Install the two cover plugs by snapping them into the holes on the side of the steering wheel 17 Arm the air bag system by following the procedures ...

Page 930: ...e screw from the column casting and the plastic plug at the end of the cable 7 Remove the 2 self tapping screws that retain the combination switch to the steering column casting Disengage the switch from the casting 8 Disconnect the 3 electrical connectors using caution not to damage the locking tabs Be sure not to damage the PRNDL cable 9 Installation is the reverse of the removal procedure Torqu...

Page 931: ...itions Position the ignition switch on the column studs and over the actuating rod Torque the retaining nuts to 40 64 inch lbs 4 5 7 2 Nm 9 Remove the wire from the slot in the housing Continue the installation in the reverse order of the removal procedure 10 Ignition Lock Cylinder Assembly REMOVAL INSTALLATION Disconnect the negative battery cable Remove the steering wheel 1 On vehicles equipped ...

Page 932: ...uivalent 8 To install the lock cylinder turn the lock cylinder to the ONposition depress the retaining pin Insert the lock cylinder housing into its housing in the flange casting Be sure that the tab at the end of the cylinder aligns with the slot in the ignition drive gear 9 Turn the key to the OFFposition This action will permit the cylinder retaining pin to extend into the cylinder casting hous...

Page 933: ...rmediate shaft until it is clear of the steering column shaft 4 Remove the nuts from the studs and remove the shift cable bracket from the steering column bracket if the vehicle is equipped with automatic transmission 5 If the vehicle is equipped with automatic transmission disconnect the shift cable from the column lever Remove the steering wheel 6 If the vehicle is equipped with tilt wheel be su...

Page 934: ...e horn brush connector to the column Remove the connector 16 Remove the 5 screws that hold the toe plate to the dash panel Loosen the toe plate clamp bolt 17 Support the steering column assembly Remove the bolts that hold the breakaway bracket to the pedal support bracket 18 Pry apart the locking tabs and disconnect the ignition switch wiring harness Carefully remove the steering from the vehicle ...

Page 935: ...r Remove the pitman arm from the steering gear sector shaft using tool T64P 3590 F or equivalent 4 To install Installation is the reverse of the removal procedure Torque the pitman arm attaching washer and nut to 170 228 ft lbs 230 310 Nm Torque the drag link ball stud nut to 51 73 ft lbs 70 100 Nm and install a new cotter pin 5 Check and adjust front end alignment as required 6 TIE ROD Raise and ...

Page 936: ...takes to remove the tie rod from the tie rod adjusting sleeve Remove the tie rod from the vehicle 3 To remove the tie rod end first remove the cotter pin and discard it A new pin will be used for installation Loosen and remove the tie rod end retaining nut HOW TO USE THIS BOOK 952 REMOVAL INSTALLATION ...

Page 937: ... then using a jawed puller loosen the tie rod stud to steering knuckle connection Loosen the tie rod sleeve clamp bolts HOW TO USE THIS BOOK REMOVAL INSTALLATION 953 ...

Page 938: ... sleeve To install Install the tie rod in the tie rod sleeve in the same number of turns it took to remove it Torque the tie rod adjusting sleeve nuts to 30 42 ft lbs 40 57 Nm 4 Be sure that the adjusting sleeve clamps are pointed down 45 Tighten the tie rod ball stud to drag link retaining bolt to 51 73 ft lbs 70 100 Nm Install a new cotter pin 5 HOW TO USE THIS BOOK 954 REMOVAL INSTALLATION ...

Page 939: ...de Control ARC service switch before lifting the vehicle off of the ground Failure to do so could damage the ARC system components Refer to Section 1 for jacking procedures OUTER TIE ROD END Position the front wheels in the straight ahead position 1 Raise and safely support the vehicle as necessary 2 Remove and discard the outer tie rod end retaining nut cotter pin 3 Remove the nut and install a p...

Page 940: ...ngage an adjustable wrench to it 8 WARNING The torque required to break the inner tie rod loose could exceed 100 ft lbs 136 Nm If this force is reacted against the pinion teeth sufficient damage may be incurred to affect the smoothness of operation Use a large wrench on the inner tie rod socket flats and an adjustable wrench on the rack teeth flats and remove the tie rod 9 To install Install the i...

Page 941: ...tal turns 7 Using the inch pound torque wrench rotate the steering wheel 90 to either side of center noting the highest torque reading over center The meshload should be 4 10 inch lbs or at least 2 inch lbs more than the preload figure 8 ADJUSTMENT Remove the steering gear from the vehicle 1 Torque the sector cover bolts on the gear to 32 40 ft lbs 2 Loosen the preload adjuster nut and tighten the...

Page 942: ...ains the flex coupling to the steering gear 2 Remove the steering gear input shaft shield 3 Remove the nut and washer that secures the pitman arm to the sector shaft Remove the pitman arm using pitman arm puller tool T64P 3590 F or equivalent Do not hammer on the end of the puller as this can damage the steering gear 4 Remove the bolts and washers that attach the steering gear to the side rail Rem...

Page 943: ...l from stop to stop several times to discharge the fluid from the gear Discard the used fluid 4 Turn the steering gear 45 from the right stop 5 Remove the steering wheel hub cover Attach an inch lb torque wrench to the steering wheel nut and determine the torque required to rotate the shaft slowly about 1 8 turn from the 45 position toward center 6 Turn the steering wheel back to center and determ...

Page 944: ...he upper U joint shield into place on the steering shaft assembly 7 Slide the flex coupling into place on the steering shaft assembly Turn the steering wheel so that the spokes are in the horizontal position Center the steering gear input shaft 8 Slide the steering gear input shaft into the flex coupling and into place on the frame side rail Install the attaching bolts and tighten to 50 62 ft lbs ...

Page 945: ...rotations by two This gives the number of rotations to achieve true center of the steering Turn the wheel in one direction to the full lock 3 Turn the wheel in the opposite direction the number of turns equal to true steering lock to lock number divided by two 4 WARNING Do not rotate the steering wheel when the shaft is disconnected from the steering gear as damage to the clock spring could occur ...

Page 946: ...g gear housing 7 Plug the ends of the lines and the fitting in the rack to avoid dirt contamination 8 Remove the two nuts securing the power steering cooler and remove the cooler 9 Remove the outer tie rod ends 10 Remove the two nuts bolts and washer assemblies retaining the steering gear housing to the front crossmember 11 To install HOW TO USE THIS BOOK 962 REMOVAL INSTALLATION ...

Page 947: ...ated then connect the two 16 Install the intermediate shaft to steering input shaft retaining pinch bolt and tighten to 30 42 ft lbs 41 56 Nm 17 Lower the vehicle and refill the power steering pump reservoir 18 Bleed the air from the power steering system Follow the procedures in this Section 19 Ensure that there are no leaks and the fluid is maintained at the proper level 20 Have the alignment ch...

Page 948: ...Exploded view of the power steering pump used on the 3 0L engine Click to enlarge HOW TO USE THIS BOOK 964 REMOVAL INSTALLATION ...

Page 949: ...L and 3 0L engines loosen the idler pulley assembly pivot and adjusting bolts to slacken the belt tension 4 On the 2 9L engine loosen the adjusting nut and the slider bolts on the pump support to slacken belt tension 5 On the 4 0L engine slacken belt tension by lifting the tensioner pulley in a clockwise direction Remove the drive belt from under the tensioner pulley and slowly lower the pulley to...

Page 950: ...allation in the reverse order of the removal procedure Adjust the belt tension to specification 13 On the 2 3L 2 5L and 3 0L engines torque the idler pivot pulley bolts 30 40 ft lbs for the 2 3L 2 5L engine and 35 47 ft lbs for the 3 0L engine 14 On the 2 9L engine torque the slider bolts to 35 47 ft lbs 15 On the 4 0L while lifting the tensioner pulley in a clockwise direction slide the belt unde...

Page 951: ...d 4 To aid in the assembly of the new plastic seal washer a tapered shaft may be required to stretch the washer so that it may be slipped over the tube nut threads 5 If the rubber O ring is damaged it cannot be serviced and the hose assembly will have to be replaced 6 Connect the tube nut and torque to 30 40 ft lbs 7 CAUTION The quick connect fitting may disengage if not fully assembled if the sna...

Page 952: ...SPECIFICATION CHARTS Torque Specifications Click to enlarge SPECIFICATION CHARTS 969 ...

Page 953: ...part of the calipers At least one cylinder in each caliper is used to force the brake pads against the disc All pistons employ some type of seal usually made of rubber to minimize fluid leakage A rubber dust boot seals the outer end of the cylinder against dust and dirt The boot fits around the outer end of the piston on disc brake calipers and around the brake actuating rod on wheel cylinders The...

Page 954: ...el cylinder bleeder screws If this does not cause the light to go on substitute a new lamp make continuity checks and finally replace the switch as necessary The hydraulic system may be checked for leaks by applying pressure to the pedal gradually and steadily If the pedal sinks very slowly to the floor the system has a leak This is not to be confused with a springy or spongy feel due to the compr...

Page 955: ...ops of the shoes are then forced against the inner side of the drum This action forces the bottoms of the two shoes to contact the brake drum by rotating the entire assembly slightly known as servo action When pressure within the wheel cylinder is relaxed return springs pull the shoes back away from the drum Most modern drum brakes are designed to self adjust themselves during application when the...

Page 956: ...the pedal and directly over under the pin 3 Slide the switch up or down trapping the master cylinder pushrod and bushing between the switch side plates 4 Push the switch and pushrod assembly firmly towards the brake pedal arm Assemble the outside white plastic washer to the pin and install the hairpin retainer 5 Don t substitute any other type of retainer Use only the Ford specified hairpin retain...

Page 957: ...cylinder and the HCU unit If the tools are not available you can still perform the procedure However you will need to tow the vehicle to a professional garage capable of bleeding the ABS system With the engine turned off push the brake pedal down to expel vacuum from the brake booster system 1 Disconnect the brake fluid level sensor wire from the reservoir 2 Disconnect the hydraulic lines use corr...

Page 958: ... master cylinder first disconnect the fluid level sensor wire Next loosen the fluid line fittings at the master cylinder with a flarenut wrench then disconnect the lines HOW TO USE THIS BOOK 976 REMOVAL INSTALLATION ...

Page 959: ...If equipped remove any bracket retaining nuts and pull the bracket from the mounting stud Remove the master cylinder to power booster attaching bolts HOW TO USE THIS BOOK REMOVAL INSTALLATION 977 ...

Page 960: ...ster cylinder before installing it to the vehicle Mount the master cylinder into a vise or suitable equivalent do not damage the cylinder Fill the cylinder to the correct level with the specified fluid Block off all the outer brake line holes but one then using a long tool such as rod position it in the cylinder to actuate the brake master cylinder Pump push tool in and out the brake master cylind...

Page 961: ...Booster pushrod gauge adjustment procedure Click to enlarge Cutaway view of the vacuum assisted power brake booster assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 979 ...

Page 962: ...Booster mounting Click to enlarge HOW TO USE THIS BOOK 980 REMOVAL INSTALLATION ...

Page 963: ...Booster vacuum hose connections for the 2 3L 2 9L engines 0L engine similar to 2 9L engine Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 981 ...

Page 964: ...t the booster assembly on the engine side of the dash panel by sliding the bracket mounting bolts and valve operating rod in through the holes in the dash panel 8 Make certain that the booster push rod is positioned on the correct side of the master cylinder to install onto the push pin prior to tightening the booster assembly to the dash From inside the cab install the booster mounting bracket to...

Page 965: ...efore disassembly use a stiff bristle brush and clean brake fluid be sure to plug the lines and ports as soon as they are opened New lines and hoses should be flushed clean with brake fluid before installation to remove any contamination REMOVAL INSTALLATION Disconnect the negative battery cable 1 Raise and safely support the vehicle on jackstands 2 Remove any wheel and tire assemblies necessary f...

Page 966: ...ging the fitting 7 Disconnect any retaining clips or brackets holding the line and remove the line from the vehicle 8 If the brake system is to remain open for more time than it takes to swap lines tape or plug each remaining clip and port to keep contaminants out and fluid in Any gaskets crush washers should be replaced with new ones during installation HOW TO USE THIS BOOK 984 REMOVAL INSTALLATI...

Page 967: ...rly bleed the brake system 13 Connect the negative battery cable 14 Bleeding The Brakes WARNING Vehicles with 4 wheel anti lock brakes require an Anti lock Brake Adapter T90P 50 ALA and Jumper T93T 50 ALA in order to bleed the master cylinder and the Hydraulic Control Unit HCU Failure to do so will trap air in the HCU unit eventually causing a spongy pedal The tools are not required for caliper or...

Page 968: ... cylinder fill cap remove the cap and fill the master cylinder with brake fluid until the level is within 1 4 in 6mm of the top edge of the reservoir 1 Clean off the bleeder screws at all 4 wheels The bleeder screws are located on the inside of the brake backing plate on the backside of the wheel cylinders and on the front brake calipers 2 Attach a length of rubber hose over the nozzle of the blee...

Page 969: ...g action to force any air out of the system When bubbles cease to appear at the end of the bleeder hose close the bleeder valve and remove the hose 5 Check the master cylinder fluid level and add fluid accordingly Do this after bleeding each wheel 6 Repeat the bleeding operation at the remaining 3 wheels ending with the one closet to the master cylinder Fill the master cylinder reservoir 7 Chilton...

Page 970: ...FRONT DISC BRAKES Introduction Exploded view of the 1991 94 front disc brake assembly 4 wheel ABS sensor not shown Click to enlarge FRONT DISC BRAKES 989 ...

Page 971: ...thickness recommended by the Ford Motor Co which is 1 32 in 0 1mm or at the minimum allowed by the applicable state or local motor vehicle inspection code Pad thickness may be checked by removing the wheel and looking through the inspection port in the caliper assembly REMOVAL INSTALLATION Single Piston Caliper CAUTION Always replace all disc pad assemblies on an axle Never service one wheel only ...

Page 972: ...tion between the bolt head and the caliper pin 1 Using a hacksaw or bolt cutter remove the bolt head from the bolt 2 Depress the tab on the bolt head end of the upper caliper pin with a screwdriver while tapping on the pin with a hammer Continue tapping until the tab is depressed by the V slot 3 Place one end of a punch 1 2 in 6mm or smaller against the end of the caliper pin and drive the caliper...

Page 973: ...ome fluid from the master cylinder Two styles of caliper pins used single tang pin is similar to the double tang Click to enlarge View of a caliper pin with the bolt head facing the outside of the caliper HOW TO USE THIS BOOK 992 REMOVAL INSTALLATION ...

Page 974: ...Use a hacksaw to remove the bolt head from the pin View of a caliper pin with the nut facing the outside of the caliper Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 993 ...

Page 975: ...r and punch and drive the caliper pin out from between the caliper and its mount When removing the pin you may need to depress the pin tab with a tool Click to enlarge HOW TO USE THIS BOOK 994 REMOVAL INSTALLATION ...

Page 976: ...Remove the anti rattle clips and remove the inner pad 10 Place the inner pads friction material against the caliper piston and assemble the C clamp to the caliper again Tighten the clamp until the caliper piston is fully seated into its bore 11 Slide the caliper assembly off of the rotor HOW TO USE THIS BOOK REMOVAL INSTALLATION 995 ...

Page 977: ...Holding the caliper as shown press down then slide the pad out to remove it from the caliper Click to enlarge Remove the outer brake pad from the caliper HOW TO USE THIS BOOK 996 REMOVAL INSTALLATION ...

Page 978: ...essary support the caliper by a length of wire from the frame Never let it hang by the hose Finally remove the inner brake pad from the steering knuckle assembly HOW TO USE THIS BOOK REMOVAL INSTALLATION 997 ...

Page 979: ...he inner pad s friction material against the caliper piston and press it in with a C clamp Ensure that the anti rattle clip is installed as shown on the inner pad HOW TO USE THIS BOOK 998 REMOVAL INSTALLATION ...

Page 980: ...orrectly installed outer pad Click to enlarge Install the upper caliper pin with the tang facing up tangs are installed facing down on the bottom pin Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 999 ...

Page 981: ...ns ensure that the tangs are free to contact either side of the caliper mount Click to enlarge To install Place a new anti rattle clip on the lower end of the inner pad Be sure the tabs on the clip are positioned properly and the clip is fully seated 1 HOW TO USE THIS BOOK 1000 REMOVAL INSTALLATION ...

Page 982: ... be installed with the lead tang in first the bolt head facing outward if equipped and the pin positioned as shown Position the lead tang in the V slot mounting surface and drive in the caliper until the drive tang is flush with the caliper assembly Install the nut if equipped and tighten to 32 47 inch lbs 4 WARNING Never reuse caliper pins Always install new pins whenever a caliper is removed Ins...

Page 983: ...Exploded view of the 4x4 Ranger front brake caliper assembly 4x2 Ranger similar Click to enlarge HOW TO USE THIS BOOK 1002 REMOVAL INSTALLATION ...

Page 984: ...Exploded view of the 4x4 Explorer Mountaineer front brake caliper assembly 4x2 models similar Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1003 ...

Page 985: ...liper and tighten the clamp to bottom the caliper pistons in their bores Remove the clamp 4 Remove the two caliper slide pin bolts and lift the caliper from the anchor plate 5 Use care to retain as much of the original caliper slide pin grease as possible Position the caliper on a frame member or suspend it with some wire Do not allow the caliper to hang by the brake hose 6 Remove the brake pads a...

Page 986: ...ump the brake pedal until it feels firm Start the engine and apply the brakes several times to readjust the caliper pistons Ensure that the pedal feels firm before operating the vehicle 8 Calipers Exploded view of the single piston caliper Click to enlarge HOW TO USE THIS BOOK Calipers 1005 ...

Page 987: ...Cross sectional view of the dual piston caliper Click to enlarge REMOVAL INSTALLATION Follow the procedures for pad removal earlier in this section 1 HOW TO USE THIS BOOK 1006 REMOVAL INSTALLATION ...

Page 988: ...aching bolt 2 then remove it along with the hose fitting and the sealing washers Always discard the old sealing washers and use new ones when installing the caliper Discard the brass washers and plug the brake hose and caliper bolt hole 3 HOW TO USE THIS BOOK REMOVAL INSTALLATION 1007 ...

Page 989: ...tighten the bolt to 1 29 ft lbs 30 40 Nm 10 Bleed the brake system Check for leaks and proper operation before placing the vehicle into service 11 OVERHAUL Some vehicles may be equipped dual piston calipers The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons O rings and dust boots Remove the caliper from the vehicle and place on a clean workbench 1 ...

Page 990: ...your fingers clear Withdraw the piston from the caliper bore For the second method you must rotate the piston to retract it from the caliper 3 If equipped remove the anti rattle clip 4 Use a prytool to remove the caliper boot being careful not to scratch the housing bore 5 HOW TO USE THIS BOOK OVERHAUL 1009 ...

Page 991: ...ully pry around the edge of the boot then remove the boot from the caliper housing taking care not to score or damage the bore Remove the piston seals from the groove in the caliper bore 6 HOW TO USE THIS BOOK 1010 OVERHAUL ...

Page 992: ...ir 10 To assemble Lubricate and install the bleeder valve and cap 11 Install the new seals into the caliper bore grooves making sure they are not twisted 12 Lubricate the piston bore 13 Install the pistons and boots into the bores of the calipers and push to the bottom of the bores 14 Use a suitable driving tool to seat the boots in the housing 15 Use the proper size driving tool and a mallet to p...

Page 993: ... Section 7 for models with manual and automatic locking hubs 7 New rotor assemblies come protected with an anti rust coating which should be removed with denatured alcohol or degreaser New hubs must be packed with EP wheel bearing grease Installation is the reverse of the removal procedure 8 1995 99 4 Wheel Drive Models Loosen the wheel lug nuts 1 Jack up the front of the vehicle and support on ja...

Page 994: ...d or grooved can be resurfaced by most automotive shops 1 Measure the rotor thickness using a caliper gauge 2 Minimum rotor thickness should be 0 81 in 20 5mm If refinishing exceeds that the rotor will have to be replaced 3 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK INSPECTION 1013 ...

Page 995: ...REAR DRUM BRAKES Introduction Click to enlarge REAR DRUM BRAKES 1015 ...

Page 996: ...Component locations on the left side 10 in brake assembly Click to enlarge HOW TO USE THIS BOOK 1016 Introduction ...

Page 997: ...been determined to be a cancer causing agent Never clean the brake surfaces with compressed air Avoid inhaling any dust from any brake surface When cleaning brake surfaces use a commercially available brake cleaning fluid Raise the vehicle so that the wheel to be worked on is clear of the floor and install jackstands under the vehicle 1 HOW TO USE THIS BOOK Brake Drums 1017 ...

Page 998: ... order to remove the brake drum This is because the drum might be grooved or worn from being in service for an extended period of time 2 then grasp hold of the drum and pull it from the axle flange and brake shoes Before installing a new brake drum be sure and remove any protective coating with carburetor degreaser 3 Install the brake drum in the reverse order of removal and adjusts the brakes 4 I...

Page 999: ...ed This is because after the outside wall of the brake drum reaches a certain thickness thinner than the original thickness the drum loses its ability to dissipate the heat created by the friction between the brake drum and the brake shoes when the brakes are applied Also the brake drum will have more tendency to warp and or crack The maximum braking surface diameter specification which is shown o...

Page 1000: ...over the ends of the wheel cylinder to prevent the pistons of the wheel cylinder from coming out causing loss of fluid 2 Contract the brake shoes by pulling the self adjusting lever away from the starwheel adjustment screw and turn the starwheel up and back until the pivot nut is drawn onto the starwheel as far as it will come 3 Clean the brake shoe assemblies with a liquid cleaning solution NEVER...

Page 1001: ...Do not attempt to pry the pivot hook from the hole 4 Remove the automatic adjuster spring and the adjusting lever 5 Remove the primary shoe to anchor spring with a brake tool Brake tools are very common and are available at auto parts stores Remove the secondary shoe to anchor spring and unhook the cable anchor Remove the anchor pin plate 6 Disconnect the adjuster lever return spring from the leve...

Page 1002: ... and remove the spring and the lever Next using a brake spring removal tool disconnect the primary brake shoe return spring from the anchor pin HOW TO USE THIS BOOK 1022 REMOVAL INSTALLATION ...

Page 1003: ...sing a pair of pliers grasp the washer type retainer on top of the hold down spring that corresponds to the pin that you are holding Push down on the pliers and turn them 90 to align the slot in the washer with the head on the spring mounting pin Remove the spring and washer retainer and repeat this operation on the hold down spring on the other shoe 8 Remove the parking brake link and spring Disc...

Page 1004: ...e adjuster screw assembly Press in the hold down springs while holding in on the nail from behind then turn the cup 90ß and release to remove the hold down spring Pull the nail out from the backing plate HOW TO USE THIS BOOK 1024 REMOVAL INSTALLATION ...

Page 1005: ...mary front brake shoe from the backing plate and the parking brake strut as well Remove the secondary shoe hold down pull the shoe out then press up on the cable spring HOW TO USE THIS BOOK REMOVAL INSTALLATION 1025 ...

Page 1006: ...le and install the brake shoes Lightly apply the proper grade of lubricant to the points shown on the backing plate Click to enlarge Assemble the parking brake lever to the secondary shoe and secure it with the spring washer and retaining clip 11 HOW TO USE THIS BOOK 1026 REMOVAL INSTALLATION ...

Page 1007: ... end of the adjusting screw is stamped with an R or an L for RIGHT or LEFT The adjusting pivot nuts can be distinguished by the number of lines machined around the body of the nut one line indicates left hand nut and 2 lines indicates a right hand nut Place the adjusting socket on the screw and install this assembly between the shoe ends with the adjusting screw nearest to the secondary shoe 19 Pl...

Page 1008: ...Exploded view of a typical brake adjuster assembly Click to enlarge The return spring and adjuster correctly installed HOW TO USE THIS BOOK 1028 REMOVAL INSTALLATION ...

Page 1009: ...ings If this is not the case replace the cable 24 Check the cable guide for damage The cable groove should be parallel to the shoe web and the body of the guide should lie flat against the web Replace the cable guide if this is not so 25 Check the pivot hook on the lever The hook surfaces should be square with the body on the lever for proper pivoting Repair or replace the hook as necessary 26 Mak...

Page 1010: ...Brake shoe adjustment gauge Step 1 Brake shoe adjustment gauge Step 2 HOW TO USE THIS BOOK 1030 ADJUSTMENTS ...

Page 1011: ... the adjusting screw using a Brake Shoe Adjustment Tool or equivalent inside the hole to expand the brake shoes until they drag against the brake drum and lock the drum 3 Insert a small screwdriver or piece of firm wire coat hanger wire into the adjusting slot and push the automatic adjusting lever out and free of the starwheel on the adjusting screw and hold it there 4 Engage the topmost tooth po...

Page 1012: ...the vehicle and make several stops while backing the vehicle to equalize the brakes at all of the wheels 7 Road test the vehicle PERFORM THE ROAD TEST ONLY WHEN THE BRAKES WILL APPLY AND THE VEHICLE CAN BE STOPPED SAFELY 8 Wheel Cylinders REMOVAL INSTALLATION To remove the wheel cylinder jack up the vehicle and remove the wheel hub and drum 1 Remove the brake shoe assemblies 2 Remove the brake sho...

Page 1013: ...em Always use clean new high quality brake fluid If dirty or improper fluid has been used it will be necessary to drain the entire system flush the system with proper brake fluid replace all rubber components then refill and bleed the system Remove the wheel cylinder from the vehicle and place on a clean workbench 1 First remove and discard the old rubber boots then withdraw the pistons Piston cyl...

Page 1014: ... can be used to remove the pistons and seals Remove the pistons cup seals and spring from the cylinder Wash the cylinder and metal parts in denatured alcohol or clean brake fluid 4 HOW TO USE THIS BOOK 1034 OVERHAUL ...

Page 1015: ...oline kerosene or paint thinner for cleaning purposes These solvents will swell rubber components and quickly deteriorate them Allow the parts to air dry or use compressed air Do not use rags for cleaning since lint will remain in the cylinder bore 5 Inspect the piston and replace it if it shows scratches 6 HOW TO USE THIS BOOK OVERHAUL 1035 ...

Page 1016: ...inder is ready for assembly Lubricate the cylinder bore and seals using clean brake fluid 7 Position the spring assembly 8 Install the inner seals then the pistons 9 Lubricate the cup seals with brake fluid HOW TO USE THIS BOOK 1036 OVERHAUL ...

Page 1017: ...l the spring then the cup seals in the bore Lightly lubricate the pistons then install them Insert the new boots into the counterbores by hand Do not lubricate the boots 10 HOW TO USE THIS BOOK OVERHAUL 1037 ...

Page 1018: ...The boots can now be installed over the wheel cylinder ends Install the wheel cylinder 11 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 1038 OVERHAUL ...

Page 1019: ...g agent Never clean the brake surfaces with compressed air Avoid inhaling any dust from any brake surface When cleaning brake surfaces use a commercially available brake cleaning fluid To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores remove or siphon part of the brake fluid out of the master cylinder reservoir connected to the front disc brakes Discard the...

Page 1020: ...caliper piston 12 Start one end of the outboard pad on the brake caliper and rotate it down until the locating lugs and the retainer spring are fully seated 13 Install new shoe slippers to the caliper mount 14 View of the caliper installed to the disc brake adapter Position the brake caliper over the rotor and align the sliding pin mounts 15 Install the caliper bolts and tighten them to 20 ft lbs ...

Page 1021: ...emove the wheel 3 Place an 8 in 203mm C clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores Remove the clamp 4 Remove the rear brake hose to caliper attaching bolt Discard the sealing washers 5 Remove the two caliper slide pin bolts 6 Use care to retain as much of the original caliper slide pin grease as possible Work the rear brake caliper off of the brake pads...

Page 1022: ...ve the adjuster plug from the back of the axle end then using a drum brake spoon adjust the parking brake shoes to release the rotor 4 Installation is the reverse of the removal procedure If necessary check the parking brake shoe adjustment 5 INSPECTION Inspect the rotor for cracks grooves or waviness Rotors that aren t too badly scored or grooved can be resurfaced by most automotive shops 1 Measu...

Page 1023: ...ted 5 in 127mm rearward of the No 1 crossmember on the inboard side of the LH frame rail 2 Speed Sensor and Exciter Ring located in the rear differential housing 3 Yellow REAR ANTI LOCK Warning Light located in the instrument cluster 4 RABS Diagnostic Connector 1991 96 located on the main wire bundle inside of cab under the dash slightly rearward driver side 5 RABS Diagnostic Connector 1997 locate...

Page 1024: ... RABS module performs system tests and self tests during startup and normal operation The valve sensor and fluid level circuits are monitored for proper operation If a fault is found the RABS will be deactivated and the REAR ANTI LOCK light will be lit until the ignition is turned OFF When the light is lit the diagnostic flashout code may be obtained Under normal operation the light will stay on f...

Page 1025: ...in the count to obtain the code number Example 3 short flashes and one long flash indicated Code No 4 The code will continue until the ignition is turned OFF Refer to the flashcode diagnosis charts for further instructions 3 Computer RABS Module REMOVAL INSTALLATION Remove any instrument panel covers to gain access to the module 1 Disconnect the wiring harness to the module 2 Remove the retaining ...

Page 1026: ...hould be between 0 8 and 1 4 k Ohms 2 If not replace the sensor 3 REMOVAL INSTALLATION Thoroughly clean the axle housing around the sensor 1 Disconnect the electrical harness plug from the sensor 2 To remove the rear wheel sensor first disconnect the electrical harness plug then remove the sensor to axle housing hold down bolt HOW TO USE THIS BOOK 1046 TESTING ...

Page 1027: ... flange hole with the threaded hole in the housing Torque the hold down bolt to 30 ft lbs If the old sensor is being installed clean it thoroughly and install a new O ring coated with clean engine oil 6 Exciter Ring The ring is located on the differential case inside the axle housing Once it is pressed off the case it cannot be reused This job should be left to a qualified service technician as it...

Page 1028: ... the fully depressed position 2 Grip the threaded rod to prevent it from spinning and tighten the equalizer nut 6 full turns past its original position on the threaded rod 3 Attach an appropriate cable tension gauge Rotunda Model 21 0018 or equivalent behind the equalizer assembly either toward the right or left rear drum assembly and measure cable tension Cable tension should be 40 600 lbs with t...

Page 1029: ...eased insert the pin into the brake control assembly as shown to lock the cable tension spring Method 1 Place the parking brake cable control in the released position 1 Have an assistant pull on the intermediate brake cable while you insert a 5 32 in 4mm diameter steel pin or drill bit into the hole provided in the parking brake control assembly 2 To release the cable tension pull out the lock pin...

Page 1030: ...control assembly mounting Click to enlarge In the event that one of the cables has broken or the cable tension release procedures were not followed perform the following procedures Remove the parking brake control assembly 1 HOW TO USE THIS BOOK ADJUSTMENT 1051 ...

Page 1031: ... control assembly is in the released position 3 Slip the front parking brake cable around the pulley and insert the cable end to the ratchet plate Click to enlarge Slip a spare front parking brake or remove you existing one cable around the pulley and insert the cable end into the pivot hole in the ratchet plate 4 HOW TO USE THIS BOOK 1052 ADJUSTMENT ...

Page 1032: ...on the control assembly holding the mounting bracket tightly against the body of the control until the cable tension rotates the cable track assembly so that the lock pin 5 32 in 4mm diameter steel pin or drill bit can be fully seated through the plate 6 Insert the lock pin so that the assembly is in the cable released position 7 Install the parking brake control lever 8 REMOVAL INSTALLATION HOW T...

Page 1033: ...Ranger and 1991 94 Explorer parking brake cable routing diagram Click to enlarge HOW TO USE THIS BOOK 1054 REMOVAL INSTALLATION ...

Page 1034: ...s relieve the parking brake cable tension as outlined under cable adjustments 3 Remove the parking brake cable from the bracket 4 Remove the jackstands and lower the vehicle Remove the forward ball end of the parking brake cable from the control assembly clevis 5 Remove the cable from the control assembly 6 Using a fishing line wire leader or cord attached to the control lever end of the cable rem...

Page 1035: ...a hoist 9 Route the cable through the bracket 10 Connect the slug of the cable to the Tension Limiter connector 11 On 1991 92 models adjust the parking brake cable at the equalizer using the appropriate procedure shown above 12 On 1993 99 models release the cable tension as outlined under cable adjustments 13 Rotate both rear wheels to be sure that the parking brakes are not dragging 14 Equalizer ...

Page 1036: ...93 99 models relieve the parking brake cable tension as outlined under cable adjustments Disconnect the left rear cable from the front cable For the right rear cable disconnect it from the cable equalizer and rear guide bracket 3 Use a 9 16 in 14mm wrench and compress the prongs that retain the cable housing to the frame bracket and pull the cable and housing out of the bracket 4 HOW TO USE THIS B...

Page 1037: ...equalizer 90 and recouple the Tension Limiter threaded rod to the equalizer 8 Install the rear brake drum and wheel and adjust the rear brake shoes 9 On 1991 92 models adjust the parking brake tension using the appropriate procedure shown above 10 On 1993 99 models release the cable tension as outlined under cable adjustments 11 Rotate both rear wheels to be sure that the parking brakes are not dr...

Page 1038: ...tension as outlined under cable adjustments 13 Install the wheel and if necessary adjust the rear parking brake shoes 14 Rotate both rear wheels to be sure that the parking brakes are not dragging 15 Lower the vehicle and tighten the wheel lug nuts to 100 ft lbs 135 Nm 16 Brake Shoes Only the Mountaineer and 1995 99 Explorer models use separate parking brake shoes REMOVAL INSTALLATION Exploded vie...

Page 1039: ... hold down pin and spring 11 Install the brake shoe adjuster spring 12 Install the outboard return spring 13 Adjust the parking brake shoes and install the rotor caliper and wheel 14 Lower the vehicle and tighten the wheel lug nuts to 100 ft lbs 135 Nm 15 ADJUSTMENT Measure the inside of the drum portion of the rear brake rotor Remove the rear disc brake rotor 1 Using Brake Adjustment Gauge D81L 1...

Page 1040: ...djust the parking brake adjuster screw until the outside diameter of the parking brake shoes measures 0 020 in 0 508mm less than the drum measurement 3 Install the rear disc brake rotor 4 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK ADJUSTMENT 1061 ...

Page 1041: ...ensor indicator rings located on the ring gear inside the rear axle housing 7 The Explorer Mountaineer G switch located on the left hand frame rail aft of the No 2 crossmember 8 The Ranger G switch located on the left hand frame rail forward of the No 3 crossmember 9 The Explorer Mountaineer main and pump motor relay located in a four relay box mounted near the battery on the left fender wall 10 T...

Page 1042: ...lic Control Unit HCU PUMP TESTING Disconnect the HCU pump motor electrical plug 1 Connect a Digital Volt Ohm Meter DVOM across the two pump terminals and record the reading 2 The reading should be between 52 68 Ohms 3 If not replace the pump motor 4 HOW TO USE THIS BOOK 1064 System Self Test ...

Page 1043: ... lift out the unit 4 Installation is the reverse of removal Torque the mounting nuts to 12 18 ft lbs and the tube fittings to 10 18 ft lbs 5 After reconnecting the battery it may take 10 miles or more of driving for the Powertrain Control Module to relearn its driveability codes Bleed the brakes 6 Electronic Control Unit REMOVAL INSTALLATION Disconnect the battery ground cable 1 Unplug the wiring ...

Page 1044: ...4 k Ohms Front left sensor 1 0 1 4 k Ohms Explorer Mountaineer 4x4 models only Front right sensor 0 270 0 330 k Ohms Front left sensor 0 270 0 330 k Ohms REMOVAL INSTALLATION Inside the engine compartment disconnect the sensor from the harness 1 Unclip the sensor cable from the brake hose clips 2 Remove the retaining bolt from the spindle and slide the sensor from its hole 3 Installation is the re...

Page 1045: ...rt falls into the axle Clean the magnetized sensor pole piece Metal particles can cause sensor problems Replace the O ring 3 Coat the new O ring with clean engine oil 4 Position the new sensor on the axle It should slide into place easily Correct installation will allow a gap of 0 005 0 045 in 5 Torque the hold down bolt to 25 30 ft lbs 6 Connect the wiring 7 Front Speed Sensor Ring HOW TO USE THI...

Page 1046: ...e newsensor ring on the hub Using a cylindrical adapter 98mm ID X 106mm OD press the ring into place The ring mustbe fully seated 6 The remainder of installation is the reverse of removal 7 Rear Speed Sensor Ring REMOVAL INSTALLATION The ring is located on the differential case inside the axle housing Once it is pressed off the case it cannot be reused This job should be left to a qualified servic...

Page 1047: ...SPECIFICATION CHARTS 4 Wheel Anti lock Brake System 4WABS diagnostic trouble code chart Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning SPECIFICATION CHARTS 1069 ...

Page 1048: ...EXTERIOR Doors REMOVAL INSTALLATION Exploded view of the Ranger front door hinge assembly Click to enlarge EXTERIOR 1071 ...

Page 1049: ...Exploded view of the Explorer Mountaineer front door hinge assembly Click to enlarge HOW TO USE THIS BOOK 1072 REMOVAL INSTALLATION ...

Page 1050: ...cover plate if equipped and matchmark the hinge to body and hinge to door location Support the door either on jackstands or have somebody hold it for you 2 Remove the lower hinge to door bolts 3 Remove the upper hinge to door bolts and lift the door off the hinges 4 If the hinges are being replaced remove them from the door pillar 5 To install If they were removed install the hinges in the same po...

Page 1051: ...nd back them out just enough to allow movement 1 To move the door safely use a padded pry bar When the door is in the proper position tighten the bolts to specification and check the door operation There should be no binding or interference when the door is closed and opened 2 Door closing adjustment can also be affected by the position of the lock striker plate Loosen the striker plate bolts and ...

Page 1052: ...Open the hood 1 Matchmark the hood to hinge position 2 Disconnect any electrical wire harness plugs 3 Have you re assistant s support the weight of the hood 4 Remove the hood to hinge bolts and lift the hood off of the hinges 5 Installation is the reverse of the removal Loosely install the hood and align the matchmarks Tighten the bolts securely 6 HOW TO USE THIS BOOK Hood 1075 ...

Page 1053: ...Before removing the hood matchmark the hood hinge to the hood If equipped disconnect the hood light wire harness plug along with any ground straps HOW TO USE THIS BOOK 1076 REMOVAL INSTALLATION ...

Page 1054: ...e hood as required to obtain the proper fit and alignment between the hood and all adjoining body panels Tighten the bolts securely when satisfactorily aligned 3 Loosen the 2 latch attaching bolts 4 Move the latch from side to side to align the latch with the striker Torque the latch bolts 5 Lubricate the latch and hinges and check the hood fit several times 6 Liftgate REMOVAL INSTALLATION HOW TO ...

Page 1055: ...View of the Explorer Mountaineer liftgate hinge to body mounting Click to enlarge HOW TO USE THIS BOOK 1078 REMOVAL INSTALLATION ...

Page 1056: ... the liftgate door 1 Support the door in the open position and disconnect the liftgate gas cylinder assist rod assemblies by carefully prying the locking spring out of the ball socket 2 Carefully move the headliner out of position and remove the hinge to header panel attaching nuts 3 Remove the hinge to liftgate attaching bolts and remove the complete assembly 4 HOW TO USE THIS BOOK REMOVAL INSTAL...

Page 1057: ...To disconnect the liftgate gas cylinders pry out on the locking spring arrow HOW TO USE THIS BOOK 1080 REMOVAL INSTALLATION ...

Page 1058: ... is open Make sure the window is closed before opening the liftgate The liftgate can be adjusted slightly in or out and side to side by loosening the hinge to header nut or bolt Some up and down adjustment can be accomplished by loosening the hinge bolts on the liftgate and moving the gate up or down The liftgate should be adjusted for even and parallel fit with adjoining panels The door latch str...

Page 1059: ...Before moving the rear liftgate striker mark its position in relation to the body for future reference HOW TO USE THIS BOOK 1082 ALIGNMENT ...

Page 1060: ...Once the center bolt is loosened the striker can be positioned Tailgate REMOVAL INSTALLATION HOW TO USE THIS BOOK Tailgate 1083 ...

Page 1061: ...Exploded view of the standard Ranger tailgate Click to enlarge HOW TO USE THIS BOOK 1084 REMOVAL INSTALLATION ...

Page 1062: ...rt strap at the pillar T head pivot 1 Lift off the tailgate at the right hinge 2 Pull off the left hinge 3 Transfer all necessary hardware to the new tailgate if necessary 4 Installation is the reverse of removal 5 Front and Rear Bumpers REMOVAL INSTALLATION HOW TO USE THIS BOOK Front and Rear Bumpers 1085 ...

Page 1063: ...Exploded view of the front bumper assembly Click to enlarge HOW TO USE THIS BOOK 1086 REMOVAL INSTALLATION ...

Page 1064: ...rame Once the bumper is removed from the truck remove the brackets from the bumper 2 Remove the valance panel and rubstrip from the bumper as required 3 Installation is the reverse of removal Use a leveling tool to ensure a level installation before tightening the bolts 4 Support the bumper and torque the bracket to frame bolts to specifications 5 HOW TO USE THIS BOOK REMOVAL INSTALLATION 1087 ...

Page 1065: ...bumper support it then remove the bumper bracket to frame bolts The same goes for removing the rear bumper Once the mounting bolts are removed simply lift the bumper from the vehicle Grille HOW TO USE THIS BOOK 1088 Grille ...

Page 1066: ...92 Ranger and 1991 94 Explorer models are similar Click to enlarge Exploded view of the Mountaineer and 1995 99 Explorer front grille Click to enlarge Remove all of the plastic retainers across the top of the grille if equipped 1 HOW TO USE THIS BOOK REMOVAL INSTALLATION 1089 ...

Page 1067: ...screws on the ends 3 Carefully push inward on the snap in retainers and disengage the grille from the headlight housings 4 Installation is the reverse of removal 5 To remove the grille assembly first remove all of the screws and fasteners then carefully push inward and lift up to disengage the remaining snap in fasteners Outside Mirrors REMOVAL INSTALLATION HOW TO USE THIS BOOK 1090 Outside Mirror...

Page 1068: ...unting screws or nuts and lift off the mirror Remove and discard the gasket 2 When installing make sure the gasket is properly positioned before tightening the screws 3 If equipped with power mirror plug in the electrical connector and test the operation of the power mirror before installing the door panel 4 To remove the outside mirror first remove the door trim panel and peel back the padding to...

Page 1069: ...rror attaching nuts Antenna REMOVAL INSTALLATION Fixed Mast Antenna Exploded view of the antenna mounting Click to enlarge Disconnect the antenna lead in cable from the cable assembly in line connector above the glove box 1 HOW TO USE THIS BOOK 1092 Antenna ...

Page 1070: ...ket 6 To install Place the gasket in position on the cowl panel 7 Insert the antenna cable through the hole and seat the antenna base on the cowl Secure with the 3 screws 8 Position the cap over the antenna base and snap it into place 9 Install the antenna mast to the base 10 Route the cable in exactly the same position as before removal behind the instrument panel 11 Connect the cable to the in l...

Page 1071: ...oosen and remove the antenna to base retaining nut 5 Disconnect the electrical wire harness plug and the antenna lead in wire at the antenna 6 Remove the antenna through the fender splash shield access 7 Installation is the reverse of the removal procedure 8 Fenders REMOVAL INSTALLATION Ranger Exploded view of the 1991 92 Ranger front fender Click to enlarge Clean out all dirt from the fender atta...

Page 1072: ...tainers and brace on the fender 10 Position the fender on the apron and loosely install the apron retaining bolts 11 Loosely install the bolt from inside the cab attaching the rear end of the fender to the cowl 12 Loosely install the bolt attaching the rear lower end of the fender to the lower corner of the cab 13 Loosely install the bolt attaching the brace to the radiator support assembly 14 Loo...

Page 1073: ...bolts attaching the fender to the rocker panel 9 Lower the vehicle and remove the fender Remove the brace from the fender 10 To install Install the fender and raise the truck 11 Position the nuts retainers and brace on the fender 12 Install the 2 bolts attaching the fender to the rocker panel 13 Install the 4 screws attaching the fender apron to the fender 14 Install the bolt attaching the brace t...

Page 1074: ...he bed 3 Unbolt the fuel filler neck from the bed opening 4 Lift the bed off of the frame 5 Installation is the reverse of removal 6 Be sure to use new bolts and other mounting hardware when installing Replacement parts should be of the same specification as the original parts i e do not use Grade 5 bolts where Grade 8 bolts were originally used 7 Chassis and Cab Mount Bushings REMOVAL INSTALLATIO...

Page 1075: ...Body to frame mounts and hardware Ranger Click to enlarge HOW TO USE THIS BOOK 1098 REMOVAL INSTALLATION ...

Page 1076: ...Body to frame mounts and hardware Ranger Super Cab Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1099 ...

Page 1077: ...nlarge Use the accompanying illustrations as a guide Remove interior trim as required 1 Back out the body mount bolt four or five turns 2 If necessary have an assistant hold the lower retainer with a wrench 3 HOW TO USE THIS BOOK 1100 REMOVAL INSTALLATION ...

Page 1078: ...a jack and a block of wood and jack the body up enough to remove the old mount from between the frame and body 6 Some of the other body mounts may need to be loosened in order to lift the body enough to remove the mount Installation is the reverse of the removal procedure 7 Spare Tire Carrier REMOVAL INSTALLATION Ranger Under frame spare tire carrier Click to enlarge HOW TO USE THIS BOOK Spare Tir...

Page 1079: ... tire carrier Explorer Mountaineer Click to enlarge Lower the spare tire and work the lift cup through the wheel to release the cable 1 Remove the 2 screws attaching the winch to the support and remove the winch assembly from the underside of the truck 2 To install Position the winch assembly on its support and install the screws 3 Insert the cable end through the center of the wheel and raise int...

Page 1080: ...switch housing 3 3 If equipped with electric outside rear view mirrors remove the power mirror switch housing 4 Using a flat wood spatula insert it carefully behind the panel and slide it along to find the push pins When you encounter a pin pry the pin outward Do this until all the pins are out NEVER PULL ON THE PANEL TO REMOVE THE PINS 5 Installation is the reverse of removal 6 Explorer Mountaine...

Page 1081: ...Exploded view of the front door trim panel Click to enlarge HOW TO USE THIS BOOK 1104 REMOVAL INSTALLATION ...

Page 1082: ...view of the Explorer and Mountaineer 4 door rear door trim panel Click to enlarge To remove the door trim panel first open the window and unscrew the door lock knob HOW TO USE THIS BOOK REMOVAL INSTALLATION 1105 ...

Page 1083: ...ull off the handle cover then remove the attaching screw 5 Remove the trim cup behind Explorer Mountaineer or around Ranger the door handle using a small prying tool Retention nibs will flex for ease of removal 6 If equipped with manual window crank handles pull back the handle cover HOW TO USE THIS BOOK 1106 REMOVAL INSTALLATION ...

Page 1084: ...behind the panel Disconnect the harness from the switches 7 Remove any retaining screws uncovered by the removed trim pieces 8 Using a flat wood spatula insert it carefully behind the panel and slide it along to find the push pins When you encounter a pin pry the pin outward Do this until all the pins are out NEVER PULL ON THE PANEL TO REMOVE THE PINS 9 Lift slightly to disengage the panel from th...

Page 1085: ... screws Pry out the trim panel to door frame retaining clips then lift up and pull the panel free Disconnect the door courtesy lamp and remove the panel completely Replace any damaged or bent attaching clips 11 Installation is the reverse of removal 12 HOW TO USE THIS BOOK 1108 REMOVAL INSTALLATION ...

Page 1086: ...n t coming out it s because you ve missed a screw somewhere Most attaching hardware is located around the perimeter or near the center of the piece Don t forget to reinstall the ornamental plug or cap that hides the screw when the part is back in place Also some moldings cannot be removed without first removing the adjacent molding It may seem like more work than necessary but if you force somethi...

Page 1087: ...Exploded view of the front windshield pillar trim Click to enlarge HOW TO USE THIS BOOK 1110 REMOVAL INSTALLATION ...

Page 1088: ...View of the Explorer Mountaineer center body pillar trim Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1111 ...

Page 1089: ...Exploded view of the 2 door Explorer rear quarter trim panel 4 door models similar Click to enlarge HOW TO USE THIS BOOK 1112 REMOVAL INSTALLATION ...

Page 1090: ...Exploded view of the Ranger Super Cab rear quarter trim panel Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1113 ...

Page 1091: ...Exploded view of the Explorer Mountaineer rear liftgate trim panel Click to enlarge Instrument Panel REMOVAL INSTALLATION HOW TO USE THIS BOOK 1114 Instrument Panel ...

Page 1092: ...Exploded view of the 1991 92 instrument panel assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1115 ...

Page 1093: ... brake and clutch pedal support 8 Disconnect the wiring from the switches on the steering column 9 Remove the front inside pillar mouldings 10 Remove the right side cowl trim cover 11 Remove the lower right insulator from under the instrument panel 12 Remove the 2 bolts retaining the instrument panel to the lower right side of the cowl 13 Remove the 2 screw retaining the instrument panel to the pa...

Page 1094: ...nel is positioned correctly at this point will avoid problems with fit and rattles after its installed Also check for pinched or cut wires Install the mouldings and the trim panels 21 Connect the heater air conditioning controls and all of the instrument panel switches 22 Connect the wiring to the steering column switches 23 Install the instrument cluster radio and ashtray assemblies 24 Install th...

Page 1095: ...Exploded view of the standard center console may have one or two cup holders Click to enlarge HOW TO USE THIS BOOK 1118 REMOVAL INSTALLATION ...

Page 1096: ...y 3 Remove the entire assembly by lifting it from its mounting bracket 4 Install the console in position and install all mounting screws 5 Headliner REMOVAL INSTALLATION Ranger Remove both sun visors 1 Remove the assist handles if equipped 2 Remove the upper windshield garnish molding 3 Remove the front pillar moldings 4 Remove the coat hooks 5 Remove the lower back window garnish molding 6 HOW TO...

Page 1097: ...eer Headliner installation Explorer Click to enlarge Remove both sun visors and visor arm clips 1 Remove the assist handles and coat hooks 2 Remove the front pillar inside moldings 3 Remove the push pin at the roof centerline 4 On 4 door models remove the B pillar upper moldings 5 Remove the top seat belt anchor cover and the anchor itself 6 Remove the body side trim panels 7 Remove the dome lamp ...

Page 1098: ...eadliner remove the U reinforcements 13 Install the body side trim panels 14 Install the top seat belt anchor and cover 15 On 4 door models install the B pillar upper moldings Install the push pins at the roof centerline 16 Install the coat hooks 17 Install the front pillar inside moldings 18 Install the assist handles 19 Install the sun visors and arm clips 20 Door Locks REMOVAL INSTALLATION Door...

Page 1099: ...Front door latch Explorer Click to enlarge HOW TO USE THIS BOOK 1122 REMOVAL INSTALLATION ...

Page 1100: ...ation is the reverse of removal 4 Door Lock Cylinder Open the window 1 Remove the trim panel and watershield 2 Disconnect the actuating rod from the lock control link clip 3 Slide the retainer away from the lock cylinder 4 Remove the cylinder from the door 5 Use a new gasket when installing to ensure a watertight fit 6 Lubricate the cylinder with suitable oil recommended for this application 7 Doo...

Page 1101: ...REMOVAL INSTALLATION Glass Door glass Ranger Click to enlarge HOW TO USE THIS BOOK 1124 REMOVAL INSTALLATION ...

Page 1102: ...Front door glass Explorer Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1125 ...

Page 1103: ... with retaining rivets remove them carefully Otherwise remove the glass from the channel using Glass and Channel Removal Tool 2900 made by the Sommer and Mala Glass Machine Co of Chicago ILL or its equivalent Remove the glass through the belt opening if possible 6 To install Install the glass spacer and retainer into the retention holes 7 Install the glass into the door position on the bracket and...

Page 1104: ...e window guide and glass bracket if equipped 3 Remove the center pins from the regulator attaching rivets 4 Drill out the regulator attaching rivets using a 1 4 in 6mm drill bit 5 Disengage the regulator arm from the glass bracket and remove the regulator 6 Installation is the reverse of removal 1 4 in 20 x 1 2 in bolts and nuts may be used in place of the rivets to attach the regulator 7 EXPLORER...

Page 1105: ...ds To install Assemble the glass bracket and regulator assembly 9 Install the assembly in the door Set the regulator base plate to the door using the base plate locator tab as a guide 10 Attach the regulator to the door using new rivets 1 4 in 20 x 1 2 in bolts and nuts may be used in place of the rivets to attach the regulator 11 Install the equalizer bracket door belt weatherstrip and glass stab...

Page 1106: ...f your body hits the windshield during the collision and prevents the glass from shattering which could cause lacerations blinding and other harm to passengers of the vehicle The other fixed windows are designed to be tempered so that if they break during a collision they shatter in such a way that there are no large pointed glass pieces The professional automotive glass technician knows how to in...

Page 1107: ...ich offer windshield chip repair products such as Loctite s Bullseye windshield repair kit These kits usually consist of a syringe pedestal and a sealing adhesive The syringe is mounted on the pedestal and is used to create a vacuum which pulls the plastic layer against the glass This helps make the chip transparent The adhesive is then injected which seals the chip and helps to prevent further st...

Page 1108: ...lectric Day Night mirror Repair kits for damaged mirrors are available and most auto parts stores The most important part of the repair is the beginning Mark the outside of the windshield to locate the pad then scrape the old adhesive off with a razor blade Clean the remaining adhesive off with chlorine based window cleaner not petroleum based solvent as thoroughly as possible Follow the manufactu...

Page 1109: ... the cushion assembly 4 Remove 4 track to seat cushion retaining screws 2 each side and remove the tracks from the cushion assembly 5 To install Position the track to the cushion assembly Install the 4 track to seat retaining screws and tighten 6 Connect the track latch tie rod assembly to the latch lever and hook in center of cushion 7 Position the seat and track assembly in the vehicle 8 Install...

Page 1110: ...Ranger bucket seat Click to enlarge Explorer Mountaineer bucket seat HOW TO USE THIS BOOK REMOVAL INSTALLATION 1133 ...

Page 1111: ...and assist spring from the tracks 4 Remove 4 track to seat cushion screws 2 each side from the track assemblies Remove the tracks from seat cushion 5 To install Position the tracks to the seat cushion Install the 4 track to seat cushion screws 2 each side and tighten 6 Connect the latch tie rod assembly and assist spring to the tracks 7 Position the seat and track assembly in the vehicle 8 Install...

Page 1112: ...Seat Belt Systems REMOVAL INSTALLATION Seat belt system Ranger with bench seat Click to enlarge HOW TO USE THIS BOOK Seat Belt Systems 1135 ...

Page 1113: ...Seat belt system Ranger with bucket seat Click to enlarge HOW TO USE THIS BOOK 1136 REMOVAL INSTALLATION ...

Page 1114: ...Rear seat belts Ranger Super Cab Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1137 ...

Page 1115: ...Outboard seat belts Explorer Click to enlarge HOW TO USE THIS BOOK 1138 REMOVAL INSTALLATION ...

Page 1116: ...Center seat belts Explorer Click to enlarge HOW TO USE THIS BOOK REMOVAL INSTALLATION 1139 ...

Page 1117: ...ing bolt securing the assembly to the floorpan or side panel 2 Remove the bolt from the strap guide if necessary and remove the assembly from the vehicle 3 Installation is the reverse of removal Refer to the proper illustration for proper torque values 4 Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 1140 REMOVAL INSTALLATION ...

Page 1118: ...SPECIFICATION CHARTS Torque Specifications Click to enlarge SPECIFICATION CHARTS 1141 ...

Page 1119: ...Torque Specifications Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning HOW TO USE THIS BOOK 1142 SPECIFICATION CHARTS ...

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