1991 1999 ford explorer chilton User Manual

							Engage the coil spring to the tab on the adjusting wheel
Engage the coil spring to the tab on the adjusting wheel in the control assembly.
2. 
Ensure the 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 
						

							While stepping on the cable end, pull upwards on the control assembly then install the lock pin
when the holes align
Click to enlarge
Position the free end of the parking brake cable on the floor and step on it, or clamp it in a vise.
5. 
Pull 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 TO USE THIS BOOK
REMOVAL & INSTALLATION 1053 
						

							Ranger and 1991-94 Explorer parking brake cable routing diagram
Click to enlarge
HOW TO USE THIS BOOK
1054 REMOVAL & INSTALLATION 
						

							Mountaineer and 1995-99 Explorer parking brake cable routing diagram
Click to enlarge
Equalizer-To-Control Cable Raise the vehicle on a hoist and support on jackstands.
1. 
On 1991-92 models, back off the equalizer nut and remove slug of front cable from the tension
limiter.
2. 
On 1993-99 models, 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, remove the
cable from the vehicle.
7. 
To install: HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1055 
						

							Transfer the fish wire or cord to the new cable. Position the cable in the vehicle, routing the cable
through the dash panel. Remove the fish wire and secure the cable to the control.
8. 
Connect the forward ball end of the brake cable to the clevis of the control assembly. Raise the
vehicle on 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-To-Rear Wheel Cables
EXCEPT REAR DISC BRAKE HOW TO USE THIS BOOK
1056 REMOVAL & INSTALLATION 
						

							View of the rear brake cable mounting assembly
Click to enlarge
Raise the vehicle and remove the wheel and brake drum.
1. 
On 1991-92 models, remove the locknut on the threaded rod and disconnect the cable from the
equalizer.
2. 
On 1993-99 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 BOOK
REMOVAL & INSTALLATION 1057 
						

							Working on the wheel side, use a 
9
/16  in. (14mm) wrench and compress the prongs on the cable
retainer so they can pass through the hole in the brake backing plate. Draw the cable retainer out of
the hole.
5. 
With the spring tension off the parking brake lever, lift the cable out of the slot in the lever, and
remove the cable through the brake backing plate hole.
6. 
To install: Route the right cable behind the right shock and through the hole in the left frame side rail. Route the
left cable inboard of the leaf spring. Pull the cable through the brake backing plate until the end of the
cable is inserted over the slot in the parking brake lever. Pull the excess slack from the cable and
insert the cable housing into the brake backing plate access hole until the retainer prongs expand.
7. 
Insert the front of the cable housing through the frame crossmember bracket until the prong expands.
Insert the ball end of the cable into the key hole slots on the equalizer, rotate the 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 dragging.
12. 
Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
13. 
REAR DISC BRAKE
View of the rear disc parking brake cable mounting
Loosen the rear wheel lug nuts.
1. 
Raise the rear of the vehicle and remove the wheel.
2. 
Relieve the parking brake cable tension as outlined under cable adjustments.
3. 
Disconnect the left rear cable from the front cable. For the right rear cable, disconnect it from the
cable equalizer and rear guide bracket.
4. 
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.
5. 
Lift the parking brake rear cable eyelet off of the parking brake lever at the rear disc brake backing
plate.
6.  HOW TO USE THIS BOOK
1058 REMOVAL & INSTALLATION 
						

							Compress the retainer fingers at the caliper adapter bracket with a 
1
/2  in. (13mm) box end wrench and
remove the parking brake cable through the hole in the bracket.
7. 
To install: Hook the cable eyelet over the parking brake lever. Push back the spring and put the exposed cable
through the slot in the backing plate bracket.
8. 
Push the cable housing end into the bracket to engage the retainer fingers.
9. 
Route the cable along its original path.
10. 
For the right rear cable, insert the cable end through the rear guide bracket until the retainer fingers
engage.
11. 
Connect the rear cables back to their original positions.
12. 
Release the cable 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 view of the rear disc brake parking brake shoe assembly Click to enlarge
Remove the rear disc brake rotor.
1. 
Remove the outboard return spring.
2. 
Remove the adjusting screw spring.
3. 
Remove the rear brake shoe hold-down spring and pin.
4. 
Remove the brake shoe adjusting screw and nut.
5. 
Remove the front brake shoe hold-down spring and pin.
6. 
Remove both parking brake shoes and the inboard return spring.
7.  HOW TO USE THIS BOOK
Brake Shoes 1059 
						

							Check the parking brake lever for excessive wear and replace as necessary.
8. 
To install: Position the front parking brake shoe to the backing plate and install the hold-down pin and spring.
9. 
Install the rear parking brake shoe with the inboard return spring.
10. 
Position the brake shoe adjuster screw and nut on the shoes and install the rear shoe 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-1103-A or equivalent, measure the inside diameter of the
drum portion of the rear disc brake rotor.
2.  HOW TO USE THIS BOOK
1060 REMOVAL & INSTALLATION 
						

							Subtract 0.020 in. (0.508mm) from the first measurement, adjust the brake shoes to that size
Adjust 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