1991 1999 ford explorer chilton User Manual

							
INSPECTION
Loosen the wheel lug nuts.
1. 
Raise and safely support the vehicle. Remove the wheel.
2. 
Looking through the rear brake caliper pad inspection hole, measure the pad thickness from the rotor
surface to the pads metal backing.
3. 
Minimum pad thickness is  1
/8  in. (3.12mm), however, your local safety inspection laws may
supersede this dimension. Contact the appropriate authorities for specific safety requirements.
4. 
Any pad which is below the minimum allowable thickness will require you to replace all of the pads
(both wheels).
5. 
Brake Caliper
REMOVAL & INSTALLATION CAUTION
Older brake pads or shoes may contain asbestos, which has 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.
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 removed fluid.
1. 
Loosen the wheel lug nuts then raise and safely support the rear of the vehicle.
2. 
Remove 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 and adapter mount.
7. 
If necessary, remove the brake pads.
8. 
To install: Inspect the rear brake caliper for damage and wear. Replace as necessary.
9. 
If removed, install the brake pads.
10. 
Install new shoe slippers to the caliper mount.
11. 
Position the brake caliper over the rotor and align the sliding pin mounts.
12. 
Install the caliper bolts and tighten them to 20 ft. lbs. (27 Nm).
13. 
Install the brake hose attaching bolt, using new sealing washers and tighten to 29 ft. lbs. (40 Nm).
14. 
Install the wheel and snug the lug nuts.
15. 
Refill the master cylinder as needed and bleed the brake system.
16. 
Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
17. 
The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump 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.
18.  HOW TO USE THIS BOOK
INSPECTION 1041 
						

							
OVERHAUL
The rear disc brake caliper is overhauled in the same manner as the front disc brake caliper. Refer to those
procedures earlier in this section.
Brake Disc
REMOVAL & INSTALLATION Remove the rear disc brake caliper, but do not disconnect the brake hose.
1. 
If equipped, remove the press-on keeper nuts from the wheel studs.
2. 
Remove the rear brake rotor from the axle flange by pulling it straight outwards.
3. 
If the rotor binds on the rear parking brake shoes, remove 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 arent too badly scored or grooved can
be resurfaced by most automotive shops.
1. 
Measure the rotor thickness using a caliper gauge.
2. 
Minimum rotor thickness should be 0.409 in. (10.4mm). 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
1042 OVERHAUL 
						

							
REAR ANTI-LOCK BRAKE SYSTEM (RABS)
Component Location
RABS component locations for 1991-96 modelsClick to enlarge
The RABS consists of the following components: RABS module-located in the dash under the instrument panel mount on a brace, center of panel area.
1. 
Dual Solenoid Electro-Hydraulic Valve is located 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)-located on the forward end of the power distribution box, under
the hood.
6. 
REAR ANTI-LOCK BRAKE SYSTEM (RABS) 1043 
						

							Diode/Resistor Element (1991-96)-located three inches left of the cluster connector takeouts in the
instrument panel wiring harness.
7. 
Diode/Resistor Element (1997)-located in the power distribution box, under the hood.
8. 
Sensor test Connector-located under the hood slightly rearward the washer bottle.
9. 
System Self-Test
RABS trouble code indexClick to enlarge
The 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 for about 2
seconds while the ignition switch is in the ON position and will go out shortly after. A flash code may be HOW TO USE THIS BOOK
1044 Component Location 
						

							
obtained only when the yellow light is ON. Before reading the code, drive the vehicle to a level area and place
the shift lever in the PARK or NEUTRAL position. Keep the vehicle ignition ON.
Starting in 1993, all vehicles use the RABS II system. The major difference between the two systems is
the addition of keep alive memory (codes are stored, even if ignition is turned off), and a code 16 can be
set which means the system is operating properly.
TO OBTAIN THE FLASH CODE: Locate the RABS diagnostic connector (orange/black wire) and attach a jumper wire to it and
momentarily (1 to 2 seconds) ground it to the chassis.
1. 
Quickly remove the ground. When the ground is made and then removed, the RABS light will begin
to flash.
2. 
The code consists of a number of short flashes and ends with a long flash. Count the short flashes and
include the following long flash 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 screws and remove the module.
3. 
To install: Place the module in position against the under dash crossmember. Install and tighten the retaining
bolts.
4. 
Connect the wiring harness to the module.
5. 
Install any instrument panels which were removed.
6. 
Check the system for proper operation.
7. 
RABS Valve
REMOVAL & INSTALLATION Disconnect the brake lines from the valve and plug the lines.
1. 
Disconnect the wiring harness at the valve.
2. 
Remove the 3 nuts retaining the valve to the frame rail and lift out the valve.
3. 
Installation is the reverse of removal. Dont overtighten the brake lines. Bleed the brakes.
4. 
RABS Sensor HOW TO USE THIS BOOK
System Self-Test 1045 
						

							
TESTING
Remove the RABS sensor from the axle housing. Connect a Digital Volt/Ohm Meter (DVOM) across the two sensor terminals and record the reading.
1. 
The reading should 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 
						

							Pull the sensor up and out of the axle housing
Remove the sensor hold-down bolt.
3. 
Remove the sensor by pulling it straight out of the axle housing.
4. 
Ensure that the axle surface is and that no dirt can enter the housing.
5. 
If a new sensor is being installed, lubricate the O-ring with clean engine oil. Carefully push the
sensor into the housing aligning the mounting 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 requires the rear differential to be
disassembled.
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1047 
						

							
PARKING BRAKE
Cable
ADJUSTMENT
1991-92 models
PRE-TENSION PROCEDURE
Pre-tension adjustmentClick to enlarge
This procedure is to be used when a new Tension Limiter has been installed. Depress the parking brake pedal.
1. 
Grip the Tension Limiter Bracket to prevent it from spinning and tighten the equalizer nut 2 1
/2  in.
(63.5mm) up the rod.
2. 
Check to make sure the cinch strap has slipped less than 1 3
/8  in. (35mm) remaining.
3. 
FINAL ADJUSTMENT
This procedure is to be used to remove the slack from the system if a new Tension Limiter has not been
installed.
Make sure the brake drums are cold for correct adjustment.
1. 
Position the parking brake pedal to 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 the parking brake pedal fully in the last detent position. If
tension is low, repeat Steps 2 and 3.
4. 
Release parking brake and check for rear wheel drag. The cables should be tight enough to provide
full application of the rear brake shoes, when the parking brake lever or foot pedal is placed in the
fully applied position, yet loose enough to ensure complete release of the brake shoes when the lever
is in the released position.
5. 
PARKING BRAKE 1049 
						

							
The Tension Limiter will reset the parking brake tension any time the system is disconnected provided
the distance between the bracket and the cinch strap hook is reduced during adjustment. When the
cinch strap contacts the bracket, the system tension will increase significantly and over tensioning may
result. If all available adjustment travel has been used, the tension limiter must be replaced.
1993-99 Models
Starting in 1993, all models use a self-adjusting parking brake cable assembly. However, in order to remove
any of the cables or components, the following procedures must be followed.
CABLE TENSION RELEASE
With the parking brake released, 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 from the control assembly.
3. 
Method 2:
For relieving tension from the rear cables only. Pull backwards on the rear cable and conduit about 1.0-2.0 in. (25-50mm) and place a clamp on the
parking brake cable and conduit behind the rear crossmember.
4. 
WARNING
Ensure that you do not damage the nylon coating on the cable.
To release the cable tension, remove the clamp holding the rear cable to the crossmember.
5.  HOW TO USE THIS BOOK
1050 ADJUSTMENT 
						

							
CABLE TENSION RESETTING
Exploded view of the parking brake 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